Part 2 - Sec 1.6.3 - 11 2010 K G RPT 2210 - Final

2x600 MW Long Phu 1 Technical Design Document
PART–2 : SECTION–1
1.6.3 : COAL HANDLING SYSTEM
(Part-2_Sec-1.6.3_11-2010-K-G-RPT-2210_Final.doc)
INDEX
CLAUSE NO. ITEM
1.00.00 INTRODUCTION
2.00.00 SYSTEM BOUNDARY
3.00.00 SYSTEM COMPONENTS
4.00.00 DESIGN CRITERIA
5.00.00 ELECTRICAL & CONTROL SYSTEM
6.00.00 CONTROL PHILOSOPHY
7.00.00 INSTRUMENTATION AND CONTROL
8.00.00 AIR POLLUTION CONTROL
9.00.00 WATER POLLUTION CONTROL
10.00.00 FIRE FIGHTING SYSTEM
11.00.00 EQUIPMENT HANDLING FACILITY
ANNEXURE
ANNEXURE-I : DESIGN PARAMETERS OF MAJOR EQUIPMENT
DRAWINGS
11/2010-K-M-DWG-2119 : LAYOUT OF COAL HANDLING PLANT
11/2010-K-M-DWG-2036 : FLOW DIAGRAM OF COAL HANDLING PLANT
11/2010-K-M-DWG-2128 : SCHEMATIC ARRANGEMENT OF CRUSHER HOUSE
11/2010-K-M-DWG-2129 : SCHEMATIC ARRANGEMENT OF COAL YARD
(Part-2_Sec-1.6.3_11-2010-K-G-RPT-2210_Final.doc)
1.00.00 INTRODUCTION
PETROVIETNAM have been entrusted to development and generation work

for 2x600 MW Long Phu 1 Coal Based Power Plant at Long Phu district, Soc
TRANG province.
Long Phu, Phase-I project shall have two (2) units of 600 MW. It is also
envisaged to add another set of two (2) units of 600 MW each in Phase II and
finally, another set of two (2) units of 1000 MW each in Phase III. The station
shall ultimately consist of 6 units of total capacity of 4400 MW. This Design
Basis Report attempts to finalise the layout and various parameters of coal
handling plant required for Phase-I of the thermal power project.
Coal for the plant shall be received from 10000 DWT ship on the Ports in Hau
River located adjacent to Long Phu 1 power plant.
2.00.00 SYSTEM BOUNDARY
The system boundary shall start from the unloading of coal port upto the coal
bunker inlet of the boiler. This includes unloading, crushing, stacking at the
coal-yard & reclaiming from the yard and bunker filling. The ship link from
main source of coal however is not included in this report.
3.00.00 SYSTEM COMPONENTS
The system components of the coal handling plant are as mentioned in brief
below. Details of these items are discussed in subsequent clauses.
3.01.00 Coal Port & Ship Un-loader
The various details of coal port is outside the scope of this Design Basis
Report (DBR). However, it has been considered that the coal port shall have
arrangement for handling the vessels of capacity maximum upto 10000 DWT.
The ship un-loaders which will unload the ship and feed the belt conveyors
are under the scope of this DBR.
3.02.00 Belt Conveyor
These shall be used to carry and convey the coal from unloading points to the
various storage points or feed to crusher, coal bunker etc.
3.03.00 Vibrating Grizzly Feeder
The Vibrating Grizzly Feeder shall be provided in crusher house before

crusher to screen the undersize fraction from the coal received from the coal
mines port in order to reduce the load on crushers as well as to reduce fines
generation.
3.04.00 Crusher
Ring Granulator type Crushers shall be employed to crush the oversize

fraction of ROM coal to meet the sizing requirement of the boiler.
(Part-2_Sec-1.6.3_11-2010-K-G-RPT-2210_Final.doc) Part-2 : Sec-1.6.3 : 1

3.05.00 Stacker-cum Reclaimer (Reversible Type)
Stacker Reclaimer are provided to stack the crushed coal as received from
Crusher House when coal is not conveyed for bunker feeding. Subsequently,
this stacker-cum-reclaimer shall be used to transfer the stacked crushed coal
to the boiler bunker as and when required.
3.06.00 Traveling Tripper
Travelling trippers are provided on the top of the coal bunker to fill the
bunkers evenly along the length upto the desired level.
3.07.00 In-line Magnetic Separator
These shall be used to remove any magnetic/ferrous metal from the coal in
order to guard the crusher/pulveriser from damage.
3.08.00 Chutes & Hoppers
These shall be provided at various transfer points for transfer of coal from one
conveyor/equipment to the other conveyor/equipment.
3.09.00 Metal Detectors
These shall be provided at downstream of the magnetic separators (ILMS) as Rev-C

shown in flow diagram.
3.10.00 Dust Extraction and Dust Suppression Equipment
These are needed to prevent fugitive coal dust flying out so as to maintain
clean environment in the vicinity.
3.11.00 Auxiliaries
Auxiliaries such as Ventilation system, in motion weigh bridge, compressed

air system, metal detectors, coal sampling unit, sump pumps shall be
considered.
4.00.00 DESIGN CRITERIA
4.01.00 Source & Quality of Coal
Coal shall be received at site from Australia or Indonesia. Due to limitation in

capacity of vessel accessing on Hau River coal shall be imported via an
intermediate port. From the intermediate port, it will be transported by 10,000
DWT coal barge or ship to the part of Long Phu 1 power plant.
According to detailed planning of sea port group No.6, to the year of 2010,
total demand of cargo transported via the ports in Hau River will be about 9.2
to 9.5 million tons/year; up to 2020, it will be about 10.5 to 11 million tons/
year, and after 2020 it will reach 15/17 million tons/year.
4.02.00 Coal Requirements
The following data have been considered for the Power plant of capacity
2x600 mw units to arrive at coal requirement figure.

Coal consumption rate of the power plants in the

Long Phu Power Complex (as received)
Sl No. Property Unit Design Coal

1 Coal HHV (adb) Kcal/Kg 5725
2 Inherent Moisture % 9.5
3 Total Moisture % 28
Coal HHV (as
4 Kcal/Kg 4554.70
received)
Plant gross
5 % 42.14
efficiency (HHV)
Plant Gross Heat
6 Kcal/KWh 2040.82
Rate (HHV)
7 Unit Capacity MW 600
Coal
8 Tons/hr 268.84
Consumption/unit
9 Plant Load factor 0.85
Daily coal
requirement/unit
10 Tons/day 6452.19
without considering
load factor
Yearly coal
consumption for 2
11 Tons/year 4003582.57
units (considering
plant load factor)
Total storage hours
12 hours 12
in bunker
Total storage in
13 tons 3226.09
bunkers of 1 boiler
No. of working
14 5
bunkers
Capacity of each
15 645.22
bunker
16 No. of working mills 5
17 Capacity of each mill Tons/hr 53.77
Average Coal requirement as deducted from above is:
Long Phu 1
power plant
537.68 T/h 12904.38 T/day 4003582.57 T/year
(2x600MW)
The whole
power
- - 14679803 T/year
complex
Note: The coal consumption rates indicated above are as per the coal analysis for the
project is finalized. CHP has been designed based on design coal data as stated Rev-C
above.

Coal to Boiler Bunker (from thermal power station requirement point of view)
a. Coal requirement by boilers per hour for 2 units working : 537.7 TPH.
b. Average capacity of Coal Handling Plant considering 12 : 537.7x24/12=1075 TPH.

hours operation of CHP through two shifts in a day as
per standard engineering practice
c. Coal requirement per day : 12904.4 TPD
d. Average related capacity of CHP System, considering : 1075 x 1.15 =1236 TPH.
15% margin
e. Average Conveyor capacity selected : 1250 TPH
Coal from Vessel (from un-loading plant of view)
a. Meteorological impact on unloading : 80%
b. Working day for coal unloading from Vessel : 365x0.8 = 292 days.
c. Co-efficient of port (considering traffic congestion after : 60%

commissioning of 2nd & 3rd Phase)
d. Coal requirement per year with 85% PLF : 537.7X24X365x0.85 =

4003582.6 T.
e. Coal evacuation from vessel will be made in a day : 18 hrs.
f. Average Coal Unloading Rate from Vessel : 4003582.6/(292x18x0.6)

= 1269.5 TPH
Machine for Unloading Coal { If Coal size (-) 50 mm}
a. Type of Un-loader : Grab type.
b. Coefficient of loading : 55%
c Peak Capacity of ship un-loader : 1269.5/0.55 = 2308 TPH
d. Maximum Un-loading Capacity : 2308 TPH
e. Design Capacity Selected : 2300 TPH.
Machine for Unloading Coal { If Coal size (-) 50 mm}
a. Type of Un-loader : Continuous chain bucket

type.
b. Coefficient of loading of continuous ship un-loader : 75%
c Capacity of ship un-loader : 1269.5/0.75 =

1692.7TPH

d. Maximum Un-loading Capacity : 1692.7 TPH
e. Design Capacity Selected : 1700 TPH.
Ship Un-loader (Grab type) :
a. Ship Un-loader Capacity : 2300 TPH
b. Ship un-loader capacity and number may be selected :
+ No standby : 2300 TPH x 1 No.

+ No standby : 1150 TPH x 2 Nos.
+ 50% standby : 1150 TPH x 3 Nos.
However out of above mentioned 4 options, the following is preferred :
Number of ship un-loader selected : 2 Nos.
Ship un-loader capacity selected : 1150 TPH
Stand-by : No stand-by considered.
c. Coal pile built up period : Not considered

separately.
Ship Un-loader (Chain Bucket type) :

a. Ship Un-loader Capacity : 1700 TPH
b. Ship un-loader capacity & number may be selected from any one of following 4
options :
+ No standby : 1700 TPH x 1 No.

+ No standby : 850 TPH x 2 Nos.
Number of ship un-loader selected : 2 Nos.
Ship un-loader capacity selected : 850 TPH
Stand-by : No stand-by considered.
c. Coal pile built up period : Not considered

separately.

Difference in availability of the unloading equipment:
Sl. Continuous/Chain-bucket type Discontinuous/Grab type Unloader

No Unloader
1 Dust-reduced during digging and Dust emission is high at grab discharge
unloading through closed system. through open system.
2 Low maintenance cost, high spare Low maintenance and spare parts cost.
parts cost.
3 Not suit able for material with bigger Not suitable for granular type material.
lump sizes.
4 Only suitable for small lump sizes and Suitable for all limp size except powder
free flowing material. type.
5 Wear resistant also against abrasive Wear resistant also against abrasive
bulk material. bulk material.
6 Multipurpose unloading only possible Multipurpose unloading without
with restrictions. problems.
7 Low operating cost Operating cost is more
8 Lower costs for the conveying equipment Higher costs for the conveying
and stacking equipment for the capacity equipment and stacking equipment for
of 1700 TPH. capacity of 2300 TPH. Rev-C
Recommendation of Ship Un-loader :
It has been envisaged that fines in the coal will be controlled from mines as
per requirement. However, it is true that some dust will be generated in coal
unloading area especially when Grab Type unloader is unloading coal in a
hopper. Chain Bucket type unloader is a closed system which will generate
less dust nuisance but will have higher cost. Further, utilisation of this system
effectively for unloading of coal from vessel of 10,000 DWT is also available
for the purpose coal unloading to suit plant requirement.
Considering the fact that dust nuisance shall be limited during unloading of
coal, the use of continuous chain bucket type unloader will be a better choice
though it is relatively costly. In view of this, we recommend continuous chain
bucket type unloader.
Standby Ship Un-loader :
As per standard engineering practice standby barge unloader is not

considered in the system. Round the clock operation of unloader is a normal
phenomenon to release the barge from jetty. Accordingly major maintenance
Rev-C
of unloader is recommended in absence of barge. Moreover unloading from
the area under the vicinity of standby/under maintenance barge will be a
regular problem.
Hence, no standby ship unloader has envisaged.

Conveyor Capacity Selection
Conveyor upto Coal Stock Pile : (Coal Size (-) 50 mm)
a. To match with maximum capacity (continuous type ship : 1700 TPH

un-loader) CHP capacity upto coal stock pile
b. Stand-by considered : 100%
Conveyor from Coal Stock Pile to Boiler Bunker :
a. Conveyor capacity (Minimum, required from power plant : 1250 TPH

demand point of view) average [Ref. Clause 4.02.00]
b. Conveyor peak capacity (required for direct conveying : 1700 TPH

from Jetty to Bunker from both the un-loaders,
Continuous Chain Bucket type) [Ref. Clause 4.02.00]
c. Conveyor peak capacity (required for direct conveying : 1250 TPH

from Jetty to Bunker from one of the two un-loader, the
other ship un-loader feeding to stock-pile via Stacker-
Cum-Reclaimer
In option (c), the following demerits of the system are

noted : :
1. With direct loading from one ship un-loader to

bunkers the average capacity of conveyor system
leading to bunker will be only of the order of 0.75
x 850 TPH i.e. running the conveyor system of
12904.38 TPD / 637.5 TPH i.e., more than 20
hours a day which is not desirable.
2. There will not be any stand-by conveyor from

Jetty upto Stacker-cum-Reclaimer as the 2nd un-
loader will be in operation to convey coal upto
coal-pile via stacker-cum-reclaimer.
Considering the above, capacity of coal stock-

pile to boiler bunker is selected as 1700 TPH.
Conclusion:
a. Ship Un-loader : Chain Bucket type 2 nos. capacity

850 TPH.
b. Belt Conv. from ship un-loader to coal pile : 1700 TPH.
c. Belt Conv. from coal pile to boiler bunker : 1700 TPH.

Major Equipment of the CHP
Belt Conveyor : a) 2x100% from un-loading station to Coal Pile 1700TPH.

b) 2x100% from Stock pile to Boiler Bunker 1700 TPH.
Ship un-loader : 2 x 50% (Chain Bucket type 2x850 TPH)
Coal Pile 2 Nos. : Covered storage yard for 15 days and open storage yard
for 15 days.
Coal yard machine : 2 nos. Reversible type Stacker / Reclaimer Machine, both
will work under covered yard as well as on open coal yard.
Stacking Capacity to suit capacity of ship un-loader
(1700TPH), average Reclaiming Capacity 1700 TPH.
Bunker Feeding Machine : 2 Nos. Motorised Traveller Tripper with 3 way/2 way coal
discharging facility to suit the available space on bunker
floor.
Coal Conveying System : Conveyor belt in covered & un-covered gallery as per
system requirement capacity.
Coal Receiving equipment : Continuous Chan Bucket type ship un-loader. 2 nos. (850
from Vessel TPH).
Coal Unloading from Vessel : Rail mounted Continuous Chan Bucket type ship un-
loader complete with travelling hopper & vibrating feeder.
Vibrating Screen : 4 Nos. (to suit capacity of ship un-loader)
Crusher : 4 Nos. (to suit capacity of ship un-loader)
Magnetic Separator : 4 Nos.
Sampling system : 2 Nos.
Bull Dozers : 2 Nos.
CHP Control Room : 1 No.
CHP Pump House : 1 No.
CHP Office Building cum : 1 No.

Store
Transfer House : 4 Nos.

Dozer Shed : 1 No.
Crusher House : 1 No.

4.03.00 Unloading of Coal and System Capacity
4.03.01 Coal for the thermal power station is envisaged to be received by 10000 DWT
vessel only and unloading shall be done on set of conveyors through hopper
at jetty dedicated for coal.
Total coal requirement/day considering BTG at full load condition is 12904

T/day considering worst coal which can be brought by an average 1.29
vessels / day.
With average theoretical rate of unloading as 1275 TPH (1700x0.75) [Ref.

Clause 4.02.00], 2.3 Vessels per day can be evacuated, average hours of
operation per day have been considered as 18 hrs. (max.). In other words,
from unloading point of view, 2nd vessel of coal is required on an average to
be started handling per day considering bunker requirement and building of
coal pile on a normal day.
4.04.00 System Description
Coal from 10000 DWT Vessel shall be unloaded in belt conveyor by means of
ship un-loaders from where coal shall be carried to the boiler bunker through
crusher house & different transfer houses. Provision has been kept for
stacking crushed coal in coal stockyard from where coal shall be reclaimed as
and when the same shall be required in coal bunkers. In this respect, Dwg
No. 11/2010-K-M-DWG-2119 for Layout and Dwg No. 11/2010-K-M-DWG-
2036 for Flow Diagram of Coal Handling Plant shall be referred to.
4.05.00 Unloading Criteria
1) The proposed layout has been made for coal unloading by Continuous
Chain bucket type ship un-loader.
2) The proposed layout has been developed in the specified area for the
plants.
4.06.00 Stockyard Facilities
First and topmost priority of the coal handling plant is to evacuate coal from
the ship when the same is available at port at any time in a day.
Coal shall be crushed & stacked in stockyard by reversible type stacker

reclaimer machine. Considering availability of land, two (2) Nos. Stacker
Reclaimer Machine with two trapezoidal piles for each machine of required
length have been envisaged.
Four (4) numbers trapezoidal piles of 50 M base x 10 M Height x 280 M

(approx.) effective length are formed with the boom length of 41 metres of the
machine. Hence coal stock available considering 0.8 T/m3 as bulk density and
370 repose angle is 329062 tonnes.
Considering two (2) units operation at 85% PLF & with average quality coal,
this quantity is thirty (30) days consumption of coal approximately.

Hence, two (2) number Stacker-Reclaimer Machines are considered to be

sufficient for 2x600 MW plant.
The outage of one stacker-reclaimer however shall not stop mechanized

stacking/reclaiming of coal as the same can be done by the other machine.
Half of coal piles formed by both the machines, for storage of fifteen days,
shall be covered by structural shed with sufficient clearance so that Stacker-
Reclaimer machines shall be able to travel inside the shed.
There will be a 12 meter high wind shield fence beside coal pile on the Power
Plant side to arrest coal dust to move through wind towards Power house.
Since half of the pile length is covered by shed, the fence have considered on
the rest part of the pile which is uncovered.
Type of Machine : Orientation of the coal pile with respect to the direction of
coal flow from unloading point to Bunker suggests that reversible type
Stacker-Cum-Reclaimer would be the economical choice.
Reversible type rail mounted Stacker/ Reclaimer machine with tripper car and
Reversible Boom Conveyor on Turn table have considered for this Plant.
While comparing with the other machines like belt stacker or portal scraper
reclaimer such high capacity pile within the available land is not
recommended. In addition to that following points are being highlighted:-
1. By using belt stacker & portal scraper reclaimer space for installation of Rev-C
two machines is more compare to single stacker-cum-reclaimer.
2. 30 days storage cannot be made by any other mechanized means within

the space allocated in the CHP area.
4.07.00 Method of Bunker Filling
For filling the Bunkers conventionally two methods are employed (a)
Travelling Tripper with side discharge chutes, (b) Reversible Shuttle
Conveyor System. Out of the two, it is proposed to provide 2x100%
Travelling Trippers with twin discharge chute on two sides from the following
considerations:
a) Travelling Trippers with twin discharge chutes gives best fill pattern in
bunker. In addition self discharge chutes with travelling tripper will be
provided for the system requirement. Hence travelling trippers with
triplet discharge chutes have been considered.
b) With Travelling Tripper arrangement, a number of shuttle conveyors

are eliminated reducing number of equipment implying less
maintenance.
c) Ease of operation with travelling tripper arrangement, compared to

operation of reversible shuttle conveyor.
d) Bunker filling with reversible shuttle feeder invite more dust generation
in the Bunker Floor.
4.08.00 CHP Layout

4.08.01 Guiding parameters for arriving at CHP layout
Following are the parameters, which were considered to be more or less

frozen for the purpose of development of CHP layout:
a) Location of Jetty has been determined with respect to the port

engineering and minimum length of direct line up to bunkers.
The Jetty length has been envisaged to accommodate 10000 DWT

ship & working of 2 nos. 850 TPH capacity rail mounted continuous
type ship un-loader.
b) Space provision for maintenance and road beside jetty has been
considered.
c) Location of power house block.
d) Availability of land.
After giving due consideration on the above fixed parameters and

other provisions as discussed earlier, the layout has been finalised.
Following guidelines have also been taken care of:
e) Skew transfer has been avoided as far as possible and transfer at an

angle less than 90 Degree has been avoided to the extent possible.
f) Locating crusher house sufficiently away from cooling towers.
g) To limit conveyor inclination within 14 degree, in general.
h) To obtain 60 degree minimum valley angles for chute and hopper.
i) To avoid direct fall of coal in discharge points.
j) To avoid feeding on inclination portion of conveyors as far as possible.
k) To achieve flexibility by providing one to two transfer as judiciously as

possible by two way chute and reversible belt feeder.
4.08.02 Miscellaneous Services
a) RCC potable water tank and RCC service water tank shall be located
near crusher house.
b) The air compressors for the DE system in Crusher House and Boiler
Bunker adjustment to the respective DE Units.
Rev-C

4.09.00 Component Redundancy
Conveyor
In general for bunker feeding 2x100% system has been adopted for
Conveyors considering standard practice. However, in case of emergency,
both streams can run simultaneously. Electrical design shall be so as to take
care of simultaneous two (2) streams operation. For building of stock pile &
receiving coal from stockpile, 2x100% conveyor system with 2 nos. of stacker
reclaimer machine, have been adopted.
Ship Unloader
In the jetty, on each of the two (2) parallel receiving conveyors, two (2) nos.
Ship Un-loader (2 x 50%) common for each conveyor have been provided.
Crusher & Screen
Ring Granulator type Crushers shall be used for crushing coal from (-) 50 mm
to (-) 20 mm. Ring Granulator type Crusher gives much less fines compared
to that of Hammer Crusher. Replacements of Rings are also a simple job.
4 x 60% ring-granulator type crushers in the crusher house have been

provided.
To match with crusher capacity 4 x 60% vibrating grizzly feeders in the

crusher house have to be provided.
Type of screen has been considered as Grizzly type in order to reduce the
jamming problem with wet coal, particularly in monsoon period.
4X60% crushers have been chosen because of limitation of available capacity

of crushers. Normally 2X60% crushers will operate and 2X60% crushers will
remain as standby. Crushers will not be evenly loaded during operation and
thus 60% crushers are used to take care of such uneven loading of crushers
during operation.
Stacker cum Reclaimer
Provision of two (2) Nos. Stacker Cum Reclaimer (Reversible type) have
been proposed along with associated Boom, which shall reclaim coal from
crushed coal stock-pile and shall discharge on to trunk conveyor for carrying
coal for Boiler Bunkers.
Travelling Tripper
Provision of 2x100% motorized travelling trippers with Bunker 1 & 2.

Accordingly two (2) nos. Travelling Trippers have been considered in the
plant as shown in the flow diagram drawing.
Air Compressor
2x100 % air compressors are envisaged.

4.10.00 Stream Change Over Chute
In general, changeover from Stream-A to Stream-B or vice-versa except in

few places has been provided as shown in flow diagram.
4.11.00 Auxiliary & Service Facilities
4.11.01 Dust Extraction, Dust suppression and Ventilation System
The Coal Handling Plant is inherently a dusty place and a highly polluted
zone. Suitable ventilation and dust control systems are to be provided at
various places to minimize hazards due to such pollution. Dust suppression &
dust extraction would be used to handle the dust generated in the system. To
the extent possible, minimum water would be used for the purpose.
The systems normally adopted are -
(a) Dilution ventilation for underground buildings / tunnels portions.
(b) Natural ventilation for crusher floor of crusher house, over ground
portions of transfer points.
(c) Pressurized ventilation for MCC/switchgear/cable spreader rooms.
(d) Air cooled Precision type air conditioner (with one stand-by module)
for control room of CHP main control building and Split type air
conditioners (with 100% stand-by units) for other control rooms.
Dust Suppression System shall be followed generally as a measure of dust

control. Areas where addition of water may be difficult shall be provided with
dust extraction system.
The dust extraction systems shall be provided at the boiler bunker area and
the crusher house. The DE systems envisaged is dry type with the captured
dust being fed back to the system.
Plain water dust suppression system shall be used for crushed coal stock pile
and receiving points at coal jetty.
Dry fog type dust suppression system shall be provided for all other transfer
points.
4.11.02 Dust Extraction System
System design and air quantity estimation shall be governed by norms

recommended by American Conference on Governmental Industrial
Hygienists (ACGIH).
Extraction air quantity at individual points shall be calculated considering

single stream to be in operation and the material to be dry. 2 x 100% DE units
shall be provided in line with general philosophy adopted.
Arrangement of compressed air system for cleaning the bags of DE units

shall be also considered.

4.11.03 Dust Suppression System
Dust suppression with plain water shall be done at crushed coal stock piles
and receiving points at coal jetty.
Surface wetting of coal shall be affected by finely atomizing spray nozzles

located near dust generation places. Water shall be sprayed for suppression
of the dust in the above zones. The minimum water spray quantity shall be
1.5 l/hr./Sq.m (coal pile surface area) for dust suppression of crushed coal
stockpile.
Dry fog system shall be used in all other areas except above areas and areas
covered under DE system.
Dust Suppression of the different areas of CHP shall be done conveniently by

combining different dust suppression systems and catering by separate
pumps. Required quantity of water shall be provided at a terminal point and
the necessary distribution of water at various consumption points for DS
system shall be carried out.
4.12.00 Ventilation System
4.12.01 Ventilation systems shall be provided for electrical rooms. Natural ventilation
shall be provided to all over ground buildings through open able windows or
louvres. Continuous opening in conveyor gallery of the order of 500mm at the
top shall be provided for ventilation as well as natural light. In Shed,
continuous opening shall be provided for the same purpose.
All rooms for electrical items, viz. MCC/Switchgear Rooms shall have dry
type pressurised ventilation system by providing Fan–Filter Units for air
supply and back draft dampers for air exhaust to maintain dust free
environment inside these rooms. A minimum air change rate of 15 per hour
shall be maintained. Electric Fuse link type fire dampers shall be incorporated
with the Fan-Filter units supplying air to the electrical rooms.
For underground Tunnels, if any, fresh filtered air shall be supplied by means
of Fan–filter unit/s (located overground) through ducting and supply air grilles
and the air will be exhausted through wall mounted exhaust fans (located on
the pent house wall ) and short ducting. A minimum air change rate of 10 per
hour shall be maintained inside the tunnels.
All control rooms shall be enclosed and air-conditioned by providing air

cooled Precision type Air Conditioners/ Split Air Conditioners (for small control
rooms/PLC rooms) as applicable.
4.12.02 Stand-by Provision
No standby arrangement is envisaged for ventilation systems, except that one

motor of each rating may be kept as spare. Standby pumps shall be provided
for DS system.
4.13.00 Service Water
Service water network throughout the entire Coal Handling Plant shall be fed
by 2x100% Dust Suppression Pumps. The service water shall be used for

floor washing cleaning, etc. One (1) service water tapping point shall be
provided at each RCC floor of Transfer Points and Crusher House.
Additionally Service Water tapping points shall be provided throughout the
conveyor gallery/tunnel at maximum span of 30.0 meters. Consumption of
service water per outlet for floor washing shall be considered as 3 Cu.m/Hr
and assuming maximum six points operating simultaneously in the entire
CHP for design purposes, the service water system shall be designed.
4.14.00 Vacuum Cleaner
Portable Vacuum cleaner shall be used for cleaning of equipments inside

transfer house as well as throughout the conveyor gallery. Vacuum cleaner Rev-C
shall be handy type so that maintenance persons can carry the same to the
vicinity of equipments.
4.15.00 Potable Water System
Like service water, potable water shall also be pumped from the storage tank
beside pump house. Water shall be pumped to tank located at suitable
altitude (preferably on roof of each building) to distribute water at all CHP
Buildings. Water shall be distributed by gravity to all buildings and Control
Rooms from the over head tank.
4.16.00 Waste Water Disposal
Service water disposal throughout the entire Coal Handling Plant shall be
collected in pit at suitable location. 2x100% disposal pumps shall be used for
disposing the water from the pit.
5.00.00 ELECTRICAL & CONTROL SYSTEM
5.01.00 The Electrical Power Distribution system is envisaged at 3.0kV & 400V, 3-
phase; and 230V, 1-phase, voltage levels for supplying power to the drives
and other electrical equipment/system of the CHP to ensure smooth operation
of the plant and to maintain the operating parameters of various equipment/
devices within allowable limits. Suitable sequence controlling facilities are
provided in the Control room of Main CHP Substation Building near Crusher
House for proper control of the entire CHP including Electrical System
Operation in addition to the process.
5.02.00 CHP drives are scattered over a large area. Power supply to the drives/
equipments above 160 KW including distribution transformers will be derived
from two (2) Nos. 3.0 KV Switchgears to be located at the Main CHP
Substation cum Control Room Building near Crusher House. Each of these
Switchgears will be fed through 2 X 100 % rated feeders from 3.0 kV Station
Switchgears located in Power House building. 3.0 kV power supply from
these 3.0 KV Switchgears will be distributed to various 3.0 kV motors (except
bunker area including TP-4) and to Stacker/Reclaimer through central land
mounted junction box, flexible trailing cable with cable reeling drum,
transformer along with machine electrical of mobile equipment.
5.03.00 All LT loads from Crusher House up to TP-4 will receive power from one (1)
no. 400V Power Cum Motor Control Centre (PMCC) installed in Main CHP
Substation Building. This PMCC will receive power from 3.0 KV Switchgear -1
via 2 X 100 percent of suitably rated LT Auxiliary Distribution Transformers

through non-segregated phase bus-duct.
5.04.00 One (1) no. 3.0 KV Switchgear located at TP-4 near bunker area will cater to
all HT Drives in the vicinity of Bunker floor including TP-4. This Switchgear
will be fed through 2 X 100 % rated feeders from 3.0 kV Station Switchgear
located in Power House building. One (1) no. 400V Power Cum Motor Control
Center (PMCC) located in TP-4 near bunker area will cater to CHP LT loads
adjacent to Bunker area including TP-4. Illumination of above building
including the associated areas except bunker floor shall also be catered from
this PMCC. This PMCC will receive power from two (2) nos. 100% rating
3.0/0.420 KV LT Dry Type Auxiliary transformers through non-segregated
phase bus-duct. These transformers will receive power from aforesaid 3.0 KV
Switchgear at TP-4.
5.05.00 220 V DC supply required at Main CHP Sub-station Building near Crusher
House shall be obtained through (1) no. 100% rating 220 V Battery & Battery
Charger located at Main CHP Substation Building.
5.06.00 DCDB installed at Track Hopper Substation Building shall receive power
through two (2) nos. feeder of 100% rating from 220V DCDB installed at Main
CHP Substation Building.
5.07.00 DCDB installed at TP-4 shall receive power through two (2) nos. feeder of
100% rating from 220 V DCDB at powerhouse building.
5.08.00 To reduce damage to equipment during earth fault by eliminating possibility of

arcing grounds and for ensuring effective operation of earth fault protective
devices, the neutral grounding system of 3.0 kV shall be resistance earthed
limiting the earth fault current to less than 300 amps for 10 sec. while that of
400V shall be solidly earthed.
5.09.00 Illumination is provided for indoors and outdoor areas with non-explosion
proof lighting fixtures. Lighting fixtures are supplied power from a number of
local lighting panels, which are in turn supplied from the main lighting
distribution boards in the Substation and PMCC/MCC room.
5.10.00 All material and accessories including cable trays, and its supports are hot dip
galvanized.
Cables are routed as per final location of the equipment.
i) Through Conveyor Galleries/Tunnels, TPs/Buildings.
ii) Through trenches for cables to be laid in Pump House.
iii) Through overhead trestles for cables to be laid outdoors. However,

cables to be routed in coal yard for flood light towers can be laid
directly buried in the ground.
iv) The bottom of the steel supporting structure of overhead trestle is

generally at 2.5 m above the grade level except for rail/road crossing
where it is 6.5 m above grade level. Walkway is provided all along the
route of cable trestles.
5.11.00 Uninterruptible Power Supply System (AC/DC)

Uninterrupted Power Supply (UPS) with adequate rating of continuous duty

with minimum 30 minutes backup is provided. Redundancy of power supplies
is provided for the UPS.
The Uninterruptible Power Supply (UPS) system is supply regulated, filtered

and uninterrupted 230V, 50 HZ, single phase power within 1 percent voltage
regulation for control system. The UPS system batteries are Ni-Cd type.
5.12.00 Buildings for Electricals & Control Equipment
The CHP is provided with following building/house/room where the required

3.0 kV switchgear/400V PMCCs/400V MCC including other electricals are
located suitably.
a) i) Main CHP Substation Building cum Control Room near Crusher

House.
ii) 400V PMCC Room in TP-4 near Bunker Area.
iii) Electric Houses of Stacker-Reclaimer.SR-1 & SR-2.
Constructional features of above buildings are indicated below:
b) Main CHP Substation Building with Control Room
The complete CHP is operated from this building located near Crusher
House. This is a two (2) storied building. The ground floor is cable
spreader room. The first floor accommodates 3.0 KV SWGR s, 400V
PMCC, 3.0/0.420 KV LT Dry type Transformers, Main Lighting
Distribution Board (MLDB), lighting panel, D.C. Distribution Board
(DCDB), Battery, Battery Charger, A. C. Distribution Board (ACDB)
etc. A separate Control Room is provided for installation of PLC,
Control Panel, Operating Station, Engineering Station, UPS, Fire
Alarm Panels including intercom panels, etc.
c) Switchgear Room at T.P-4.
Cable spreader room is provided below the floor where the electrical
equipment is installed. The floor for the equipment accommodates 3.0
KV Switchgear, 3.0/0.420 KV LT Dry Type Transformers, 400V Power
cum MCC, MLDB, ELDB, Lighting Panel, PLC remote I/O Rack, UPS,
DCDB, ACDB and any other Control Panel. A separate control room
shall be provided for installation of Remote I/O.
d) Electrical house / operator’s cabin of Stacker Reclaimer:
This houses the necessary electrical equipments of the Stacker-

Reclaimer Unit.
6.00.00 CONTROL PHILOSOPHY
6.01.00 Control & Operation of Coal Handling Plants (CHP) shall be integrated in
Station Control & Monitoring System (SCMS) through VDU based Man

Machine Interface (MMI) located in Coal Handling Control Building as well as

in Central Control Room (CCR). All Electrical System monitoring & operation
shall also be achieved in SCMS
6.02.00 Control operation of the Stacker / Reclaimer is operated from the operator’s
cabin mounted on the machine and to be implemented through a proprietary
Programmable Logic Control (PLC) system.
6.03.00 Following Equipment shall come under interlock scheme and shall be
controlled & monitored from operator workstation in Main CHP substation
building cum Control Room Building with fault annunciation facility:
a) All belt conveyors.
b) Crushers.
c) Flap Gates
d) Rack and Pinion Gate
e) Magnetic Separator
f) Metal Detector.
However, all the above mentioned equipment has its local control panels /
station for start & stop and / or any other function required with suitable
lockable type local / remote selector switch (to be housed in local panel /
station and placed near drives).
6.04.00 Following equipment shall not generally be under interlock scheme and shall
be started / stopped / controlled from their respective MCC / local panel with
status indication on Operating Station:
a) Stacker/Reclaimer : Individual Boom Conveyor

Running
b) Waste water pumps : On indication area wise
c) Travelling Tripper : Tripper position indication on each

bunker
d) Dust Extraction / Dust / : Individual indication
Suppression / Drinking /
Water Pump / Ventilation
6.05.00 Following equipment shall not come under interlock Scheme and shall be
operated from its respective local panel without any indication in operator
workstation.
a. Electric Hoist
b. Ventilation System
6.06.00 Power Distribution System:

Remote controlling, synchronization, metering & annunciation of 3.0 KV

Power and 400V PMCC/MCC shall be implemented through Operating
Station in Coal Handling Control Building as well as from Central Control
Room.
7.00.00 INSTRUMENTATION AND CONTROL
7.01.00 The design of I&C system is such that isolation of any piece of defective
equipment would be possible without shutting down the main equipment or
disturbing the operation of associated instrument and accessories.
7.02.00 Satisfactory operation of the electronic equipment and components for

temperature range of 5 Deg. to 50 Deg. C, 95% humidity under corrosive and
polluted atmosphere prevailing in the plant is guaranteed.
7.03.00 Field Instruments
a) Vibration pads on the Crushers and crusher motors for mounting the
vibration probes and measurement.
b) Microwave Radar Type Bunker Level Indicators
c) Belt weighers for coal mass flow rate & totalisation
d) Pull Chords Switches, Belt Sway Switches, Zero sped Switches,
e) All the parameters shall be displayed and recorded in SI Units
7.04.00 For further details ref. Part-2 Section-3 of Technical Design Document.
Rev-C
8.00.00 AIR POLLUTION CONTROL
Air pollution in the vicinity of CHP area through windage of coal dust shall be
suitably arrested by providing adequate green belt through planting of trees in
the periphery of CHP area. However, adequate measures shall be taken to
control local generation of dust by providing dust extraction and dust
suppression systems.

9.00.00 WATER POLLUTION CONTROL
Only possibility of water pollution from CHP area is through drainage water,
which may carry coal dust particles and fines. To control the same the
drainage water from the main CHP area shall be taken up to a coal dust
disposal settling pond to bring down the turbidity of drainage water within
acceptable limits stipulated in relevant pollution control standards.
10.00.00 FIRE FIGHTING SYSTEM
Refer respective volume of the Fire Fighting System Report.
11.00.00 EQUIPMENT HANDLING FACILITY.
Suitable handling facility shall be provided at the following area.
Crusher House
Transfer Points
Coal Jetty
Control Room
Bunker House
Pump/Compressor Houses
However exact facilities shall be decided during detail engineering.

ANNEXURE–I
DESIGN PARAMETERS OF MAJOR EQUIPMENT
Ship un-loader
a) Quantity : Two (2) Nos.
b) Type : Continuous Chain Bucket.
c) Travel : Rail mounted reversible type.
d) Capacity (Design) : 1700 TPH
e) Size of Material : (-) 50 mm.
f) Moisture content (Max.) : 28% maximum.
g) Rail Gauge : As per manufacturer standard
h) Overturning Protection : By rail clamp and storm anchors.
i) Effective Travel Length : To suit 10000DWT cap. barge.
j) Unloading System : Through Vibrating Feeder.
Crusher
a) Type : Ring Granulator type
b) Capacity : 1020 TPH (Design & Guaranteed)
c) Number : Four (4)
d) Size Reduction : Input size (-) 50 mm,

Output size 98% (-) 20 mm.
e) Moisture content (Max.) : 28% maximum.
f) Hard Groove Grind- : 50 / as per coal data (whichever is

lowest) Rev-C
ability Index
g) Protection Switches : Zero Speed Switch & Vibration Monitor.
h) Mounting : Vibration isolation system shall be

provided.
Vibrating Grizzly Feeder
a) Type : Vibrating screen fitted with grizzly.
b) Capacity : 1020 TPH. (Design & Guaranteed)

c) Number : Four (4) (Two for each stream)
d) Max. Lump Size : (-) 50 mm

(Input Coal)
e) Screen Undersize : (-) 20 mm.
Stacker-Cum-Reclaimer
Quantity : Two (2) Nos.
Type : Rail mounted reversible type with Boom

Stacker & Bucket Wheel Reclaimer.
Capacity (Design) : 1700 TPH stacking and

1700 TPH average reclaiming.
Size of Material : (-) 20 mm.
Boom Length : 41 Meter
Rail Gauge : 8.5 M (Minimum)
Luffing Mechanism : Hydraulic
Slewing Mechanism : Hydraulic Drive
Overturning Protection : By rail clamp and storm anchors.
Dust Suppression : By swiveling nozzles fixed by the side of

piles.
Limitation : Outer side of piles to be pushed with

dozers within reclaim range as and
when required.
Compaction of Pile : By Bull Dozers.
Stock Pile Height : 10 meters.
Effective Stock Pile Length : 280 meters each (Approx.).
Traveling Tripper
Quantity : Four (4) Nos.
Type : Motorized travelling with side discharge

chute.
Special Feature : With Bunker slot sealing facility by

sealing belt.
Approximate Length of Travel : 100 Meters, with central feed.
Belt Conveyors

Capacity : 1700 TPH (Design)
Belt Width : 1400 mm
Troughing Angle : 35 Degree.
Belt Speed : 2.9 m/Sec. (Approx)
Belt Type : All synthetic fire resistant.
Drive : Single snub drive.
Gear box : Helical / Bevel Helical.
Fluid Coupling : Delayed fill traction type.
Power & Tension Calculation : By CEMA Method.
Margin on motor power : 15% over requirement based on design

capacity for drive motor upto 90 KW and
10% over requirement based on design
capacity for drive motor above 90 KW.
Maximum operating Belt : Not to exceed 80% of maximum Tension

allowable rated tension.
Magnetic Separator
Quantity : Four (4) Nos.
Type : In-line, DC operated, Electromagnetic.
Minimum Tramp Iron Size : 20 mm cube MS.

to be separated
Maximum Tramp Iron Size : 250 mm x 250 mm x 100 mm MS Plate.

to be separated
Maximum Cast Iron Size : 20 Kg.

(Brake shoe)
Weight of maximum MS round : 50 Kg.

bar to be lifted
Operating Gap : 400 mm – 500 mm.
Gauss Strength : 1000 gauss minimum at specified

distance after stabilization.
Force Index : 100,000 minimum.

Chutes & Hoppers
Valley Angle (Minimum) : 60 Degree.
Hopper Lining : SS
Chute Material & Liner : 10 mm thick MS with 6mm thick SS liner

on sliding & adjacent side.
Air compressors for DE
Type : Screw type oil lubricated.
Number : 2 x 100%.
Capacity : To suit.
Coal Sampling Unit
Quantity : Two (2) sets.
Type : Automatic two stage.
Primary Sampler Type : Sweep Type/Cutter Type.
Secondary Sampler Type : Vezin/Moving Hopper.
Sample Crusher : Roll/Hammer Mill.
Material handled : Uncrushed coal/Crushed coal.
Input Lump Size : (-) 50 mm / (-) 20 mm.
Size of Sample Particle : (-) 3.0 mm.

desired

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Part 2 - Sec 1.6.3 - 11 2010 K G RPT 2210 - Final

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2x600 MW Long Phu 1 Technical Design Document

1.6.3 : COAL HANDLING SYSTEM

CLAUSE NO. ITEM

2.00.00 SYSTEM BOUNDARY

3.00.00 SYSTEM COMPONENTS

4.00.00 DESIGN CRITERIA

5.00.00 ELECTRICAL & CONTROL SYSTEM

6.00.00 CONTROL PHILOSOPHY

7.00.00 INSTRUMENTATION AND CONTROL

8.00.00 AIR POLLUTION CONTROL

9.00.00 WATER POLLUTION CONTROL

10.00.00 FIRE FIGHTING SYSTEM

11.00.00 EQUIPMENT HANDLING FACILITY

ANNEXURE-I : DESIGN PARAMETERS OF MAJOR EQUIPMENT

11/2010-K-M-DWG-2119 : LAYOUT OF COAL HANDLING PLANT

11/2010-K-M-DWG-2036 : FLOW DIAGRAM OF COAL HANDLING PLANT

11/2010-K-M-DWG-2128 : SCHEMATIC ARRANGEMENT OF CRUSHER HOUSE

11/2010-K-M-DWG-2129 : SCHEMATIC ARRANGEMENT OF COAL YARD

PETROVIETNAM have been entrusted to development and generation work

2.00.00 SYSTEM BOUNDARY

3.00.00 SYSTEM COMPONENTS

3.01.00 Coal Port & Ship Un-loader

3.02.00 Belt Conveyor

3.03.00 Vibrating Grizzly Feeder

The Vibrating Grizzly Feeder shall be provided in crusher house before

Ring Granulator type Crushers shall be employed to crush the oversize

(Part-2_Sec-1.6.3_11-2010-K-G-RPT-2210_Final.doc) Part-2 : Sec-1.6.3 : 1

3.05.00 Stacker-cum Reclaimer (Reversible Type)

3.06.00 Traveling Tripper

3.07.00 In-line Magnetic Separator

These shall be provided at downstream of the magnetic separators (ILMS) as Rev-C

3.10.00 Dust Extraction and Dust Suppression Equipment

Auxiliaries such as Ventilation system, in motion weigh bridge, compressed

4.00.00 DESIGN CRITERIA

4.01.00 Source & Quality of Coal

Coal shall be received at site from Australia or Indonesia. Due to limitation in

4.02.00 Coal Requirements

(Part-2_Sec-1.6.3_11-2010-K-G-RPT-2210_Final.doc) Part-2 : Sec-1.6.3 : 2

Coal consumption rate of the power plants in the

Sl No. Property Unit Design Coal

Average Coal requirement as deducted from above is:

(Part-2_Sec-1.6.3_11-2010-K-G-RPT-2210_Final.doc) Part-2 : Sec-1.6.3 : 3

b. Average capacity of Coal Handling Plant considering 12 : 537.7x24/12=1075 TPH.

c. Coal requirement per day : 12904.4 TPD

e. Average Conveyor capacity selected : 1250 TPH

Coal from Vessel (from un-loading plant of view)

a. Meteorological impact on unloading : 80%

c. Co-efficient of port (considering traffic congestion after : 60%

d. Coal requirement per year with 85% PLF : 537.7X24X365x0.85 =

e. Coal evacuation from vessel will be made in a day : 18 hrs.

f. Average Coal Unloading Rate from Vessel : 4003582.6/(292x18x0.6)

Machine for Unloading Coal { If Coal size (-) 50 mm}

a. Type of Un-loader : Grab type.

b. Coefficient of loading : 55%

c Peak Capacity of ship un-loader : 1269.5/0.55 = 2308 TPH

d. Maximum Un-loading Capacity : 2308 TPH

e. Design Capacity Selected : 2300 TPH.

Machine for Unloading Coal { If Coal size (-) 50 mm}

a. Type of Un-loader : Continuous chain bucket

b. Coefficient of loading of continuous ship un-loader : 75%

c Capacity of ship un-loader : 1269.5/0.75 =

(Part-2_Sec-1.6.3_11-2010-K-G-RPT-2210_Final.doc) Part-2 : Sec-1.6.3 : 4

d. Maximum Un-loading Capacity : 1692.7 TPH