59928126 Operation Control Philosophy

LARSEN & TOUBRO LIMITED

PROJ PROJE ECT

NLC TUTICO ICORIN TPP-C P-CHP

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TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

OPERATION & CONTROL PHILOSOPHY OF COAL HANDLING SYSTEM (NLC TUTICORIN-TPP)

TABLE OF CONTENTS

PREPARED

GSRK/ARUN

DOCUMENT TITLE OPERATION & CONTROL PHILOSOPHY OF

CHECKED

MS/NH

COAL HANDLING SYSTEM FOR NLC TUTICORIN-TPP

Sheet 1 Of Of 71

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TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

TITLE

1.0.0

SYSTEM DESCRIPTION

2.0.0 .0.0

OPE OPERAT RATION ION & CON CONT TROL ROL PH PHILO ILOSOPHY

2.0.1 .0.1

COA COAL HA HANDLIN DLING G PL PLANT CO CONTR NTROL ROOM

2.0.2 .0.2

STACK TACKE ER / RE RECLAI LAIMER MER CO CONTR NTROL ROO ROOM

3.0.0

SYSTEM OPERATION

3.1.0

CONVEYOR SY SYSTEM

3.1.1

FLAP GA GATES / FLOW DI DIVIDERS

3.1.2

METAL DE DETECTORS

3.1.3

INLINE MA MAGNETIC SE SEPARATOR

3.1.4

IN-LI -LINE CONVEYOR SCALE

3.1.5

COAL SA SAMPLING UN UNIT

3.1.6

TRAVELLING TRIPPERS

3.1.7 .1.7

3-D BUNK UNKER LE LEVEL TRANS RANSM MITTE ITTER R

3.1.8

HOISTS & CRANES

4.0.0

UTILITIES

4.0. 4.0.1 1

SWP/ SWP/PW PWP/ P/CW CWP/ P/WT WTDP DP/W /WTP TP/D /DSP SP/T /THP HP/P /PFP FP/D /DFD FDS S SYST SYSTEM EM::

4.0.2

CYCLONE TY TYPE DE DE SY SYSTEM

4.0.3

VENTILATION SYSTEM

4.0.4

AIR CONDITIONING SYSTEM

5.0. 5.0.0 0

SEQU SEQUEN ENTI TIAL AL INTE INTERR-LO LOCK CK FOR FOR CON CONVE VEYO YORS RS & OTHE OTHER R EQUI EQUIPM PMEN ENTS TS

6.0. 6.0.0 0

THE THE PER PERMI MISS SSIV IVE E CON CONDI DITO TONS NS FOR FOR OPE OPERA RATI TION ON OF CHP CHP COAL FLOW CIRCUIT:

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 2 Of Of 71

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6.0.1 6.0.1 6.0.2 6.0.3

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

FLOW FLOW PATH PATH-- I: I: SHIP SHIP UNLOA UNLOADER DERS S TO TO STOCK STOCKYA YARD RD VIA CRUSH CRUSHER ER HOUSE HOUSE FLOW PATH-II : SHIP UNLOADERS TO BUNKER UNITS VIA CRUSHER HOUSE (WITHOUT STACKING) FLOW PATH-III : SHIP UNLOADERS TO BUNKER UNITS VIA CRUSHER HOUSE (WITH STACKING)

6.0 6.0.4

FLOW FLOW PATHATH-IV IV:: STO STOCK CK YARD YARD TO BUNK BUNKER ER UNIT UNITS. S.

6.0.5

COMBINATION OF ABOVE

7.0.0

ANNUNCIATION SYSTEM

8.0.0

STATUS INDICATION ON OWS

1.0.0 1.0.0 SYST SYSTEM EM DESC DESCRIP RIPTIO TION N This description shall be read in conjunction with the following drawings. Flow Flow Diag Diagra ram m - L&T L&T draw drawin ing g no. no. O911 O91133-MM-BM BM-C -CSS-FD FD-0 -000 002 2 & Proj Projec ectt draw drawin ing g no. no. NTPL/TA2/BE/02/0502 General Plant layout - L&T drawing no. O9113-M-BM-CS-PP-0001 & Project drawing no. NTPL/TA2/BE/02/0501

COAL HANDLING SYSTEM (CHS) is a Turnkey package including Civil, Structural, Mechanical, Electrical, Instrumentation Instrumentation & Communication Communication etc. for Stacking, Reclaiming Reclaiming and conveying coal to Bunker Unit (BU). The coal handling system shall consist of two conveying streams streams from unloading to coal bunkers with one stream normally operating and the second stream as stand by. However, it shall be possible to operate both the streams simultaneously. The material to be handled by the proposed system is Coal. Processed coal is required to be conveyed to Bunkers. Coal would be received at the plant boundary by Ship. 1.

Coal Coal will will be recei received ved at the dedicat dedicated ed new new jetty jetty at the Tutico Tuticorin rin port. port. Coal Coal will will be

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 3 Of Of 71

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NLC TUTICORIN TPP-CHP

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unloaded from the ships with help of shore unloaders and will be conveyed to conveyors 1A/1B. Conveyor 1A/1B conveys coal to Conveyor 2A/B at Junction house JT-1. Two nos Metal detectors (MD1 mounted on Conv 1A & MD2 mounted on Conv 1B) are provided for detecting metallic materials present in the “As received” coal. Two nos In line magnetic separators (ILMS -1 on Conveyor 1A & ILMS – 2 on Conveyor 1B) are mounted on discharge end of respective conveyors at JT-1 for removal of metallic ferrous tramp present in the “As received “coal. Further Conveyor 1A/1B is having facility for manual stone picking at a suitable location. 2.

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

1 & 2. Conveyor 3 A1/B1 will feed coal to either of Conv 3A2/B2 in JT-2A by means of flap gates FG 1A & 1B. Conveyor 3 A2/B2 will feed coal to either of Conv 4A/B in

JT-3 by means of flap

gates FG 2A & 2B. Conveyor 4 A/B will feed coal to either of Conv 5A/B in JT-4 by means of flap gates FG 3 & 4.

3.

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

for metering of “As Received” coal. Two nos Metal detectors (MD3 mounted on Conv 3A1 & MD4 mounted on Conv 3B2) are provided for detecting metallic materials present in the “As received” coal.

4.

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

FG 5 & 6. 2 nos Roller Screens each of capacity 1250 MTPH (RS-1 & RS-2) are provided in one path which permits the coal of size -50mm to their respective conveyors (6A/6B) & by pass the oversized coal to their respective crushers each of capacity 1250 MTPH (CR-1 & CR-2) for reducing the coal size to -50mm. The crushed coal is then allowed to fall over the respective conveyors (6A/6B). The other path by passes the coal from conveyor 5 A/B to conveyor 6 A/B through FG 5 & 6 if the received coal size is -50mm.

5.

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

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 4 Of 71

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are provided at the head end of respective conveyors for removal of metallic tramp from the “As received” coal. Two nos Metal detectors (MD5 mounted on Conv 5A & MD6 mounted on Conv 5B) are provided for detecting metallic materials present in the “As received” coal.

6.

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

7A/B will further discharge the coal in JT-5 through Diverter Gate DG 1 & 2 to either Conveyor 18A/B for stacking coal in the crushed coal stockyard or on to Conveyor 8A/B for onward conveying to Boiler Bunkers. Two nos. Belt scale (BS-3 & BS-4) are mounted on Conv 7A/7B respectively for metering of “As fired” coal.

7.

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

gates FG 9 & 10. Conveyor 9A/B will feed coal on to Conveyor 10A/B at JT-8 through flap gates FG 11 & 12. Conveyor 10A/10B will feed coal on to the bunker conveyor 11 at JT-9 or Conv 12A/B at JT-9 through flap gates FG 13 & 14. Conveyor 12A/12B will feed coal on to the bunker conveyor 13 at JT-10 or Conv 14A/B at JT-10 through flap gates FG 16 & 17. Conveyor 14A/14B will feed coal on to the bunker conveyor 15 at JT-11 or Conv 16A/B at JT-11 through flap gates FG 21 & 22. Conveyor 16A/16B will feed coal on to the bunker conveyor 17 at JT-12.

8.

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

fired coal”. Two nos. In line magnetic separators (ILMS – 5 over Conv 9A & ILMS – 6 over Conv 9B) are provided at the head end of respective conveyors for removal of metallic tramp from the “As fired” coal. Further Conveyor 9A/9B is having facility for manual stone picking at a suitable location. Two nos Metal detectors (MD7 mounted on Conv 9A & MD8 mounted on Conv 9B) are provided for detecting metallic materials present in the “As fired” coal.

9.

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

metering of “As fired” coal.

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 5 Of 71

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10.

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

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

(i.e. total four nos. of traveling trippers – TT-1 to TT-4) to feed the coal into Raw coal bunkers of the boiler units (Unit 1 & 2).

11.

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

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

12.

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

(reclaiming) capacity are provided on Yard conveyors 19 & 21 respectively. The Stacker Reclaimer machine operates on rails for stacking / reclaiming the coal in the stock yard area. During reclaiming operation the reclaimed coal will be conveyed to the yard conveyors 19 & 21 by the Boom conveyor of the respective S/R machine which in turn will feed the same to Conveyor 22A/B by means of flap gates FG 29 & 30 at JT-15 and at JT-16 respectively. Two nos. Belt scale (BS-5 & BS-6) are mounted on Conv 19 & 21 respectively for metering of “Stocking & Reclaiming” coal.

13.

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

coal can be conveyed to the raw coal bunker by Conv 9A/B, 10A/B, 12 A/B, 14 A/B 16A/B & 11/13/15/17 to the desired row of bunkers. 14.

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

& JT-12 to facilitate movement of man & material in these buildings. MAJOR EQUIPMENTS IN THE HANDLING PLANT ARE:

PREPARED



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



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

GSRK/ARUN


CHECKED

MS/NH


Sheet 6 Of 71

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2.0

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A



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



4 nos. Travelling Trippers, capacity 1200TPH



Conveyor stream capacity 2000 /1200 TPH.



1 no. Coal sampling Unit.



3 nos. Passenger cum Goods Elevator.

OPERATION & CONTROL PHILOSOPHY The COAL HANDLING PLANT is controlled from the Control Room located in PMCC-2 near to Crusher House.

2.0.1 COAL HANDLING PLANT CONTROL ROOM

The PLC Automation system for Coal and Handling Package shall be as per Automation System Configuration diagram L&T Drg No. O9113-E-BM-CS-DD-300 and APML Drg. No. TIR1-EPC-CHP-DIF-300.

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 7 Of 71

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

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

•

Stacker Reclaimer (ON/OFF status with stop facilities)

•

Travelling Trippers (tripper position indications).

•

Complete Dust Suppression system

•

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

•

Ventilation system (group/individual control as required)

•

Inline magnetic separators (ON/OFF control with indication)

•

Metal detectors (ON/OFF control with indication)

•

Coal Sampling Units

•

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

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

Stacker-Cum-Reclaimer

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

Travelling Tripper

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

PREPARED

•

Coal sampling units.

•

Scoop Coupling System.

•

Inline magnetic separator.

•

Inline belt conveying system.

•

Metal Detector.

•

Sump Pump (Only Local Operation).

•

Dust Extraction system.

•

Dust Suppression system.

GSRK/ARUN


CHECKED

MS/NH


Sheet 8 Of 71

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All the above mentioned local control panels are accessible & located near their respective equipment & will be complete with all the required controls, interlocks, and annunciations etc. Necessary controls, indications and annunciations for all the above equipment will also be provided at main CHP control room. In addition to the remote control of various equipments, Local stop push button stations will be provided for all equipment. 2.0.2

Stacker / Reclaimer Control Room

The entire control & operation of Stacker Recamier machine will be from the operators’ cabin on the machine itself. 3.0.

SYSTEM OPERATION

Typical operation philosophy of the plant is mentioned below to develop the control & monitoring scheme of plant & equipment under the package. Coal flow path selection will be done from HMI to select any one of the following conveying paths. •

Ship Unloaders to Stock yard via Crusher House.

•

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

•

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

•

Combination of above.

Operator will select any one of the above paths from HMI located in the Control desk from CHP Control Room in PMCC-2. The flow stream path is then selected by positioning different Flap Gates/Diverter gates at desired positions by means of keyboard available at the control desk. Once the system is in the operation, the gates cannot be moved from their positions and path. After the selected path is in operation the movement of path selector will not have any effect on the system. Flap gates which do not come in the stream in which coal flow is taking place, can be operated at any time. The control system will be designed for “Auto” & “Manual” operation of the conveyors in the selected path. Auto/Manual selection will be done from faceplate in HMI.

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 9 Of 71

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AUTO MODE: In the ‘auto’ mode, the conveyors and related equipment shall start sequentially when the ‘system start’ is initiated. During stopping, when the ‘system stop’ is activated, all conveyors will also stop sequentially (in the reverse sequence) allowing time delays for clearing the belts. MANUAL MODE: In manual mode, the operator shall start the conveyor system, in the same sequence as in auto mode from MMI. The operator shall also stop the conveyor system, by pressing ‘system stop’ or individual ‘stop’ command from MMI in the reverse sequence. During ‘sequence start’ in both auto and manual modes, first the required number of hooters (3 phase induction motor type) will be energized simultaneously for a preset time of 1 minute or so (adjustable at site) as per the program. After the preset time, the hooters will stop and a preset time of two minutes (adjustable at site) as per program will be allowed for the movement of the personnel and for the permissive of the conveyor system operation. This condition shall be indicated on the panel by glowing of lamp ‘COAL HANDLING SEQUENCE START’. The starting permissive shall be available for a period of 5 minutes (pre-programmed and adjustable in the field). In the event the last conveyor / equipment is not started within this preset time of 5 minutes, the start command for equipment not activated shall be withdrawn. The system cannot be started again unless the ‘sequence start’ push button is again pressed and the hooters sound again, as described before. Those conveyors and equipment, which have already started, shall continue to run. The status indication in the graphic display against all conveyors and equipment in the selected path / stream shall start slow flickering. But all status indications against all flap gates in the selected path shall glow steadily. Therefore, from the selected flow stream path of the flap gates, the operator will come to know the conveyors and equipment to be started for the selected path / stream. After a conveyor / equipment are started, the status indications against that conveyor / equipment shall change to steady glow indicating that it is running. Graphic display status indicators associated with a particular motor / equipment shall flicker fast in case of fault / trip. In addition, emergency stop push button for immediate shut down of complete plant shall be provided in

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 10 Of 71

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the CD Console. For changeover of feed from one row of bunkers to another row of bunkers without stopping of the CHP, provision shall be made for interlock bypass on the control panel for flap gates of all conveyors in boiler area for the preset period. If the changeover, in above specified time, is not completed then the entire CHP shall stop.

3.1.0 CONVEYOR SYSTEM •

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

against the damage to the edge of the belt due to excessive sideways movement. In addition, each conveyor is provided with one (1) no. Speed detection devices (Zero Speed Switch). These Zero speed switches will be designed to sense belt speed. In case of speed of belt goes below 90% of rated speed, it will trip the conveyor. •

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

flow of material i.e. 

In case of direct conveying of coal to boiler bunkers, start from bunker conveyor & end up with Conveyor 1 A/ 1B.



In case of stacking of coal in stock yard, start from yard conveyor and end up with Conveyor 1 A/ 1B. However, for yard conveyor to start, the Stacker Cum Reclaimer should be in operation.



In case of reclamation of coal from stock yard, start from bunker conveyors and end up with yard conveyor along with Stacker / Reclaimer.



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



Once a conveyor trips, flap gate directing coal from this conveyor shall change over its position with a time delay and shall come back to the original position again.

•

PREPARED

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

GSRK/ARUN


CHECKED

MS/NH


Sheet 11 Of 71

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•

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

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

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

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

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

belt conveyor, which will enable the respective conveyor to be stopped immediately. Belt Protection switches, Pull Chord Switch & Belt Sway Switch, will be identified/addressed by a specific number in the Main Control Room. •

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

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

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

switches and Zero speed switches. •

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

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

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

granulators will trip in case Speed/vibration is going beyond tolerable limits of design. Temperature sensing devices are installed on all bearings of each of the ring granulator to trip the same in case of temperature goes beyond limit. Audio-visual annunciation is provided in OWS. •

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

running along with conveyor belt at speed higher than the rated speed by providing an over speed sensing device on the equipment. •

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

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

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

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 12 Of 71

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there is no spillage of coal from any downstream conveyors during next start. INTER-LOCKING: a)

Plant Interlock Scheme:

The entire CHP System will have three modes of control. •

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

individual equipment/mechanism. •

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

•

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

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

Conveyors



Crushers



Flap Gates & Flow Dividers.



In Line Magnetic Separators



Metal Detectors



In Line Belt Weigh Scale



Stacker cum Reclaimer



Travelling Tripper.

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

All dust suppression systems & service water system.



Ventilation systems.



Hoist(Local operation only)



Elevator(Local operation only)



Crane(Local operation only)



Sump Pump(Local operation only)

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

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 13 Of 71

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



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

Belt scale shall be started when relevant conveyors are started. The dust suppression systems will be energized as soon as the conveyors at the transfer points are energized. Coal handling plant shall be tripped in case of detection of fire. b)

Interlock Of HT Motor:

HT motors used will continue to run on no load by disengaging the fluid coupling in case of failure of any process interlock. The HT motors will however be tripped incase of any motor fault like O/L, high motor winding temperature etc. In addition, in case of normal stop command, after running of the system, motors will stop. 3.1.1 FLAP GATES/FLOW DIVIDERS All flap gates / Flow Dividers / Diverter gates will be motorized and remote controlled from the main control desk. Their position will be indicated on the mimic of main control room. Once a conveyor trips, flap gate directing coal from this conveyor will change over its position with a time delay and will come back to the original position again. This is to prevent jamming of gate. 3.1.2 METAL DETECTORS •

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

detector ‘reset’ condition. Once the metal is detected, the corresponding conveyor will trip. It will be possible to restart the conveyors, after local resetting of metal detector & putting back the marker bag in position. Metal detector ON/OFF facilities is provided in the OWS. •

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

•

Following individual indications are provided on Local Control panel 1. Metal Detector ‘ON’ 2. Metal Detected

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 14 Of 71

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3.

Metal Detector ‘reset’

4.

Metal Detector Faulty

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

3.1.3 IN LINE MAGNETIC SEPARATORS •

It is possible to start the conveyor only after energizing the magnet of ILMS. Further, if conveyor system trips magnetic separators will get de-energized after a time lag. Also if drive motor of cleated belt of ILMS trips, Magnetic separator will not get de energized, but conveyor system will trip and audio-visual annunciation will appear at main CHP control room.

•

Following individual indications are provided on Local control panel 1. Magnetic separator ON. 2. Incoming supply ON 3. Under current relay operated. 4. Cleated belt motor ON/OFF/TRIP. 5. Oil temperature high

3.1.4 IN LINE BELT WEIGH SCALE Each Belt scale will give output to DDCMIS for display of flow rate and totalizer on Remote Flow rate Indicator & Remote Totalizer respectively at main CHP control room. Each Belt scale will also have rate flow indicator & totaliser mounted near the unit.

3.1.5 COAL SAMPLING UNIT 1 set of Coal sampling unit, CSU-1 in JT-8 building for taking samples of Coal has been provided. Coal sampling unit is controlled through CSU control panel located in the respective

a.

building (JT-8) and Starter Panel/DB for the same shall be located inside the Buildings of MCC-3 & MCC-6 respectively. Controls & interlocks for proper material flow is provided similar to Conveyor system. b.

PREPARED

Only one start/stop push button for coal s ampling system will be provided for

GSRK/ARUN


CHECKED

MS/NH


Sheet 15 Of 71

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TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

automatic operation of complete coal sampling system. In any case, local push button stations will be provided for all individual equipment of coal sampling system near the equipment. c.

All necessary automatic controls will be provided for meeting the requirements of ASTM-D-2234.

d.

In case of primary cutter getting stuck between parking positions, preceding conveyor will be tripped.

e.

There will be protection in the primary coal sampler to trip the conveyor belt in case primary sampler falls on running conveyor due to coupling failure etc.

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

3.1.6 MOBILE TRIPPERS •

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

as per instructions given from main CHP control room. •

End travel limit switches are also provided.

•

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

•

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

•

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

bunker feeding position to last bunker feeding position. •

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

•

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

emergency stop button, one on each side will be provided on tripper to stop the machine at any position. The control unit on tripper will be provided with start / stop push button and indication lamp for travel / gate. The tripper brakes & rail clamps will be energized (released) when the tripper motors are ON and the brakes will be applied when the travel motors are OFF. Two travel limit switches will be provided at either end of tripper carriage for limiting the travel drive between two ends of the track. The first one will be normal limit and the second one for over travel limit. In

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 16 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

addition to above, position indication for bunker position of tripper will be provided through limit switches in Main control room. Following individual indications are provided on local control panel. 

Motor ON/OFF/TRIP



Brakes applied



Rail clamps applied



Flap gate position •

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

•

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

feeders or Stacker / reclaimers from the tripper. •

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

case of blockage.

3.1.7

3-D Type Level Transmitter

3-D Level Transmitter (4-20mA type) shall be provided for boiler bunkers present in Bunker Unit 1, Bunker Unit-2, Bunker Unit-3 & Bunker Unit-4. The 3-D level Scanner employs an array of three antennas to transmit low frequency pulses and to receive echoes of the pulses from the content of the Bunker/Container. Using three antennas the unit measures not only the time/distance of each echo but also its direction. Local display and annunciation shall be provided for High and Low level signals on the instrument and level reading shall be available for operator at Control Room by means of 4-20mA. In case of level high LH in bunker level, the feeding conveyor shall be stopped. Bunker level shall be continuously displayed with low, low-low, high and high-high indications on the HMI. 3.1.8

HOISTS AND CRANES

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 17 Of 71

PROJECT


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O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

The hoists and cranes will be controlled through Pendent. The same will be approachable from the floor. The pendant control panel will be provided with up / down / forward / reverse travel push buttons and indicating lamps for operating the same. 4.0.0

UTILITIES.

The Utility System of Coal handling System at NLC Tuticorin-TPP consists of SWP/PWP/CWP/WTDP/WTP /DSP /THP/DFDS system, DE system, Ventilation system and Air conditioning system. 4.0.1 SWP/PWP/CWP/WTDP/WTP/DSP/THP/PFP/DFDS SYSTEM: The pump house is installed near to the coal transfer area, RCC water tanks is placed close to the pump station. Water from the tank shall be supplied to the service points by the pumping system The water pumps located in Pump House. The pumps shall be centrifugal multi stage type suited for continuous operation selected on the basis of best efficiency. The water pumping system shall consist of Duplex strainer with SS element 250 microns in the suction side of the Pump. . Each pump shall have a gate valve at the suction and discharge. Each pump shall have a check valve at the discharge. A pressure relief valve with a bypass Globe & gate valve shall be provided at the return line of each pumping system so that the excess water is discharged back to the water tank. Pumping system so that the excess water is discharged back to the water tank. Water tanks shall be with accessories like motorized butterfly valve/ Gate valve at inlet of tank, Level Switch, Gate valve for Drain. Motorized valves will be operating /controlled by level switch. In case of low level MOV shall open and make-up water will be filled-up. In case of high level MOV shall closed. The water pump shall be interlocked with low level switch of the water tank to prevent the pump from dry running. The pumps will be operated from control room. Following individual inputs will be provided to DDCMIS system for alarms / indications:

PREPARED

1.

Motor On, Off & Trip

2.

Discharge water pressure low

GSRK/ARUN


CHECKED

MS/NH


Sheet 18 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

3.

Water level is low in tank

4.

Water level is high in tank

5.

Compressor On, Off & Trip

6.

Air receiver pressure High, Low

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

Pressure switch is introduced in the delivery line to maintain the minimum set pressure during the operation. If the pressure falls down below the set pressure the standby pumps will start automatically after time delay. Even after the pressure is not healthy inside the system the pump will trip automatically after certain predetermined set time. The control circuit should be designed to meet the fallowing interlocks. •

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

•

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

•

Low contact of Level switch to be interlocked.

•

After starting the pump if the pressure is not built within the specified time the running pump should be stopped and other pump can be tried. If it is the same case with other pump too then the system should stop and announce the alarm.

•

Differential pressure switch in the duplex strainer gives the filter clogged signal. This No contact to be used to announce the alarm “FILTER CLOGGED”.

•

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

4.0.2 SERVICE WATER SYSTEM: Service water system is primarily intended for cleaning building floors, conveyor galleries / tunnels, electrical rooms and toilets. Service water connections shall be provided in conveyor galleries/tunnels at 30 m intervals. Minimum 2 nos of Tap points shall be provided at each floor in the junction towers, 4 nos at each floor of crusher house, 1 no at toilets of MCC and Control rooms. Each service water connection shall be provided with a globe valve and quick coupler of 25 NB size. 25 NB flexible hose of 25 m long shall be provided with

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 19 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

storage boxes at each building and conveyor gallery. The service water pump (SWP-1A/B) located in Pump House (near Stock pile) takes plain water (cooling tower blow down water) from the on ground RCC storage tank-1 adjacent to the Pump House and supplies to various service water tapings nearby surrounding buildings through network of pipe. The service water pump (SWP-1A/B) capacity has been designed considering one tap point at each conveyor gallery & JNT/ crusher house and toilets of MCC/control room under simultaneous operation and each tap point consuming 12.5 lpm at 2.5 kg/cm2. 1000 ltrs. PVC water tanks shall be provided on the top of MCC/control room for storage of service water. Group

Pump Tag No.

SWS

SWP-1A/B

Application Area As per Schematic

OWS

P.B in Pump House

Start & Stop

Start & Stop

diagram POTABLE WATER SYSTEM: Potable water connections shall be provided at all control rooms / MCC rooms, and complex building of coal handling plant. Potable water pump (PWP-1A/B) located in Pump House shall take potable water from RCC PW tank-3 located adjacent to the Pump House and supplies to the overhead PVC potable water storage tanks (1000 Liters.) located at roof top of above mentioned buildings. No PVC tank shall be provided for Transfer Points and junction house. Client shall ensure the quality of drinking water as per IS: 10500.Potable water from the overhead PVC tank shall flow to the potable water tapping of respective building by gravity. Group

PREPARED

Pump Tag No.

GSRK/ARUN

Application Area

OWS

P.B in Pump House


CHECKED

MS/NH


Sheet 20 Of 71

PROJECT


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O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

PWS

PWP-1A/B

As per Schematic

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

Start & Stop

Start & Stop

diagram

STOCKPILE DUST SUPRESSION SYSTEM: Sprinkler type dust suppression system shall be provided for stockpiles. The pumps for plain water (CTW & ROW) DS system shall be located in Pump House and takes plain water from the on-ground RCC storage tank-2 adjacent to the Pump House. It supplies water to a common header of DS system. Water from the common header goes to the ring headers around stockpiles (one no for each stockpile). The swiveling sprinklers are mounted on vertical riser, whose height of spray shall match with the stockpile height 10m), at an interval of 35 meter and the vertical risers are mounted on the ring headers. Each sprinkler shall be provided with a manually operated globe valve for controlling of water flow through the sprinkler. 4 nos sprinkler shall be mounted on one sub-header which will be connected with main header through solenoid valve (with manual over-rider) as shown in schematic diagram. The pump capacity has been designed considering 6.25 ltrs of water per hour per ton of coal stocked in section of 90 m length of stock pile. Three nos of 50% capacity centrifugal pumps (DSP-1A/B/C) shall be provided for the system.2 no of pumps shall be working and 1 no of pump shall be stand by for the system. 4 nos of sprinklers of capacity of each 22.2 m3/hr at pressure 4.0 kg/cm2 shall work on both side of stock pile when one (1) pump is in operation. Dust control is accomplished by spraying water on large stockpile areas. Water is sprayed in at regular intervals depending on the site condition. The dust control is achieved by the agglomeration of dust particles with finely atomized water droplets equal to / close to / larger than the dust particles as the case may be, the Collision between the water droplets and dust particles plays an important role in the process of agglomeration and heavier mass thus formed settles down to the source. Plain water at a pressure of about 4.0 Bar is sprinkled over the stockpile area. This system is envisaged to control the dust generated in the stockpile area. Water header will be provided along both sides of

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 21 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

the coal stockpile, sufficient number of sprinklers suitably installed in a header to cover the entire tockpile area produces water spray over the stockpile. The sprinklers are of swiveling type. The operation of the sprinklers for stock piles is automatic by means of Sequential Control Panel and Solenoid Valves for every two sprinklers. And each stockpile shall have solenoid valve with strainer at the header inlet. Before each sprinkler globe valve shall be provided. Group

Pump Tag No.

DS-5

DSP-1A/B/C


OWS

P.B in Pump House

Start & Stop

Start & Stop

diagram Programmed logic control panel is used for sprinkling system of coal stock pile. Total 128 sprinklers are controlled by 64 solenoids. Two solenoids of opposite side sprinklers are made as pair and they get ON together. At a time any eight sprinklers can be switch ON. Manual Mode: Solenoid pairs can be switched ON/OFF by using Push Buttons provided. In the Solenoid box. These push buttons are provided for Stacking & reclaiming purpose. Any sprinkler switched ON in manual mode continues in ON status till it is switched off/mode is changed. Corresponding indicator glows in the panel when any solenoid is ON. Auto Mode: In auto mode control of the sprinklers are R1 to R32 can be used for this purpose. Switching the relay R1 turns ON Solenoid 1 and 2. R2 for S3 and S4. Like wise it continues up to S128. This is maintained type contact. Till the relays are ON solenoids remains ON. Sprinkler ON time and sequence can be programmed as per the requirement of the client. At a time more than one relay should not be switched ON, is the only one interlock which client has to take care. Pumps are rated for only eight sprinklers. If more than one is switched ON at a time, required through will not be available from the sprinklers. DRY FOG DUST SUPRESSION SYSTEM:

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 22 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

The dry fog dust suppression system will consists of centrifugal pump (vertical) with drive motor, air compressor with drive motor, local control panel, Flow control unit, pressure regulating unit, solenoid valve, Nozzles, Nozzle headers, displacer operated level switch, pressure gauge, pressure switch, duplex strainer with differential pressure gauge & differential pressure switch etc. The pumps will start automatically. Load sensing units will be installed in the MCC, which will measure the current consumption of each conveyor motor. When the current drawn by conveyor exceeds a predefined set value, the load sensing unit will send signals to pumps. On receipt of signals from load sensing unit, pumps will be operated. The compressor will also start automatically taking signal from pressure switch (low) installed on compressor and it will trip automatically taking signal (high) from pressure switch installed on air receiver. The Flow Activation Stations have provision for both manual and automatic operation. For manual operation, the system becomes operational with selector switch in manual mode and in auto mode, the fogging operation starts on receiving a signal either from a Respective conveyor current load monitor or Flap gate limit switches installed at a strategic location in the material Conveyor line or potential free contact from the drive motor of equipment as per requirements. Each application point is provided with requisite number of spray bar assemblies with Air Atomized Nozzles. FAS are provided at group of application points. FAS can be connected to one or more PRU. A PRU is used to regulate the air and water pressure for a group of headers. Dry Fog type Dust Suppression System will be used for suppressing dust by means of air atomized nozzles that are caused during the operation of above mentioned areas. This system is envisaged to control the dust generated during the operation of above mentioned areas, Headers are provided at dust generating points for respective nozzles. Water will be stored in a tank. In the makeup waterline to the water tank Float valve will be provided. Water from the water tank shall be supplied to the spray headers by a pump. The water pump shall be interlocked with low-level switch of the water tank to

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 23 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

prevent the pump from dry running. A pressure switch at the pump discharge line shall be provided to bypass water to store tank in case the pressure increases above the set value. The pumping system along with control panel is placed in a pump house near the water tank. Compressor shall be mounted in the pump house with an air receiver.A FAS shall be provided for a group of material transfer points. The FAS shall be interlinked with the signals for running of Conveyors and equipments to ensure that the spray is activated only when the Conveyors are running with load. Additionally the pressure switch at the FAS ensures that the solenoid valves at the air and water lines are switched ON only when there is adequate air pressure at the system.Each application point shall have a set of spray bar of air and water. The nozzles shall be fixed at the discharge hoods/suction hoods and shall be connected by flexible tubing with the headers.Each PRU shall have air and water pressure regulators to ensure that the medium at the required pressure is flowing through the nozzles. This in turn ensures proper atomization of the water which is essential for the effective dust suppression. Group

Pump Tag No.

DS-6

DFP-1A/B


OWS

P.B in Pump House

Start & Stop

Start & Stop

Start & Stop

Start & Stop

diagram SC-A1/A2/A3

As per Schematic diagram

FLOW ACTIVATION STATION (FAS)-OPERATION:

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 24 Of 71

PROJECT


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O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

Operation: In FAS Box Electrical Controls are provided in the top compartment. An Isolation from Mains Incomer is provided by a MCB, Solenoids operation is by both modes Manual & AUTO through Auto/Manual Selector Switch for Dry fog Dust Suppression System. Modes Manual Mode: AIR Line pressure is monitored continuously through PRESSURE Switch inside FASBox, If the pressure drops below the set point, Pressure Healthy indicator goes off. This will also not allow switching on any Solenoid in any mode. AIR & WATER solenoids can be switched on /off by respective Push Buttons. IN auto mode Solenoids can be switched on by client PF (Potential Free) Signal, or UBS Signal or any other Remote system Signal, any one of the signal will open solenoids & remain ON condition until contacts in closed position. Terminals provided for this signal inside FAS Box is X1-3 TO X1-6. Following Indication are provided: Type Lamps 

Control supply healthy : L1



Pressure healthy : L3



Solenoids open : L2

FLOW CONTROL UNIT (FCU) Operation: In FCU Box Electrical Controls are provided in the top compartment. Isolation from Mains Incomer is provided by a MCB, Solenoid operation is by both modes Manual & AUTO through Auto/Manual selector switch for Plain water system. Modes Manual Mode:WATER Solenoid can be switched on /off by respective Push Buttons. Auto Mode:In auto mode Solenoid can be switched on by client PF (Potential Free)Signal or UBS Signal or any other remote system signal any one of the signal will open Solenoid & remain ON until this contacts are closed. Terminals provided for this signal inside FCU Box is X1-3 TO X1-6 Following Indication are provided

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 25 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

Type Lamps 

Control Supply Healthy : L1



Water solenoid open (ON) : L2

SOLENOID OPERATING CONDITIONS FOR DS/DFDS SYSTEMS. 1. STOCK PILE DUST SUPPRESSION SYSTEM Sl. No. Location Spray Location Stockpile Header side-1 1 Stockpile-1 Stockpile Header side-2 2 Stockpile Header side-1 3 Stockpile-2 Stockpile Header side-2 4 Stockpile Header side-1 5 Stockpile-3 Stockpile Header side-2 6 Stockpile Header side-1 7 Stockpile-4 Stockpile Header side-2 8 100 NB Solenoid valves has been considered for each stock pile at header inlet 2. DRY FOG DUST SUPPRESSION SYSTEM Sl. No. Location Spray Location 1 Discharge of Conv.5A to FG 2 Discharge of Conv.5B to FG 3 4

1 T N J

5 6 7 8

PREPARED

Receipt of Conv.6A from FG 5A Receipt of Conv.6A from FG 5B Receipt of Conv.6B from FG 5A

T 2 N J

GSRK/ARUN

Receipt of Conv.6B from FG 5B Discharge of Conv.6A Discharge of Conv.6B

Signal for Solenoid valve From sequential Panel / LCP From sequential Panel / LCP From sequential Panel / LCP From sequential Panel / LCP From sequential Panel / LCP From sequential Panel / LCP From sequential Panel / LCP From sequential Panel / LCP From sequential Panel / LCP

Signal for Solenoid valve Conv-5A Current load signal Conv-5B Current load signal Conv-5A Current load signal +FG signal Conv-5A Current load signal +FG signal Conv-5B Current load signal +FG signal Conv-5B Current load signal +FG signal Conv-6A Current load signal Conv-6B Current load signal


CHECKED

MS/NH


Sheet 26 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

9 10 11

Receipt of RBF-1 Discharge of RBF-1 side- 1 Discharge of RBF-1 side- 2

12 13 14 15 16

Receipt of RBF-2 Discharge of RBF-2 side- 1 Discharge of RBF-2 side- 2 Discharge of Conv.7 Discharge of Conv.9

17

Receipt- 1 of Conv.10A from FG

18

Receipt- 2 of Conv.10A from FG

19

Receipt- 1 of Conv.10B from FG

20


21


22


23

Receipt- 1 of Conv.10C from FG

24

Receipt- 2 of Conv.10C from FG

25

Receipt of BCN- 9

26

Receipt of BCN- 7

27

Discharge of AFD- 1

28

1 H T

Receipt of Conv.2A from AFD- 1

29 30

T 2 H

Receipt of Conv.2B from AFD- 1 Discharge of AFD- 2

PREPARED

GSRK/ARUN

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

Conv-6A Current load signal +FG signal RBF -1 motor signal RBF -1 motor signal Conv-6B Current load signal +FG signal RBF -2 motor signal RBF -2 motor signal Conv- 7 Current load signal Conv- 9 Current load signal Conv-10A Current load signal +FG signal Conv-10A Current load signal +FG signal Conv-10B Current load signal +FG signal Conv-10B Current load signal +FG signal Conv-10B Current load signal +FG signal Conv-10B Current load signal +FG signal Conv-10C Current load signal +FG signal Conv-10C Current load signal +FG signal RBF- 1 running / discharge Signal RBF- 2 running / discharge Signal Apron feeder -1 running signal Conv-2A Current load signal +FG signal Conv-2B Current load signal +FG signal Apron feeder -2 running


CHECKED

MS/NH


Sheet 27 Of 71

PROJECT


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O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

31

Receipt of Conv.2A from AFD- 2

32

Receipt of Conv.2B from AFD- 2

33 34 35 36 37 38

3 H T

4 H T

39 40 41 42 43

Discharge of AFD- 3 Receipt of Conv.2A from AFD- 3 Receipt of Conv.2B from AFD- 3 Discharge of Conv. 1A Discharge of Conv. 1B Receipt of Conv.2A from 1A Receipt of Conv.2B from 1B Discharge of Conv.2A Discharge of Conv.2B

5 H T

Receipt of Conv.6A from FG 2A Receipt of Conv.6A from FG 2B

44

Receipt of Conv.6B from FG 2A

45

Receipt of Conv.6B from FG 2B

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

signal Conv-2A Current load signal +FG signal Conv-2B Current load signal +FG signal Apron feeder -3 running signal Conv-2A Current load signal +FG signal Conv-2B Current load signal +FG signal Conv-1B Current load signal Conv-1A Current load signal Conv-2A Current load signal +FG signal Conv-2B Current load signal +FG signal Conv-2A Current load signal Conv-2B Current load signal Conv-6A Current load signal +FG signal Conv-6A Current load signal +FG signal Conv-6B Current load signal +FG signal Conv-6B Current load signal +FG signal

4.0.3 CYCLONE TYPE DE SYSTEM OPERATIONAL LOGIC FOR BAG FILTER & CYCLONE OF DE SYSTEM FOR BOILER BUNKER AREA UNIT- 1, 2, 3 & 4:

The following sequence to be maintained for start the equipment’s 1) Start Screw conveyors of bag filter & cyclone outlet

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 28 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

2) Start RAV of Cyclone & bag Filter 3) Power to sequential controller 4) Start Centrifugal Fan Motor 5) Open motorized damper of fan inlet The equipment will be interlocked with following instruments for smooth operation of DE system 1) DPS will energize at pre set pressure and will command to sequential controller for solenoid valve (24 V DC) energization. 2) After air purging in sequence of solenoid valves through sequential controller with pre set pause and on time the DPS will be de-energized at fixed differential set pressure. 3) Sequential controller will not provided output to solenoid valve if air pressure at compressed air line will be low from the desired pressure as per preset pressure of Pressure Switch. In that case the whole system will be shut down immediately. 4) ZSS of the system will show rotation of rotating part of the RAV during running Condition. If any RAV of cyclone, Bag filter fail to run then the whole system will be shut down Immediately. OPERATIONAL LOGIC FOR BAG FILTER & CYCLONE OF DE SYSTEM FOR JUNCTION HOUSE 4

The following sequence to be maintained for start the equipments 1) Start Screw conveyors of bag filter & cyclone outlet 2) Start RAV of Cyclone & bag Filter 3) Power to sequential controller 4) Open motorized damper ( 2 nos) installed at receipt points of conv.BCN-12A & 12B depending on flap gate position and discharge of material from conv.11A & 11B. 5) Start Centrifugal Fan Motor 6) Open motorized damper of fan inlet The equipment will be interlocked with following instruments for smooth operation of DE system

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 29 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

1) DPS will energize at preset pressure and will command to sequential controller for solenoid valve (24 V DC) energization. 2) After air purging in sequence of solenoid valves through sequential controller with pre set pause and on time the DPS will be de-energized at fixed differential set pressure. 3) Sequential controller will not provide output to solenoid valve if air pressure at compressed airline will be low from the desired pressure as per preset pressure of Pressure Switch. In that case the whole system will be shut down immediately. 4) ZSS of the system will show rotation of rotating part of the RAV during running condition. If any RAV of cyclone, Bag filter fail to run then the whole system will be shut down immediately. OPERATIONAL LOGIC FOR BAG FILTER & CYCLONE OF DE SYSTEM FOR JUNCTION HOUSE – 5 to 9 & 11 to 15

The following sequence to be maintained for start the equipments 1) Start Screw conveyors of bag filter & cyclone outlet 2) Start RAV of Cyclone & bag Filter 3) Power to sequential controller 4) Open motorized damper ( 2 nos) installed at receipt points of conv.BCN-12A & 12B; 13A & 13B; 14A & 14B ;15A & 15B; 16A & 16B; 17A & 17B;18A & 18B; 19A & 19B; 20A & 20B;24A & 24B;25A & 25b;26A & 26B; 27A & 27B; 28A & 28B; 29A & 29B depending on flap gate position, FTR 1A/1B,2A/2B,3A/3B,4A/4B & 5A/5B position and discharge of material from respective conveyors. 5) Start Centrifugal Fan Motor 6) Open motorized damper of fan inlet The equipment will be interlocked with following instruments for smooth operation of DE system 1) DPS will energize at pre set pressure and will command to sequential controller for solenoid valve (24 V DC) energization. 2) After air purging in sequence of solenoid valves through sequential controller with pre set

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 30 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

pause and on time the DPS will be de-energized at fixed differential set pressure. 3) Sequential controller will not provided out put to solenoid valve if air pressure at compressed air line will be low from the desired pressure as per preset pressure of Pressure Switch. In that case the whole system will be shut down immediately. 4) ZSS of the system will show rotation of rotating part of the RAV during running condition. If any RAV of cyclone, Bag filter fail to run then the whole system will be shut down immediately.

OPERATIONAL LOGIC FOR BAG FILTER & CYCLONE OF DE SYSTEM FOR JUNCTION HOUSE – 10 &16

The following sequence to be maintained for start the equipments 1) Start Screw conveyors of bag filter & cyclone outlet 2) Start RAV of Cyclone & bag Filter 3) Power to sequential controller 4) Start Centrifugal Fan Motor 5) Open motorized damper of fan inlet The equipment will be interlocked with following instruments for smooth operation of DE system 1) DPS will energize at pre set pressure and will command to sequential controller for solenoid valve (24 V DC) energization. 2) After air purging in sequence of solenoid valves through sequential controller with pre set pause and on time the DPS will be de-energized at fixed differential set pressure. 3) Sequential controller will not provided out put to solenoid valve if air pressure at compressed air line will be low from the desired pressure as per preset pressure of Pressure Switch. In that case the whole system will be shut down immediately. 4) ZSS of the system will show rotation of rotating part of the RAV during running condition. If any RAV of cyclone, Bag filter fail to run then the whole system will be shut down

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 31 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

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

The following sequence to be maintained for start the equipments 1) Open Slide gate at bottom of screw conv. depends on conv. running of 11A/11B/23A/23B. 2) Start Screw conveyors of bag filter & cyclone outlet 3) Start RAV of Cyclone & bag Filter 4) Power to sequential controller 5) Open motorized damper on line as per followings when stream – 1 & stream -2 (conv.BCN10B & conv.BCN-10C running) Motorized Damper no. 15 & 16 will open & Motorized Damper 17 will close. Motorized Damper no. 11/12 will open when RSC will discharge material on BCN-11A/B. Motorized Damper no.13 &14 will open Motorized Damper no.9/10 will open when RSC will discharge material on BF- 1/2.. Motorized Damper no. 7/8 will open when SC-2 will discharge material on BF-1/2. Motorized Damper no.5 & 6 will open when BF-1/2 will discharge material . Motorized Damper no.3/4 will open as per Flap gate position of BF-2 discharge to conv. BCN- 23A/B. Motorized Damper no. 1/2 will open as per Flap gate position of BF-1 discharge to conv. BCN- 23A/B. Open motorized damper on line as per followings when stream – 2 ( conveyor BCN-10A in running condition ) Motorized Damper no. 17 will open and Motorized Damper no. 15 & 16 will close. All other dampers will close. The schematic is enclosed 6) Start Centrifugal Fan Motor 7) Open motorized damper of fan inlet

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 32 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

The equipment will be interlocked with following instruments for smooth operation of DE system 1) DPS will energize at pre set pressure and will command to sequential controller for solenoid valve (24 V DC) energization. 2) After air purging in sequence of solenoid valves through sequential controller with pre set pause and on time the DPS will be de-energized at fixed differential set pressure. 3) Sequential controller will not provided out put to solenoid valve if air pressure at compressed air line will be low from the desired pressure as per preset pressure of Pressure Switch. In that case the whole system will be shut down immediately. 4) ZSS of the system will show rotation of rotating part of the RAV during running condition. If any RAV of cyclone, Bag filter fail to run then the whole system will be shut down immediately.

4.0.4 VENTILATION SYSTEM: Below mentioned ventilation system for the application areas can be operated in-group/individual through keyboard/OWS. The operation of each group/individual indication is available in main CHP control desk monitor. All other Ventilation system except for Boiler bunkers can be operated from OWS. All ventilation fans will have local start/stop facility (wherever required).

i)

SCHEDULE FOR MECHANICAL VENTILATION SYSTEM (SUPPLY FAN)

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 33 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

ii)

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

Sl.No

System No.

Catering Area

OWS

1

Track Hopper underground portion

Start & Stop

2

VS-1 to VS-3 VS-4

Start & Stop

3

VS-5

5

VS-7

6

VS-8

Wagon Tippler – 1 & 2 and TH-1 & 2 underground portion Wagon Tippler – 3 and TH-3 underground portion U/G portion of Conveyor 2A/B tunnel from TH-3 up to TH-1 & 2 U/G portion of Conveyor 2A/B tunnel from TH-1 & 2 up to TH-4, U/G portion of TH-4 and U/G portion of Conveyor 2A/B from TH-4 up to TH-5 U/G portion of TH-5

7

VS-8A

U/G portion of Conveyor 5A/B tunnel up to pent house

Start & Stop

8

VS-9

U/G portion of Crusher house

Start & Stop

9

VS-10

Start & Stop

10

VS-11

U/G portion of Conveyor 23A/B tunnel up to pent house U/G portion of Conveyor 11A/B tunnel up to pent house

Start & Stop

Start & Stop

Start & Stop

Start & Stop

SCHEDULE FOR MECHANICAL VENTILATION SYSTEM (EXHAUST FAN)

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 34 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

Sl.No.

2

System No. VE-1 to VE-3 VE-4

3

VE-5

5

VE-7

6 7

VE-8 VE-8A

8 9

VE-9 VE-10

10

VE-11

11 12

VE-12 VE-13

1

PREPARED

GSRK/ARUN

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

Catering Area

OWS

Track Hopper underground portion

Start & Stop

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

Start & Stop

Wagon Tippler – 3 and TH-3 underground portion U/G portion of Conveyor 2A/B tunnel from TH-3 up to TH-1 & 2 U/G portion of Conveyor 2A/B tunnel from TH-1 & 2 up to TH-4, U/G portion of TH-4 and U/G portion of Conveyor 2A/B from TH4 up to TH-5 U/G portion of TH-5 U/G portion of Conveyor 5A/B tunnel up to pent house U/G portion of Crusher house U/G portion of Conveyor 23A/B tunnel up to pent house U/G portion of Conveyor 11A/B tunnel up to pent house Battery room of MCC-1 Battery room of MCC-2

Start & Stop

Start & Stop

Start & Stop Start & Stop Start & Stop Start & Stop Start & Stop Start & Stop Start & Stop


CHECKED

MS/NH


Sheet 35 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

iii)

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

SCHEDULE FOR PRESSURISED VENTILATION SYSTEM (SUPPLY FAN) Sl.No 1 2 3 4 5 6 7

System No. VS-12 VS-13 VS-14 VS-15 VS-16 VS-17 VS-18

Catering Area MCC-1 MCC-2 MCC-3 MCC-4 MCC-5 MCC-6 MCC-7

OWS Start & Stop Start & Stop Start & Stop Start & Stop Start & Stop Start & Stop Start & Stop

4.0.5 AIR CONDITIONING SYSTEM:

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 36 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

Air Conditioning system is generally provided for the treatment of air so as to control, simultaneously, its temperature, humidity, cleanliness and distribution to meet the comfort requirements of occupants, of the conditioned space. Air Conditioning system consists of hermetic compressor (scroll/rotary type), direct expansion multi row deep cooling coil of copper having mechanically bonded aluminum fins complete with refrigerant distributor & thermostatic expansion valve, v-belt driven (in case of Packaged Air Conditioning system) evaporator with air blower (s) suitable for external static pressure. All air conditioning systems will have local start/stop facility (wherever required).

SYSTEM SUMMARY FOR PACKAGED AIR CONDITIONING SYSTEM Sl. No.

Building & Location

1.

Control Room - 1, near WT-1

2.


3.


4.

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

SCHEDULE FOR WATER COOLED PAC SYSTEM CONDENSER PUMPS Sl.No 1

System No. ACP-1A/B

Catering Area Control room-1

2

ACP-2A/B

Control room-2

3

ACP-3A/B

Control room-3

4 ACP-4A/B Main CHP control room SYSTEM SUMMARY FOR WINDOW AIR CONDITIONER UNIT Sl.

PREPARED

Building & Location

GSRK/ARUN


CHECKED

MS/NH


Sheet 37 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

No. 1.

RIO Room in MCC-1 (On wall)

2.

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

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

5.0.0 SEQUENTIAL INTERLOCK FOR CONVEYORS & OTHER EQUIPMENT System Stop: When system stop command is given, first all feeding equipment (Like Stacker Reclaimer) will stop &after some time delay all equipments will stop sequentially. Emergency Stop: In case of emergency stop PB pressed all drives shall be stopped immediately. Fire Protection: In case of fire detection all drives shall be stopped immediately.

5.0.1 CONVEYOR When start command to conveyor is given first the command will go to start respective Oil circulating pump for scoop coupling of conveyor and release the brake (simultaneously), after releasing the brake command will go to conveyor main motor, after starting main motor, command will go to engage (OUT) scoop through actuator for scoop coupling of conveyor. If off command is given to conveyor, first the scoop will get dis-engaged then brake is applied after which main motor stops and finally oil circulating pump stops.

Main conveyor Motor: There

is no auto-on

and

auto-off commands for

conveyor

(except

sequence start/stop

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

PREPARED



All winding temperature less than 120 deg C.



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



Brake for respective conveyor is released

GSRK/ARUN


CHECKED

MS/NH


Sheet 38 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO: 

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



Electrical conditions are healthy.



Local Stop Not Pressed /Reset.

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

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

Any winding temperature is more than 130 deg C.



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



Electrical trip conditions are present.



Brake for respective conveyor not released.

Brake for Conveyor: When command to main conveyor is given, it will auto on (release) the brake and when conveyor motor is off or fluid coupling dis-engaged then brake will be applied automatically. Permissive conditions: 1) Electrical conditions are healthy. Trip condition: 1)

Electrical conditions are not healthy.

Oil Circulating Pump for Scoop Coupling of Conveyor: When command to main conveyor is given, it will auto start oil circulating pump and when conveyor motor is given off command then oil circulating pump will stop automatically after some time delay (30 Sec Adjustable). Permissive (All the below conditions should be present to start oil circulating pump for scoop coupling of conveyor):

PREPARED



DP across filter < 0.5bar



Oil Line pressure ≥ 1.2 bar



Oil temp ≤ 90 deg C.



Oil Cooler fan started.

GSRK/ARUN


CHECKED

MS/NH


Sheet 39 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO: 




Electrical condition healthy.

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

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

˃



DP across filter



Oil Line pressure < 0.8 bar



Oil temp



Oil Cooler fan motor fails.



Local Stop Pressed.



Electrical trip condition present.

˃

1.1 bar

110 deg C.

Actuator For Fluid Coupling Of Conveyor: When start command to main conveyor is given, it will engage (OUT) scoop coupling and when conveyor motor is given off command then it will dis-engage (IN) scoop coupling automatically. Permissive conditions (actuator for scoop coupling of conveyor will OUT (engaged) scoop automatically when all the below conditions are present): 

Oil circulating pump for respective conveyor is ON.



Main motor of respective conveyor is ON.



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



PCS (Pull cord switch) is not operated.



BSS (Belt sway switch) is not operated.



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



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






Succeeding conveyor main motor on & scoop coupling engaged and only one Flap gate/shuttle head drive is in position to feed succeeding conveyor & other flap gate can be positioned on

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 40 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

TIR1-EPC-CHP-DM-W-0097 30.11.2010

REV NO:

A

the same conveyor only if the same upstream conveyor not running (if applicable according to Down stream Feeders) 




Trip command from machines (Stacker Reclaimer, Travelling Tripper) to respective conveyors. Applicable for Conv. 19 & 21

•

- Trip Command from Stacker

Cum Reclaimer-1 & Stacker Cum Reclaimer-2 respectively. Applicable for Conv. 11/13/15/17

•

- Trip Command from Travelling

Tripper-TTR1, TTR2, TTR3 & TTR4 respectively. Trip conditions (actuator for scoop coupling of conveyor will IN (dis-engage) scoop if any of the condition will be present): 

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



PCS (Pull cord switch) is operated.



BSS (Belt sway switch) is operated.



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



Oil circulating pump OFF.



Respective conveyor main motor is OFF.



Succeeding conveyor main motor off or scoop coupling dis-engaged and running conveyor feeding to that conveyor.



Electrical trip conditions are present



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



Metal is detected (if applicable)



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

5.0.2 CRUSHER:

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 41 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

When start command to crusher is given first the command will go to start respective oil circulating pump for scoop coupling of crusher then that command will go to crusher main motor, after starting main motor, command will go to engage (OUT) scoop through actuator for scoop coupling of crusher. Main Crusher Motor: There are no auto-on and auto-off commands for crusher (except sequence start/stop commands). Permissive conditions (crusher can be started automatically or manually when all the conditions given below are available) 

All winding temperature less than 120 deg C.



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



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









Hydraulic door closed.

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

Any winding temperature is more than 130 deg C.



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




Coupling Cooling Oil Circulating Pump for Crusher: When command to main crusher is given, it will auto start oil circulating pump and when crusher motor is given off command then oil circulating pump will stop automatically after some time delay (30 Sec Adjustable). Permissive (All the below conditions should be present to start oil circulating pump):

PREPARED



DP across filter < 0.5bar



Oil Line pressure ≥ 1.2 bar

GSRK/ARUN


CHECKED

MS/NH


Sheet 42 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO: 

Oil temp ≤ 90 deg C.



Oil Cooler fan started.






Electrical condition healthy.

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

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



DP across filter



Oil Line pressure < 0.8 bar



Oil temp



Oil Cooler fan motor fails.



Local Stop Pressed.



Electrical trip condition present.

˃

1.1 bar

110 deg C.

Actuator For Fluid Coupling Of Crusher: When start command to main crusher is given, it will engage (OUT) scoop coupling and when crusher motor is given off command then it will dis-engage (IN) scoop coupling automatically. Permissive conditions (actuator for fluid coupling of crusher will be OUT (engaged) automatically when all the below conditions are present):

PREPARED



Oil circulating pump for respective crusher is ON.



Main motor of respective crusher is ON.



Crusher ZSS (Zero speed switch) is NOT operated.



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



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









Hydraulic door closed.

GSRK/ARUN


CHECKED

MS/NH


Sheet 43 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

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

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



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



Oil circulating pump OFF.



Respective crusher main motor is OFF.






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



Respective Crusher Vibration Trip.



Hydraulic door open.

5.0.4 TRAVELLING TRIPPER Permissive conditions: 

Bunker Conveyor running.






Motor O/L not tripped.



Over travel limit switch not tripped.

Trip conditions: 

Local Stop Pressed.



Motor O/L tripped.



Over travel limit switch tripped.

5.0.5 ILMS (INLINE MAGNETIC SEPERATOR) There is no Auto ON/OFF Conditions. Permissive conditions: 

PREPARED

ILMS should be selected in remote.

GSRK/ARUN


CHECKED

MS/NH


Sheet 44 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO: 

Under current relay trip signal not available.



Control supply should be healthy.



Local stop not pressed / Reset condition

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

Trip conditions: Respective conveyor off with on delay of 600 sec. Under current relay trip signal available. Control supply not healthy. Cleated belt trip. 5.0.6 MD (METAL DETECTOR) There is no Auto ON/OFF Conditions. Permissive conditions: 

MD should be selected in remote.



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



Local stop not pressed / Reset condition


Respective conveyor off with on delay of 600 sec.



Metal detected.

5.0.7 IN-LINE BELT WEIGH SCALE: There is no Auto ON/OFF Conditions. Permissive conditions: 

BS should be selected in remote.



Respective Conveyor is ON.

5.0.8 FG (FLAP GATE) There is no Auto ON/OFF Conditions:Permissive conditions:

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 45 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

Feeding conveyor “OFF FEEDBACK” will be permissive for forward and reverse direction ( Not applicable for bunker flap gate from FG-30 to FG-41 for BU-1,2&3 and FG-52 to FG-59 for BU4&5).Flap gate can be changed (FG-30 to FG-41 for BU-1,2&3 and FG-52 to FG-59 for BU-4&5) only when succeeding conveyor running. 5.0.9 FLOW DIVIDER (FD) There is no Auto ON/OFF Conditions. Permissive conditions: Feeding Conveyor/Equipment “OFF FEEDBACK” will be permissive for forward and reverse directions. 5.0.10 ROLLER SCREEN There is no Auto ON/OFF Conditions. Permissive conditions: 




Local stop not pressed / Reset condition.



Respective Crusher ON



Respective BF/SC/RSC is ON



CBS (chute block switch) is not operated.





Respective Crusher OFF



Respective BF/SC/RSC is OFF



CBS (chute block switch) operated.

5.0.14 UTILITY PUMP’S (SWP, PWP, THP, WTP, WTDP, DSP, DFP): When running pump trips standby pump starts automatically. Electrical Condition: Same as LT drive. Permissive conditions: 

PREPARED


GSRK/ARUN


CHECKED

MS/NH


Sheet 46 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A






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



Centrifugal Pump (Running + Standby) Water Level Permissive



Centrifugal Pump (Standby) Not running.





Centrifugal Pump (Running + Standby) Water Level Low



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

Ann. Condition : DP switch (In pump suction) high will be annunciated 5.0.15 SOLENOID VALVES (FOR DUST SUPPRESSION SYSTEM): Auto ON Conditions 

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

Auto OFF Conditions 

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

Permissive conditions: 

Centrifugal Pump running.


Centrifugal Pump not running.

5.0.15 VENTILATION SYSTEM: CENTRIFUGAL FAN / AXIAL FAN (For VE, VS): There is no Auto ON/OFF Conditions. Electrical Condition: Same as LT drive. Permissive conditions: 





Trip conditions:

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 47 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO: 

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

Electrical conditions are not healthy.

6.0.0 THE PERMISSIVE CONDITONS FOR OPERATION OF CHP * Feeding Flap gates to be positioned after selection of path. 6.0.1 FLOW PATH – 1: SHIP UNLOADERS TO STOCKYARD S.No.

Equipment CONV. 19(STACKING)

Permissive conditions STACKER STR-1 IS RUNNING

OR

OR

CONV. 21(STACKING)

STACKER STR-2 IS RUNNING CONV. 19 (STACKING) IS RUNNING AND FLAP GATE FG 27

1

2

CONV. 18 A

IS POSITIONED (POS-1) TO FEED CONV. 19 OR CONV. 20 A IS RUNNING AND FLAP GATE FG 27 IS POSITIONED (POS-2) TO FEED CONV. 20 A CONV. 19 (STACKING) IS RUNNING AND FLAP GATE FG 28

3

CONV. 18 B

IS POSITIONED (POS-1) TO FEED CONV. 19 OR CONV. 20 B IS RUNNING AND FLAP GATE FG 28 IS POSITIONED (POS-2) TO FEED CONV. 20 B

CONV. 20 A 4

OR

CONV. 21 (STACKING) IS RUNNING

CONV. 20 B

5

PREPARED

CONV. 7 A

GSRK/ARUN

CONV. 18 B IS RUNNING AND DIVERTER GATE DG -1 IS POSITIONED (POS-1) TO FEED CONV. 18 B.


CHECKED

MS/NH


Sheet 48 Of 71


PROJ PROJE ECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO

APML DATED

ECC DIVISION

REV NO:

6

CONV. 7 B

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

CONV. 18 A IS RUNNING AND DIVERTER GATE DG -2 IS POSITIONED (POS-1) TO FEED CONV. 18 A. CONV. 7 A IS RUNNING AND FLAP GATE FG -7 IS POSITIONED (POS-1) TO FEED CONV. 7 A.

7

CONV. 6 A

OR CONV. 7 B IS RUNNING AND FLAP GATE FG -7 IS POSITIONED (POS-2) TO FEED CONV. 7 B. CONV. 7 A IS RUNNING AND FLAP GATE FG -8 IS POSITIONED (POS-1) TO FEED CONV. 7 A.

8

CONV. 6 B

OR CONV. 7 B IS RUNNING AND FLAP GATE FG -8 IS POSITIONED (POS-2) TO FEED CONV. 7 B. CONV. 6 A IS RUNNING AND FLAP GATE FG -5 IS POSITIONED (POS-1) TO FEED CONV. 6 A.

9

CONV. 5 A

OR ROLLER SCREEN 1 & CRUSHER 1 ARE IN OPERATION AND FLAP GATE FG -5 IS POSITIONED (POS-2) TO FEED

10

CONV. 5 B

ROLLER SCREEN AND CONV. 6 A IS RUNNING. CONV. 6 B IS RUNNING AND FLAP GATE FG -6 IS POSITIONED (POS-1) TO FEED CONV. 6 B. OR ROLLER SCREEN 2 & CRUSHER 2 ARE IN OPERATION AND FLAP GATE FG -6 IS POSITIONED (POS-2) TO FEED

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 49 Of Of 71


PROJ PROJE ECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO

APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

ROLLER SCREEN AND CONV. 6 B IS RUNNING. CONV. 5 A IS RUNNING AND FLAP GATE FG-3 IS POSITIONED (POS-1) TO FEED CONV. 5 A AND ILMS-3 & MD-5 ARE ON. 11

CONV. 4 A

OR CONV. 5 B IS RUNNING AND FLAP GATE FG-3 IS POSITIONED (POS-2) TO FEED CONV. 5 B AND ILMS-4 & MD-6 ARE ON. CONV. 5 A IS RUNNING AND FLAP GATE FG-4 IS POSITIONED (POS-1) TO FEED CONV. 5 A AND ILMS-3 & MD-5 ARE ON.

12

CONV. 4 B

OR CONV. 5 B IS RUNNING AND FLAP GATE FG-4 IS POSITIONED (POS-2) TO FEED CONV. 5 B AND ILMS-4 & MD-6 ARE ON. CONV. 4 A IS RUNNING AND FLAP GATE FG-2A IS POSITIONED (POS-1) TO FEED CONV. 4 A.

13

CONV. 3 A2

OR CONV. 4 B IS RUNNING AND FLAP GATE FG-2A IS POSITIONED (POS-2) TO FEED CONV. 4 A. CONV. 4 A IS RUNNING AND FLAP GATE FG-2B IS POSITIONED (POS-1) TO FEED CONV. 4 A.

14

CONV. 3 B2

OR CONV. 4 B IS RUNNING AND FLAP GATE FG-2B IS POSITIONED (POS-2) TO FEED CONV. 4 A.

15

CONV. 3 A1

CONV. 3 A2 IS RUNNING AND FLAP GATE FG-1A IS POSITIONED (POS-1) TO FEED CONV. 3 A2 AND MD-3 IS

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 50 Of Of 71


PROJ PROJE ECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO

APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

ON. OR CONV. 3 B2 IS RUNNING AND FLAP GATE FG-1A IS POSITIONED (POS-2) TO FEED CONV. 3 B2 AND MD-4 IS ON. CONV. 3 A2 IS RUNNING AND FLAP GATE FG-1B IS POSITIONED (POS-1) TO FEED CONV. 3 A2 AND MD-3 IS 16

ON.

CONV. 3 B1

OR CONV. 3 B2 IS RUNNING AND FLAP GATE FG-1B IS POSITIONED (POS-2) TO FEED CONV. 3 B2 AND MD-4 IS ON. CONV. 3 A1 IS RUNNING AND FLAP GATE FG-1 IS POSITIONED (POS-1) TO FEED CONV. 3 A1.

17

CONV. 2 A

OR CONV. 3 B1 IS RUNNING AND FLAP GATE FG-1 IS POSITIONED (POS-2) TO FEED CONV. 3 B1. CONV. 3 A1 IS RUNNING AND FLAP GATE FG-2 IS POSITIONED (POS-1) TO FEED CONV. 3 A1.

18

CONV. 2 B

OR CONV. 3 B1 IS RUNNING AND FLAP GATE FG-2 IS

19 20 21

PREPARED

CONV. 1 A CONV. 1 B FROM SHIP

POSITIONED (POS-2) TO FEED CONV. 3 B1. CONV. 2 A IS RUNNING CONV. 2 B IS RUNNING CONV. 1 A IS RUNNING AND ILMS-1 & MD-1 ARE ON.

UNLOADERS

OR

GSRK/ARUN


CHECKED

MS/NH


Sheet 51 Of Of 71


PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO

APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

CONV. 1 B IS RUNNING AND ILMS-2 & MD-2 ARE ON. 6.0.2

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

1

TTR-4

2

CONV. 17

BUNKERS OF BUNKER UNIT BU-4 ARE NOT FULL BUNKERS OF BUNKER UNIT BU-4 IS NOT FULL (AND) TRAVELLING TRIPPER TTR-4 IS RUNNING AND FLAP GATE FG-25 OR 26 IS POSITIONED (POS1/2) TO FEED BU-4

CONV. 16 A 3

OR

CONV. 17 IS RUNNING

CONV. 16 B CONV. 16 A IS RUNNING AND FLAP GATE FG-21 IS 4

CONV. 14 A

POSITIONED (POS 1) TO FEED CONV. 16 A. OR CONV. 15 IS RUNNING AND FLAP GATE FG-21 IS POSITIONED (POS 2) TO FEED CONV. 15. CONV. 16 B IS RUNNING AND FLAP GATE FG-22 IS

5

CONV. 14 B

POSITIONED (POS 1) TO FEED CONV. 16 B. OR CONV. 15 IS RUNNING AND FLAP GATE FG-22 IS

6

TTR-3

7

CONV. 15

PREPARED

GSRK/ARUN

POSITIONED (POS 2) TO FEED CONV. 15. B UNKERS OF BUNKER UNIT BU-3 ARE NOT FULL BUNKERS OF BUNKER UNIT BU-3 IS NOT FULL (AND) DOCUMENT TITLE OPERATION & CONTROL PHILOSOPHY OF

CHECKED

MS/NH


Sheet 52 Of 71


PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO

APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

TRAVELLING TRIPPER TTR-3 IS RUNNING AND FLAP GATE FG-23 OR 24 IS POSITIONED (POS1/2) TO FEED BU-3 CONV. 14 A IS RUNNING AND FLAP GATE FG-17 IS POSITIONED (POS 1) TO FEED CONV. 14 A. 8

CONV. 12 A

OR CONV. 13 IS RUNNING AND FLAP GATE FG-18 IS POSITIONED (POS 2) TO FEED CONV. 13. CONV. 14 B IS RUNNING AND FLAP GATE FG-18 IS POSITIONED (POS 1) TO FEED CONV. 14 B.

9

CONV. 12 B

OR CONV. 13 IS RUNNING AND FLAP GATE FG-18 IS

10

TTR-2

11

CONV. 13

POSITIONED (POS 2) TO FEED CONV. 13. BUNKERS OF BUNKER UNIT BU-2 ARE NOT FULL BUNKERS OF BUNKER UNIT BU-2 IS NOT FULL (AND) TRAVELLING TRIPPER TTR-2 IS RUNNING AND FLAP GATE FG-19 OR 20 IS POSITIONED (POS1/2) TO FEED BU-2 CONV. 12 A IS RUNNING AND FLAP GATE FG-13 IS POSITIONED (POS 1) TO FEED CONV. 12 A.

12

CONV. 10 A

OR CONV. 11 IS RUNNING AND FLAP GATE FG-14 IS POSITIONED (POS 2) TO FEED CONV. 11.

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 53 Of 71


PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO

APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

CONV. 12 B IS RUNNING AND FLAP GATE FG-14 IS POSITIONED (POS 1) TO FEED CONV. 12 B. 13

CONV. 10 B


14

TTR-1

BUNKERS OF BUNKER UNIT BU-1 ARE NOT FULL BUNKERS OF BUNKER UNIT BU-1 IS NOT FULL (AND)

15

CONV. 11

TRAVELLING TRIPPER TTR-1 IS RUNNING AND FLAP GATE FG-15 OR 16 IS POSITIONED (POS1/2) TO FEED BU-1 CONV. 10 A IS RUNNING AND FLAP GATE FG-11 IS POSITIONED (POS 1) TO FEED CONV. 10 A AND BW7 IS ON.

16

CONV. 9 A

OR CONV. 10 B IS RUNNING AND FLAP GATE FG-11 IS POSITIONED (POS 2) TO FEED CONV. 10 B AND BW8 IS ON. CONV. 10 A IS RUNNING AND FLAP GATE FG-12 IS POSITIONED (POS 1) TO FEED CONV. 10 A AND BW7 IS ON.

17

CONV. 9 B

OR CONV. 10 B IS RUNNING AND FLAP GATE FG-12 IS POSITIONED (POS 2) TO FEED CONV. 10 B AND BW8 IS ON. CONV. 9 A IS RUNNING AND FLAP GATE FG-9 IS POSITIONED (POS 1) TO FEED CONV. 9 A AND ILMS5 & MD7 ARE ON.

18

CONV. 8 A

OR CONV. 9 B IS RUNNING AND FLAP GATE FG-9 IS POSITIONED (POS 2) TO FEED CONV. 9 B AND ILMS6 & MD8

19

PREPARED

CONV. 8 B

GSRK/ARUN

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


CHECKED

MS/NH


Sheet 54 Of 71


PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO

APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

POSITIONED (POS 1) TO FEED CONV. 9 A AND ILMS5 & MD7 ARE ON. OR CONV. 9 B IS RUNNING AND FLAP GATE FG-10 IS POSITIONED (POS 2) TO FEED CONV. 9 B AND ILMS6 & MD8 ARE ON.

20

CONV. 7 A

21

CONV. 7 B

CONV. 8 A IS RUNNING AND DIVERTER GATE DG-1 IS POSITIONED (POS 2) TO FEED CONV. 8 A.

CONV. 8 B IS RUNNING AND DIVERTER GATE DG-2 IS POSITIONED (POS 2) TO FEED CONV. 8 B. CONV. 7 A IS RUNNING AND FLAP GATE FG -7 IS POSITIONED (POS-1) TO FEED CONV. 7 A.

22

CONV. 6 A

OR CONV. 7 B IS RUNNING AND FLAP GATE FG -7 IS POSITIONED (POS-2) TO FEED CONV. 7 B . CONV. 7 A IS RUNNING AND FLAP GATE FG -8 IS

23

CONV. 6 B

POSITIONED (POS-1) TO FEED CONV. 7 A. OR CONV. 7 B IS RUNNING AND FLAP GATE FG -8 IS

24

PREPARED

CONV. 5 A

GSRK/ARUN

POSITIONED (POS-2) TO FEED CONV. 7 B. CONV. 6 A IS RUNNING AND FLAP GATE FG -5 IS POSITIONED (POS-1) TO FEED CONV. 6 A. DOCUMENT TITLE OPERATION & CONTROL PHILOSOPHY OF

CHECKED

MS/NH


Sheet 55 Of 71


PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO

APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

OR ROLLER SCREEN 1 & CRUSHER 1 ARE IN OPERATION AND FLAP GATE FG -5 IS POSITIONED (POS-2) TO FEED ROLLER SCREEN AND CONV. 6 A IS RUNNING. CONV. 5 A IS RUNNING AND FLAP GATE FG-3 IS POSITIONED (POS-1) TO FEED CONV. 5 A AND ILMS-3 & MD5 ARE ON. 25

CONV. 4 A

OR CONV. 5 B IS RUNNING AND FLAP GATE FG-3 IS POSITIONED (POS-2) TO FEED CONV. 5 B AND ILMS-4 & MD6 ARE ON. CONV. 5 A IS RUNNING AND FLAP GATE FG-4 IS POSITIONED (POS-1) TO FEED CONV. 5 A AND ILMS-3 & MD-

26

CONV. 4 B

5 ARE ON. OR CONV. 5 B IS RUNNING AND FLAP GATE FG-4 IS POSITIONED (POS-2) TO FEED CONV. 5 B AND ILMS-4 & MD6 ARE ON. CONV. 4 A IS RUNNING AND FLAP GATE FG-2A IS POSITIONED (POS-1) TO FEED CONV. 4 A.

27

CONV. 3 A2

OR CONV. 4 B IS RUNNING AND FLAP GATE FG-2A IS POSITIONED (POS-2) TO FEED CONV. 4 A.

28

PREPARED

CONV. 3 B2

GSRK/ARUN

CONV. 4 A IS RUNNING AND FLAP GATE FG-2B IS POSITIONED (POS-1) TO FEED CONV. 4 A.


CHECKED

MS/NH


Sheet 56 Of 71


PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO

APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

OR CONV. 4 B IS RUNNING AND FLAP GATE FG-2B IS POSITIONED (POS-2) TO FEED CONV. 4 A. CONV. 3 A2 IS RUNNING AND FLAP GATE FG-1A IS POSITIONED (POS-1) TO FEED CONV. 3 A2 AND MD-3 IS ON. 29

CONV. 3 A1

OR CONV. 3 B2 IS RUNNING AND FLAP GATE FG-1A IS POSITIONED (POS-2) TO FEED CONV. 3 B2 AND MD-4 IS ON. CONV. 3 A2 IS RUNNING AND FLAP GATE FG-1B IS POSITIONED (POS-1) TO FEED CONV. 3 A2 AND MD-3 IS ON.

30

CONV. 3 B1


31

CONV. 2 A


32

CONV. 2 B


33 34

PREPARED

CONV. 1 A CONV. 1 B

GSRK/ARUN

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


CHECKED

MS/NH


Sheet 57 Of 71


PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO

APML DATED

ECC DIVISION

REV NO:

35

6.0.3 1 2

FROM SHIP UNLOADERS

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

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

PATH- III: SHIP UNLOADERS TO BUNKER UNITS VIA CRUSHER HOUSE WITH STACKING TTR-4 CONV. 17

BUNKERS OF BUNKER UNIT BU-4 ARE NOT FULL BUNKERS OF BUNKER UNIT BU-4 IS NOT FULL (AND) TRAVELLING TRIPPER TTR-4 IS RUNNING AND FLAP GATE FG-25 OR 26 IS POSITIONED (POS1/2) TO FEED BU-4

CONV. 16 A 3

OR

CONV. 17 IS RUNNING

CONV. 16 B CONV. 16 A IS RUNNING AND FLAP GATE FG-21 IS POSITIONED (POS 1) TO FEED CONV. 16 A. 4

CONV. 14 A


5

CONV. 14 B


6

TTR-3

POSITIONED (POS 2) TO FEED CONV. 15. BUNKERS OF BUNKER UNIT BU-3 ARE NOT FULL BUNKERS OF BUNKER UNIT BU-3 IS NOT FULL (AND)

7

CONV. 15

TRAVELLING TRIPPER TTR-3 IS RUNNING AND FLAP GATE FG-23 OR 24 IS POSITIONED (POS1/2) TO FEED BU-3

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 58 Of 71


PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO

APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

CONV. 14 A IS RUNNING AND FLAP GATE FG-17 IS POSITIONED (POS 1) TO FEED CONV. 14 A. 8

CONV. 12 A


9

CONV. 12 B


10

TTR-2


11

CONV. 13


CONV. 12 A IS RUNNING AND FLAP GATE FG-13 IS POSITIONED (POS 1) TO FEED CONV. 12 A. 12

CONV. 10 A


PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 59 Of 71


PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO

APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A


CONV. 10 B


14

TTR-1

15

CONV. 11

BUNKERS OF BUNKER UNIT BU-1 ARE NOT FULL BUNKERS OF BUNKER UNIT BU-1 IS NOT FULL (AND) TRAVELLING TRIPPER TTR-1 IS RUNNING AND FLAP GATE FG-15 OR 16 IS POSITIONED (POS1/2) TO FEED BU-1 CONV. 10 A IS RUNNING AND FLAP GATE FG-11 IS

16

CONV. 9 A

POSITIONED (POS 1) TO FEED CONV. 10 A AND BW7 IS ON. OR CONV. 10 B IS RUNNING AND FLAP GATE FG-11 IS POSITIONED (POS 2) TO FEED CONV. 10 B AND BW8 IS ON. CONV. 10 A IS RUNNING AND FLAP GATE FG-12 IS

17

CONV. 9 B

POSITIONED (POS 1) TO FEED CONV. 10 A AND BW7 IS ON. OR CONV. 10 B IS RUNNING AND FLAP GATE FG-12 IS POSITIONED (POS 2) TO FEED CONV. 10 B AND BW8 IS ON. CONV. 9 A IS RUNNING AND FLAP GATE FG-9 IS

18

CONV. 8 A

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

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 60 Of 71


PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO

APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

CONV. 9 B IS RUNNING AND FLAP GATE FG-9 IS POSITIONED (POS 2) TO FEED CONV. 9 B AND ILMS6 & MD8 ARE ON.

CONV. 9 A IS RUNNING AND FLAP GATE FG-10 IS POSITIONED (POS 1) TO FEED CONV. 9 A AND ILMS5 & MD7 19

CONV. 8 B

ARE ON. OR CONV. 9 B IS RUNNING AND FLAP GATE FG-10 IS POSITIONED (POS 2) TO FEED CONV. 9 B AND ILMS6 & MD8 ARE ON.

20

CONV. 7 A

CONV. 8 A & CONV. 18 B ARE RUNNING AND DIVERTER GATE DG-1 IS POSITIONED (POS 3) TO FEED BOTH CONV. 8 A & CONV. 18 B.

21

CONV. 7 B

CONV. 8 B & CONV. 18 A ARE RUNNING AND DIVERTER GATE DG-2 IS POSITIONED (POS 3) TO FEED BOTH CONV. 8 B & CONV. 18 A.

CONV. 22

19(STACKING) OR CONV. 21(STACKING)

STACKER STR-1 IS RUNNING OR STACKER STR-2 IS RUNNING CONV. 19 (STACKING) IS RUNNING AND FLAP GATE FG 27

23

CONV. 18 A

IS POSITIONED (POS-1) TO FEED CONV. 19 OR CONV. 20 A IS RUNNING AND FLAP GATE FG 27 IS

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 61 Of 71


PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO

APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

POSITIONED (POS-2) TO FEED CONV. 20 A CONV. 19 (STACKING) IS RUNNING AND FLAP GATE FG 28

24

CONV. 18 B

IS POSITIONED (POS-1) TO FEED CONV. 19 OR CONV. 20 B IS RUNNING AND FLAP GATE FG 28 IS POSITIONED (POS-2) TO FEED CONV. 20 B

CONV. 20 A 25

OR

CONV. 21 (STACKING) IS RUNNING

CONV. 20 B CONV. 7 A IS RUNNING AND FLAP GATE FG -7 IS POSITIONED (POS-1) TO FEED CONV. 7 A. 26

CONV. 6 A

OR CONV. 7 B IS RUNNING AND FLAP GATE FG -7 IS POSITIONED (POS-2) TO FEED CONV. 7 B. CONV. 7 A IS RUNNING AND FLAP GATE FG -8 IS

27

CONV. 6 B

POSITIONED (POS-1) TO FEED CONV. 7 A. OR CONV. 7 B IS RUNNING AND FLAP GATE FG -8 IS POSITIONED (POS-2) TO FEED CONV. 7 B. CONV. 6 A IS RUNNING AND FLAP GATE FG -5 IS POSITIONED (POS-1) TO FEED CONV. 6 A.

28

CONV. 5 A

OR ROLLER SCREEN 1 & CRUSHER 1 ARE IN OPERATION AND FLAP GATE FG -5 IS POSITIONED (POS-2) TO FEED ROLLER SCREEN AND CONV. 6 A IS RUNNING.

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 62 Of 71


PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO

APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

CONV. 6 B IS RUNNING AND FLAP GATE FG -6 IS POSITIONED (POS-1) TO FEED CONV. 6 B. 29

CONV. 5 B

OR ROLLER SCREEN 2 & CRUSHER 2 ARE IN OPERATION AND FLAP GATE FG -6 IS POSITIONED (POS-2) TO FEED ROLLER SCREEN AND CONV. 6 B IS RUNNING. CONV. 5 A IS RUNNING AND FLAP GATE FG-3 IS POSITIONED (POS-1) TO FEED CONV. 5 A AND ILMS-3 & MD5 ARE ON.

30

CONV. 4 A

OR CONV. 5 B IS RUNNING AND FLAP GATE FG-3 IS POSITIONED (POS-2) TO FEED CONV. 5 B AND ILMS-4 & MD6 ARE ON. CONV. 5 A IS RUNNING AND FLAP GATE FG-4 IS POSITIONED (POS-1) TO FEED CONV. 5 A AND ILMS-3 & MD5 ARE ON.

31

CONV. 4 B

OR CONV. 5 B IS RUNNING AND FLAP GATE FG-4 IS POSITIONED (POS-2) TO FEED CONV. 5 B AND ILMS-4 & MD6 ARE ON. CONV. 4 A IS RUNNING AND FLAP GATE FG-2A IS POSITIONED (POS-1) TO FEED CONV. 4 A.

32

CONV. 3 A2

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

33

PREPARED

CONV. 3 B2

GSRK/ARUN

POSITIONED (POS-2) TO FEED CONV. 4 A. CONV. 4 A IS RUNNING AND FLAP GATE FG-2B IS POSITIONED (POS-1) TO FEED CONV. 4 A.


CHECKED

MS/NH


Sheet 63 Of 71


PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO

APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

OR CONV. 4 B IS RUNNING AND FLAP GATE FG-2B IS POSITIONED (POS-2) TO FEED CONV. 4 A. CONV. 3 A2 IS RUNNING AND FLAP GATE FG-1A IS POSITIONED (POS-1) TO FEED CONV. 3 A2 AND MD-3 IS ON. 34

CONV. 3 A1

OR CONV. 3 B2 IS RUNNING AND FLAP GATE FG-1A IS POSITIONED (POS-2) TO FEED CONV. 3 B2 AND MD-4 IS ON. CONV. 3 A2 IS RUNNING AND FLAP GATE FG-1B IS POSITIONED (POS-1) TO FEED CONV. 3 A2 AND MD-3 IS ON.

35

CONV. 3 B1


36

CONV. 2 A


37

CONV. 2 B


38 39 40

PREPARED

CONV. 1 A CONV. 1 B FROM SHIP

POSITIONED (POS-2) TO FEED CONV. 3 B1. CONV. 2 A IS RUNNING CONV. 2 B IS RUNNING CONV. 1 A IS RUNNING AND ILMS-1 & MD-1 ARE ON.

UNLOADERS

OR

GSRK/ARUN


CHECKED

MS/NH


Sheet 64 Of 71


PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO

APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

CONV. 1 B IS RUNNING AND ILMS-2 & MD-2 ARE ON. 6.0.4 1

PATH- IV: STOCK YARD TO BUNKER UNITS TTR-4 BUNKERS OF BUNKER UNIT BU-4 ARE NOT FULL BUNKERS OF BUNKER UNIT BU-4 IS NOT FULL (AND)

2

CONV. 17


CONV. 16 A 3

OR

CONV. 17 IS RUNNING

CONV. 16 B CONV. 16 A IS RUNNING AND FLAP GATE FG-21 IS POSITIONED (POS 1) TO FEED CONV. 16 A. 4

CONV. 14 A


5

CONV. 14 B


6

TTR-3

POSITIONED (POS 2) TO FEED CONV. 15. BUNKERS OF BUNKER UNIT BU-3 ARE NOT FULL BUNKERS OF BUNKER UNIT BU-3 IS NOT FULL (AND)

7

CONV. 15

TRAVELLING TRIPPER TTR-3 IS RUNNING AND FLAP GATE FG-23 OR 24 IS POSITIONED (POS1/2) TO FEED BU-3 CONV. 14 A IS RUNNING AND FLAP GATE FG-17 IS

8

CONV. 12 A

POSITIONED (POS 1) TO FEED CONV. 14 A. OR CONV. 13 IS RUNNING AND FLAP GATE FG-18 IS

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 65 Of 71


PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO

APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

POSITIONED (POS 2) TO FEED CONV. 13. CONV. 14 B IS RUNNING AND FLAP GATE FG-18 IS POSITIONED (POS 1) TO FEED CONV. 14 B. 9

CONV. 12 B


10

TTR-2

11

CONV. 13

POSITIONED (POS 2) TO FEED CONV. 13. BUNKERS OF BUNKER UNIT BU-2 ARE NOT FULL BUNKERS OF BUNKER UNIT BU-2 IS NOT FULL (AND) TRAVELLING TRIPPER TTR-2 IS RUNNING AND FLAP GATE FG-19 OR 20 IS POSITIONED (POS1/2) TO FEED BU-2 CONV. 12 A IS RUNNING AND FLAP GATE FG-13 IS POSITIONED (POS 1) TO FEED CONV. 12 A.

12

CONV. 10 A



CONV. 10 B


14

TTR-1


15

CONV. 11

TRAVELLING TRIPPER TTR-1 IS RUNNING AND FLAP GATE

CONV. 9 A

FG-15 OR 16 IS POSITIONED (POS1/2) TO FEED BU-1 CONV. 10 A IS RUNNING AND FLAP GATE FG-11 IS

16

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 66 Of 71


PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO

APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

POSITIONED (POS 1) TO FEED CONV. 10 A AND BW7 IS ON. OR CONV. 10 B IS RUNNING AND FLAP GATE FG-11 IS POSITIONED (POS 2) TO FEED CONV. 10 B AND BW8 IS ON. CONV. 10 A IS RUNNING AND FLAP GATE FG-12 IS POSITIONED (POS 1) TO FEED CONV. 10 A AND BW7 IS ON. 17

CONV. 9 B

OR CONV. 10 B IS RUNNING AND FLAP GATE FG-12 IS POSITIONED (POS 2) TO FEED CONV. 10 B AND BW8 IS ON. CONV. 9 A IS RUNNING AND FLAP GATE FG- 31 IS POSITIONED (POS 1) TO FEED CONV. 9 A AND ILMS5 & MD7 ARE ON.

18

CONV. 22 A

OR CONV. 9 B IS RUNNING AND FLAP GATE FG-31 IS POSITIONED (POS 2) TO FEED CONV. 9 B AND ILMS6 & MD8 ARE ON. CONV. 9 A IS RUNNING AND FLAP GATE FG- 32 IS POSITIONED (POS 1) TO FEED CONV. 9 A AND ILMS5 & MD7 ARE ON.

19

CONV. 22 B

OR CONV. 9 B IS RUNNING AND FLAP GATE FG-32 IS POSITIONED (POS 2) TO FEED CONV. 9 B AND ILMS6 & MD8 ARE ON.

20

CONV. 19

SR 2 RECLAIMER IS RUNNING & CONV. 22 A IS RUNNING AND FLAP GATE FG-30 IS POSITIONED (POS 1) TO FEED CONV. 22 A.

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 67 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

OR SR 2 RECLAIMER IS RUNNING & CONV. 22 B IS RUNNING AND FLAP GATE FG-30 IS POSITIONED (POS 2) TO FEED CONV. 22 B. SR 1 RECLAIMER IS RUNNING & CONV. 22 A IS RUNNING AND FLAP GATE FG-29 IS POSITIONED (POS 1) TO FEED 21

CONV. 22 A.

CONV. 21

OR SR 1 RECLAIMER IS RUNNING CONV. 22 B IS RUNNING AND FLAP GATE FG-29 IS POSITIONED (POS 2) TO FEED CONV.

22

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

GROUND HOPPER

6.0.5 COMBINATION OF ANY OF THE ABOVE:

7.0.0

ANNUNCIATION SYSTEM

Alarms shall be available at HMI for the following audio-visual fault annunciation purposes. Wherever group annunciation is provided, alarm status of individual equipment will be provided on HMI. a)

6.6 KV Breaker Trip (group wise for each board)

b)

415 V PMCC Breaker Trip (PMCC wise)

c)

415V MCC Breaker Trip (MCC wise)

d)

Bus under voltage for LT MCC Buses( Group Wise)

e)

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

f)

Following group wise annunciation is provided for transformers: 1) Buchholz alarm 2) Winding / oil temp. High alarm

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 68 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

3) Oil level low alarm 4) Buchholz trip 5) Winding / oil temp. High trip g)

AC control supply failure

h)

DC control supply failure

i)

Stand-By CPU in service.

j)

Both CPU fail.

k)

HT motor trip on electrical fault (Group)

l)

LT motor overload tripped (Group)

m)

Belt sway switch operated (Group)

n)

Pull cord switch operated (Group)

o)

Zero speed switch operated (Group)

p)

Chute blocked (Group)

q)

Magnetic separator fault and cleaning belt trip(Group)

r)

Metal detector fault (Group)

s)

In-line conveyor scale fault (Group)

t)

Sampling System faults and trips (Group)

u)

Crusher low speed & crusher bearing temperature – high.

For identification of the fault for a particular conveyor or equipment, the status indication against that conveyor/equipment in the graphics window will start fast flickering and the alarms will be flickering against the particular fault. Also a buzzer will start sounding. After acknowledgement of the fault, the buzzer will stop, but the fast flickering on the mimic & the steady glow on the HMI will continue until the fault is cleared and the alarm is acknowledged. When the fault is cleared and the alarm acknowledged, the status indication of that conveyor/equipment on the graphic will start slow blinking if it is on selected path.

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 69 Of 71

PROJECT


L&T

O9113-M-BM-CS-DB-0097

DOC NO


APML DATED

ECC DIVISION

REV NO:

TIR1-EPC-CHP-DM-W-0097 30.11.2010 A

At the time of fault, the faulty conveyor / equipment as well as the preceding conveyors / equipment in the interlock sequence, will stop except HT motors will continue to run for process fault. In case of motor fault, the HT motor will trip but the succeeding conveyors / equipment will continue to run. The status indication against the preceding conveyors / equipment will start slow blinking while the faulty conveyor / equipment will be fast blinking. Start command will not be indicated alarm is acknowledged after clearance of fault. The sequence of operation of the annunciation system will be as follows:

Sequence Normal

Fault

Press Accept PB

Press Reset PB

Condition Annunciation window. Status Indication Buzzer Annunciation window. Status Indication Buzzer Annunciation window. Status Indication Buzzer Annunciation window. Status Indication

Status Off Steady Glow Off Flickering Fast Flickering Sounding Steady Glow Fast Flickering Off Off Steady Blinking (if on Selected path)

Buzzer

Off(if not on selected path) Off

. 8.0.0 STATUS INDICATION IN OWS (OPERATOR WORK STATION)

The following individual status indications will be provided in LVS. 1.

Conveyor ON

2.

Flap Gate/ Flow Divider

3.

In-line conveyor scale flow rate indication & totalizer

PREPARED

GSRK/ARUN


CHECKED

MS/NH


Sheet 70 Of 71

59928126 Operation Control Philosophy

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