TENDER DOCUMENT FOR BLOCK-B CHP (4.

5 MTY) CMPDI

CHAPTER IV
DETAILED TECHNICAL SPECIFICATIONS

4.1 MECHANICAL
4.1.1 SEMI-MOBILE CRUSHING PLANT (SKID MOUNTED)

4.1.1.1 DUTY REQUIREMENTS

The entire crushing plant shall be supplied, erected & commissioned through OEM
having experience of manufacturing similar plants (Mobile/semi-mobile) of at least
1000 tph and having satisfactory performance of 2 years in operation. If experience
towards Overseas jobs is submitted, then the same should be vetted/ endorsed by
the relevant* embassy/high commission concerned, towards authenticity of
document in English or translated in English language. *(Relevant embassy/High
Commission means the embassy/High Commission in India of the country where
the bidder has executed the said work or country of origin of the bidder OR the
Indian embassy in the country where bidder has executed the work or country of
origin of the bidder.).

Sizer will operate on an average for 15 hours a day over 330 days per year in
general, but the design of the assemblies/ parts of Sizer should be such that it can
be operated for all the 365 days, for 24 hours per day, if required.

The Sizer shall have a ROM feed size up to 1500 mm x 1000 mm x 1000 mm in
general but occasional pieces bigger than this dimension cannot be ruled out. The
rated capacity shall be 1600tph. However, peak capacity will be 1920 tph with
desired product size of (-) 300 mm nominal. Over size, if any, should not be more
than 400 mm in any direction.

The Sizer will be operated continuously and therefore, provision for running and
preventive maintenance should be incorporated in such a way that it can be
performed during operation period. The sizer shall be mounted on rails so that it can
be shifted sideways easily for maintenance. There shall be enough room on the
sizer platform for maintenance.

The Sizer design should be such that it should be able to start in the full load
condition and choke feeding condition.

The Sizer is required to operate in high dusty atmosphere and for this, necessary
design measures should be taken especially for electrical, lubrication and hydraulic
installations.

Occasionally, ROM feed may contain some metallic pieces of large size such as
excavator teeth and track pads etc. Necessary protection should be incorporated in
the design to take care of this. Also the sizer shall be able to be scrolled and
arrangement shall be made to remove tramp metals.

The Sizer is required to operate in ambient temperature and humidity varying widely
at different time during the year.

For deciding the size of Sizer, crushing strength as given in clause no. 2.10 of
Chapter II (Vol-II) (considering the worst scenario viz. crushing only coal with 20%
moisture & 30% shale) shall be factored.
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For percentage of shale in ROM coal feed, refer to clause no. 2.10 of Chapter II
(Vol- II). Sizer selection shall take care of this factor.

Bulk density of shale shall be determined by the contractor through laboratory test.
The test report shall be submitted along with the drawings for approval.

The percentage of moisture in rainy season may go up to 20%. The Sizer shall be
selected considering the worst scenario i.e. crushing only coal with 20% moisture.

Any other details required for selection of Sizer shall be decided by the contractor in
consistence with the requirements of this Bidding Documents.

4.1.1.2 OPERATIONAL PARAMETERS, CHARACTERISTICS AND BASIC DATA

1 Refer to Chapter II (Vol-II) for these information.

Nominal Crushing capacity (tph) 1600

Peak Crushing capacity (tph) 1920

Receiving Hopper size(minimum) (t) : 170

4.1.1.3 COMPLIANCE WITH STANDARDS

The design, selection, and construction of equipment, components and material

shall conform to relevant Indian Standard Specifications and Codes of Practice
(latest revisions) or in their absence to equivalent BS/ DIN/ ANSI Standards. Copy
of the relevant standard(s) shall be furnished along with the drawing.

4.1.1.4 GENERAL DESCRIPTION

The semi-mobile crushing plant should be designed in two parts in order to be

moved, when relocation warranted. During crushing operations, part I (feed unit)
with feed hopper, apron feeder and control cabin should rest on a substructure with
legs and part II Sizer unit on another substructure also with legs. The ground on
which the legs of the plant parts I and II stand at the same height must be in level.
The two parts are not connected. Hard wooden buffers serve for correct spacing.

4.1.1.4.1 COAL RECEIVING UNIT

Coal receiving unit is low height, semi-mobile, skid mounted unit consisting of Apron
feeder, with design capacity. Dumper receiving arrangement has been shown in the
drawing.

The apron feeder will be of suitable width, with capacity equal to that of the crushing unit
with matching suitable electric drive motor. Adequate height skirt plates will be installed
on the apron feeder in such a way that the assembly acts as a receiving hopper to
receive coal from dumpers. The apron feeder will be of robust construction, heavy duty
type and suitable for round the clock continuous operation. It will be suitable for use in
adverse environmental conditions and dusty and moist surroundings. The feeder will be
capable of absorbing the impact of freely falling lumps of maximum size from the dumper
discharge height. The overlapping pan (apron) design should prevent passing of fine coal
to underneath of the feeder. Pans (apron) will preferably be heavy steel plates with
replaceable wear resistant liners for this type of duty. A feeding governor or sliding gate of
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suitable design will be provided to maintain a stipulated thickness of material layer. The
side boards will be lined with replaceable wear plates.
4.1.1.4.2 CRUSHING UNIT
Crushing unit will be skid mounted, low height, semi-mobile type, consisting of Sizer and
discharge chute (integral part of Sizer unit, but it can be easily dismounted for relocation)
etc.
The Sizer roll(s) will be fitted with replaceable crushing teeth. The tooth design will
be in such a way that it can easily nip the in pit coal lumps and generate minimum
fines. The Sizer design will be such that it is able to operate round the clock
continuously. It will be suitable for dusty condition. It will be able to start at full load
conditions and robust enough to absorb the impact of freely falling coal lumps.
Occasionally, ROM feed may contain some metallic pieces of large size such as
excavator teeth and track pads etc. Necessary protection should be incorporated
in the design to take care of this.
Suitable lifting devices will be provided for ease in installation, dismantling and
taking out components for maintenance. The components/ parts will also be
provided with lifting lugs.

Unit will be designed to provide suitable maintenance platform for inspection,

maintenance etc. It will also have an operator's cabin installed at a suitable location
for the operator of the machine. Operator should be able to view the crushing
operation.

4.1.1.5 SPECIFICATION OF ASSOCIATED EQUIPMENT

4.1.1.5.1 HOPPER:
The coal receiving hopper of minimum 170 te capacity shall be constructed by
building up side skirts on Apron Feeder. Steel plate sections shall be bolted to
feeder sections to build up capacity of the receiving hopper. Hopper includes
suitable rail /structural stiffeners at its outer side with 16 mm thick MS base plate
and 16 mm thick suitable Mn-steel liners to be fitted with counter sunk bolts. Skirts
shall extend the whole length of Apron Feeder to receive dumpers simultaneously
as shown in the drawing. The general arrangement of the hopper is shown in the
said drawing.

4.1.1.5.2 APRON FEEDER

DUTY
The apron feeder will be of robust construction and extra heavy-duty type. It will be
able to take impact of coal/ shale lump size indicated elsewhere from a height as
indicated in Operational Parameters. It will be able to handle wet material during
rainy season without loss of efficiency. The working place may be quite dusty.
Inclination of the Feeder may be up to 20 degree.

OPERATIONAL PARAMETERS
Free fall height: To be kept as minimum as possible.
Feeder size : a) Width between skirts to suit system design.
(Minimum 2000mm).
b) Length between sprocket centres to suit system design.
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Capacity (tph):
a) Nominal 1600
b) Peak 1920
c) Lower limit: 50% of nominal capacity.

Constructional Features

In general, the construction of the Feeder will be to suit the duty requirements as
stated earlier. The overlapping pans should prevent spillage. The construction
materials will be such that maximum life with abrasive coal mixed with shale and
sandstone could be achieved. The equipment will be easily accessible. Shafts are
of forged steel machined precisely. In particular, it will have the following specific
features:

(a) MAIN FRAME AND SIDE BOARD

These will be of heavy steel construction suitably cross braced and welded with
heavy cross members to withstand the repeated and continuous service conditions.
The side board will be lined with replaceable liners at wear points. The side board
will extend full length in order to guide material.

(b) PAN
Pans are to be constructed of heavy overlapping manganese steel plates of
minimum thickness 25 mm which are attached to heavy duty conveyor chains. The
construction is to also eliminate any spillage from between the pans.

(c) CONVEYOR CHAINS

Chains are to be made of forged alloy steel, case hardened to give a high degree of
abrasion resistance. Bushings and pins are also to be case hardened in order to
have sufficient tensile strength to withstand continuous severe operation for a long
period. Chain seals should prevent entry of abrasive foreign materials for longer
chain life. Construction should ensure that the chains are performing duty of pulling
pans only. The combined breaking strength of chain should not be less than 400
tonne.

(d) UPPER IMPACT ROLLERS

During operation the feed point of the coal shale dropping on the apron pans are at
very high level. To absorb load of impact it is desirable that the upper impact rollers
are made of high quality manganese steel and hardened. These impact rollers
mounted on bush bearings will be rigidly placed on the upper face of the frame
along the direction in which the apron proceeds. The rollers should support each
pan at three points and throughout the entire length of the apron feeder.

(e) RETURN ROLLERS

Return run of the apron pans will be supported by manganese steel and hardened
return rollers fitted on shaft with bush bearings.

(f) LUBRICATION
The bearings are babbitted and shall be greased occasionally. Alternatively, heavy
duty bearings with proper lubrication system may also be provided. To facilitate
such greasing, a centralised lubrication system with compressed air operated (for
cleaning of the tubes before every filling) shall be provided. This consists of
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compressed air operated grease pump, distribution valves and accessories such as
fittings, flexible hoses, piping and etc

(g) DRIVE
The apron feeder will be provided with a variable speed AC motor drive
arrangement to give varying discharge. The controls indicators will be housed in
dust and vermin proof steel enclosure. Suitable interlock and sequence control will
also be provided. The drive will be complete with necessary speed reducers,
couplings etc.

(h) GUARDS
Necessary guards will be provided for all moving parts. Easy approach must be available
for inspection and maintenance purpose.

4.1.1.5.3 SIZER

In general the Sizer shall have the following features:

(a) HOUSING FRAME

The housing frame shall be fabricated from heavy steel plates to withstand heavy
shocks and loads. End frames shall be machined from solid frame. Side members shall
be spigotted and bolted to end plates forming a very robust assembly capable of
containing any dynamic forces created by Sizer while in operation. The sections shall
be easily removable for ease in maintenance.

(b) SIZER ROLL

The shaft and gears shall be fully machined from solid one piece forging of high carbon
steel/Alloy steel and slotted to accept crushing segments. Circumferential dia. of shaft
with forged ring tip should be 1100mm minimum. The shaft bearing shall be self-
aligning double roll spherical roller bearing or split cylindrical roller bearings with
swiveling cartridge and shall be selected for rated life of at least 50,000 hrs at full load.

The gears shall be oil/grease lubricated. The tooth profile shall be designed suitably to
meet the duty conditions and produce minimum of fine generation. In order to minimise
fine generation the roll speed shall be minimum.

(c) LUBRICATION

All bearings gears and pinions shall be oil lubricated. Non drive end shaft bearings shall
be lubricated from manual fill oil baths. Oil levels should be checked by slight glasses.

(d) WEAR PLATES

The Sizer shall be fitted with wear plates completely covering the inside of body and
crushing chamber. These plates shall be made from high wear resistant steel and shall be
doweled and bolted to units allowing easy removal when required and positive secure
long term location.

(e) DRIVE AND CONTROL

The Sizer shall be driven by an AC induction motor of suitable rating which provides
high starting torque for above mentioned duty conditions. Drive shall be direct type

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or with reduction unit of suitable type of gearbox and controlled torque coupling.
Necessary protective devices will be incorporated in the system to protect the motor
from severe surge load resulting from large piece of tramp iron in the crushing
chamber.

The hydraulic lubrication and electro-mechanical controls, which forms inherent part
of the Sizer and its auxiliaries will be in the scope of supply and will be properly
designed to achieve the desired signaling and protective requirements. The power
supply to the main motor and auxiliary motors will be fed from the CHP motor control
centers. The sequence control and inter-lock of all auxiliary motors and other
protective devices of the Sizer will also form part of the scope of supply and included
in the offer.

Suitable protective devices shall be provided for mechanical overload. Suitable

speed monitor shall also be provided to prevent damage in the event of jamming
and inter locking in case speed falls below the pre-determined speed.

(f) ELECTRICAL

MOTOR

The Sizer motor shall be suitable for 6.6 kV, 3 phase 50 Hz supply system with +/-
10% voltage variation, complete with cables boxes with glands. Other LT motors will
be suitable for 415V, 3phase, and 50Hz supply system with +/- 10% voltage
variation, complete with cables boxes with glands. The Motor shall have high power
factor say
0.9 lagging approx. at 75% to 100% full load and shall have low weight/ kW ratio.

STARTER AND CONTROL PANEL:

This shall be adequately rated for the operation of the Sizer. The control panel shall
have the following features and confirm to relevant IS specifications.

a) Off-load isolator
b) Circuit breaker with under voltage release and electrical/ mechanical inter lock
c) Interlock with the door for the isolator
d) Protections
i) Motor control centre
ii) Motor protection relay with over load, earth fault, single phase stall protection
and unbalance condition, solid state
Cable entry box for incoming and outgoing entry
Enclosure shall be suitable for outdoor duty dust/ vermin proof and top canopy as
per IS: 55.
Space heater shall be provided for motor rating 30 kW and above.

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