| maracenco (Matarashira State Power Generation Co. Ltd. SPECIFICATION: M17A SPECIFICATION FOR COAL SAMPLING SYSTEM ‘Dousavesl TPS Expansion Project ‘Votume = Fe 2X FAO LAM, Balance of Plan’ Package wa, ageMAHAGENCO Manurashara Suxte Powet Generation Co,Ltd . BHUSAWAL TPS EXPANSION PROJECT - 2x 500 MW SPECIFICATION FOR COAL SAMPLING SYSTEM 1.00.00 COAL SAMPLING FROM CONVEYORS 4.01.00 Automatic coal sampling unit for sampling of crushed coull to be fed to the ‘coal bunkers shall be provided by the Bidder. The system shall be complete ‘with primary end secondary samplers, crushers, belscrew conveyor, necessary chutes, hoppers and supports. The coal samplers shall be suitable for (}20-mm coal size and moisture content up to 20% “The enal sampling unit snail be provided at transfer point TP-105 for crushed. coal. The sample shall be taken from both convoyors 107-A and 107-8. 1.02.00 The Coal samplers shall consist of a small rotating bucket whec! or swcep, made of stainless siecl, mounted on rollers above the conveyor before head puley. The rotatng mechonism shall be motor driven, through a worm reduction and roller chain gear. The drive mechanism and ail electric parts shall rave dust tight protection. 1.03.00 Under ine bottom opening of the chute trom each primary sampler, there shall he a suitable feed arrangement by belt conveyor for feeding the coat to the sample enssher. 1.04.00 At the specified location mentioned above, the-sample-crushet shall be provided. This crusher shail ve of an approved make and capacity for crushing the coal to a graded product capable of at least 95% coal pessing ough 8 mesia B.S. Test sieve and 100% below 1/4" {4-mesh size) 1.05.00 The Secondary.Sampler stalk be Vezinf movable hopper type. Stainless steel sample collecting bins of adequate size and quantity shall be provided so that the misimum operator attention is required for the system. 1.05.00 ‘The sampler reject material shall have 10 be fed back to the system downstream conveyors by suitable arrangement of belt Conveyor! Screw Conveyors! Flap Gates, 1.07.00 All necessary suppotting structure, platform, ladders etc. for the above ‘equipment are to be provided adjacent to the transfer tower TP105. 1.08.00 Provision shall be mada to caltect samples from both the streams when both the streams are running simultansously. 1.09.00 The Sarmpling System shall generally conform to the provisions of IS: 436 (Patt-’Sec.2) - Indian Standard Methods of Sampling of Coat & Coke Part i, ‘Sampling of Coal - Section 2, Mechanical Sampling. 1.10.00 Tho schematic arrangoment for the system envisaged is shown in Org. No. K6V02-000-SKT-M-FS20. Bhusawal TPS Expansion Project Volua lt 2X 500 MV, Balance of Plant Package + MA Poor 1Ta MARAGENCO Mahorashtra State Power Generation Co. Ltt. 1.11.00 2.00.00 2.01.00 201.01 2.01.02 2.01.03 2.91.04 2.01.05 2.01.08 For furher details the atached Data Sheets shail be referred. AUGER SAMPLING FROM RAIL WAGONS: General ‘The Bidder shal provide a mobile mechanical augor coal samnpling system roving the following main features. ‘The mobile auger sampling system shail be truck trailer mounted and shall have a boom type sample collector with two-stage sample preparation system. The sampling system shad consist of sampling probe/barrel suitable tor collecting samples of raw coal of -300 mm sie, sample separator. crusher, crushed sample collection and revact system capable of putting the roject coal back into the wagons. The complete sampling unit shall be portable to bo placed at the coal marshalling yard between two rail tracks ‘meant for Wagon Tippler-1 and Wagon Tippler-2. The location envisaged for the auger sampling unit is shown in Dra. No. K6V02-000-SKT-MEGAIS. ‘The auger assembly shall be complete with primary spbiting, crusting and crushed coal sampling devices. Each auger increment shall be split in the sample separator. A potion of the uncrushed split sample shall be used for size analysis, while the test sample shall pass through the crushers to cbtain the samples of requited sizes. ‘Samples ior determination of total moisture shall be drawn trom the gross samples colected for UHV determination at the first stage of reduction of gross samples of up ig about 12 mm size. About 5 kg of samples shall be collected by not less than 10 approximate incraments while the coal is discharged from the crucher. ‘The auger sampling system shail be confonming to ASTM standards D-4916 (Standard Practices for Mechanical Auger Sampling), D-2234 (Siandard Practice for Collection of a Gross Sample of Coal, and D-2013 (Standard Method of Preparing Coat Samples for Analysis). “The auger shall be moved over the unit to be sampled using @ boom type crane with flexible lui and swoep. A completely automated sampling ‘operation using a processor-based control system shall be provided. The cab shall be complete with fighting, air conditioning, electrisat controls and boom ‘operation controls. The crane operator shail select the designated wagorts for the sample, using the control panel in tha crane sab. The auger shall be moved lo that position and samples shal be drawn automaiicatty. This primary sample shall be crushed, re-sampled and lhe secondary sample shalt bbe deposttad in the sample containers. ‘The system offered shal generally conform to the design and type offered by ‘SGS India Pvt. Ltd/ Johnson industries, USA or equivalont, Bhnioawal TPS Expanaien Project Vetume — 1 2 X00 MAW, Batanes of Pant Package MITA Page: 2MAHAGENCO, Matavashira State Power Generation Co. Lid. 201.07 2.02.00 2.02.01 2.02.02 2.93.00 2.03.01 2.0302 2.03.03 ‘The Bidders shall bring out the modes of taking primary! secondary samples in their propasals. System Requirement ‘The auger type coalszmpling device shall be provided for the efficient extraction of 2 core sample of coal from the rail wagons, and crushing et tho extracted coal sample into particles useful for laboratory analysis. Uncrushad pieces of extracted coal shall be transported to a separating device that shall allow most of these extracted cosl pieces to fall back info the wagon through, several openings. The separating device shall also include an additional nassage Ihrovgh whieh the extracted coal pieces will fall inio the crushing device, The crished cnal preces shall fall out of the botiom of the coal crushing device, and 2 portion of the crushed pieces shall be collected by a sample collecting receptacte, which accumulates portions of the crished coai thoughout the core extraction process so thal a true representative sample of the ictal extracted core & collected, The crushed coal samples shal be removed from the receptacle by 8 vacuum or air pressure to propel the crushed coal pieces through a hose or pipe the sample collecting station. ‘The sampling device shall comprise a tubular member containing an auger ‘with a cutting tool The tube shall be stationary while the auger shall be rotated by 2 motor positioned at the upper end of the tube, The cutting tool shall be located at the bottom end of the tube and attached to the auger. The ‘entire assombly shall be moved vertically for insertion into and removal from the materia! io be sampled. The cutting too} shad cut through and remove a ofindsical core“of the material being sampled in such a’ way that a representative sample of the material is oblained. ‘System Components: “The cat ramping wnit-sirall'be-complete wilh A coal extractor comprising an auger for extracting uncrushed coal from the ‘wagon , thereby creating a primary coal sample. The coal extractor shall have an outlet through which the exiracted coal will be removed. [An iegral coal separator for separating the coal sample received from the outlet of the coal extractor. The coal separator shall include 2 camping outlet, through whieh a portion of the coal sample shall be directad for crushing and further procassing. The saparator shall also have discharge oxtets at ite ‘bottom portion through which the remaining unused portion of the extracted coal sernple shall fall back into the wagon. Goal Ciusher, to generals -sariples’ of about -12 mm size, for crusting 2 poviion of the coal sample that passes through the sampling outlet into articles sultable for laboratory analysis, thereby delivering crushed coal samples. Tha part of he crushed coal not collected for analysis snail be returned to the wagons, - ‘Bhusawal TPS Expansion Project Vokane— Page: 3 2 X600 MW, Balance of Plant Paeloge wal "pO MAHAGENCO ‘Manarashira State Power Ganeration Co. tic. 2.03.04 2.03.05 2.03.08 2.03.07 2.04.00 2.04.01 2.04.02 2.04.03 2.04.04 ‘A coal collector for coleciing ne crushed coal samples received from ihe ‘ulet of the coal crushers, for analysis. The coal collector system shall comprise an arm, support, and 2 sample collecting receptacle, The arm shall have an upper end pivotally attached to the support, the lower end teminatiny in Ihe somple collecting receptacle. The arm shall be able fo swing so that the collecting receptacle can periodically pass beneath the oullet of the coal crusher during operation 10 obtain a representative coal sample The coal sampting unit shalt include means (e.g. a hose/pipe through which air pressure oF vacuum can be appled for pneumatic transfer of the samples) for tranaporting the collected crushed coal samples to a collecting station located in the operator's cab. Necessary Ait Compressor/ Extractor shall be cluded for this purpose, The coal sampling system shall be portable and shall include a boom type ‘crane mounted on tnick trailer. The sampling system shall be mounted and suppested from the boom TYPICAL ASEMBLY DESCRIPTION ‘The coal sampling device shall be suspended by a truck mounted boom assembly. The sampling device shall inciude a vertical blade auger, which tums inside an auger tube. The auger tip, which contains the teeth of the ‘auger assembly, shall be localed at the bottom portion of auger tube. ‘Adjacent to the uppermost portion of the auger, a funnel shaped separator subassembly shall be provided. The blade of the auger shall end in the ‘soperator subassembly, however, the auger shaft shall protrude further up in the vertical direction to the auger drive coupling. The Auger shaft shall be even by @ hydraulic motor, through a reduction gearbox. During opesaticn, the coal sampking device shall be-iowered inte the coai wagon until the auger tip reaches the top portion of the coal. As the auger tums, the coal is extracted from tie wagon and the coal moves up the enclosing auger tube The sampling device is Ioweted vertically throughout the coal bed in the wagon. Thus, @ complete core sample will be axtracted from the wagon. As coal is extracted upward, tis contained by the auger ube. Near the top of the auger blade, the outer wall of the auger tube shall be turned outward 1o form a circular horizontal shelf, which shall provide an outiet for the exacted ‘o0al moving Up auger tube. Surrounding this portion of coal sempling device a tepered conical wall of separator subassembly shall be provided, which shall ‘extend downward toward the auger tip. Saveral openings shall be provided ‘near the top portion of the separator subassembly. At the botiom-most portion of the taporod conical wall anothor opening shall be provided to discharge the unused primary samples into the wagon. Bhusawal TPS Espansion Project Voiume — it Pages 4 2X 600 MY, Balance of Prant Package MATA aral MAHAGENCO ‘Manafasnara State Power Generavion Co. Lad. 204.05 2.04.06 2.08.07 2.04.08 2.04.00 204.10 ‘A rotating arm shall be attached to the auger shat, so thal when the hydraule ‘irve motor turns, the auger and the rotaling arm will turn 2t the same rate. A sproader bar hall be attached to tha ouler diameter portion of the rotating farm. Ac the auger ‘ums. uncrushed places of coal, which have traveled up the auger tube. are gushed onto the horizontal shell. When the spreader bar comes into contact with such pieces of coal, it tends to push those pieces of Goal off horizontal shelf and though the openings. Such coal pieces then fai by gravity through the funnetshaped separator subassembly and are guided by the tapered conical wal unti they fall trough the opening provided at the bottom of the separator. These openings provide path for the unused samples back into the wagon ‘The separator! divider subassembly chali be divided into several sections, each providing one outlet. One of these outets of the separator subassembly shail direct the coai samples though an onffet duct into the crushers, for {urther processing and sampling. ‘The crushers shall be powered by electiss motor and pulley assembles. The coal pieces that enter crushers are continuously crashed info smaller particles ‘until they are small enough fo pass through the holes in the bottom floor of the crushers. Tha size of the holes in ezushor floor shall be solected to suit the desired sampic sizes. The crushed coal will fal back te the container via the holes in the crusher floor, unless captured by @ sampler subassembly, The sampler subassembly shell typically comprise a pivol, a pivolable elongated arn and sample colecting retainers. drive motors with speed seducing gearboxes. crankshafi and connecting fod... The sample selainers, shall be movanie about the pot. The sample retainers end travel includes zest positions at ends and aigo intermediate positions at mid-travel, While sample retainer is looated in either end positions, it will not accumulate, any coal particles faling out of the crusher floor. Such coal particles will be accumulated ony as the sampie retainer moves between rest positions al ends, ‘.. while the sample retainer is in a moving rakitravel postion. The sweeping time and frequency of sweep of the sample collector! ratainer for cotlection of the crushed particles shall be adjustable ‘Tho auger size shall be suitable for raw coal up 0 300 mm, and the length shalt be suitable for taking coal from about 3 m deep coal bed. The size of the ‘openings in the separator assembly shall be selected accordingly. The separator assembly shail be designed so that about one-twelfth of the coal extracted enters the crushers, “The coal particies shall be removed from the sample retainers pnetmatically (by pressure or vacuum) through @ hosef pips at time intervals during which ‘the sample retainers are in designated positions. Thus, th coal sample is transported from sample retainers into the sample receptacle bags without the use of any conveyer mechanism. ‘Bhusawal TPS Exparraion Project ‘Vota = 2. X.500¢20, Balance of Plant Package MtzA Page: 5a MAHAGENCO Habarehtre State Powor Goneration Ca. Lid. 2.04.11 2.04.12 2.04.13, The coal sampling device shall ba entirely suspended from and supported by the boom subassembly, without requiring any type of towor or framework. The unused coal pieces shall normalfy fall through the opening af the bottom of the separator subassembly into ihe wagon. However, provision shall be kept {0 capture a part of such coal pieces also for size analysis of raw coal, Atraller of adequate capacity shall be attached with we engine driven truck ‘Tre trailer shall contain the operator's cab and a hysrauic lft for operating the ‘500m subassembly, which shail inciude @ boom an of adequate radius of operation, to draw samples from any part of the adjacent rail wagon (BOX! BOXN type). The boom shall be connected to the coal sampling device via a hwo-wery pivol. By use of this boom and hydraulic lét combination, the coal sampling device shali be readily shiftable in the vertical direction so as to be raised above the cal wagon and then lowered into the load of coal within the wagon. The boom am shail be readily shiftabie in the horizontal divection ‘thrdugitout its radius s0 as ta accommodate diferent positions of coal wagons 38 they approach ine traler. The above description is meant for Bidders’ guidance regarding the type the equipment/ aseembly envisaged. Tho final design and arrangement of system and components shall be as per the equipment supplio’s standard and proven design. Bhusawal TPS Expansion Project Volume a Page: 2X SDDMW, Galance of Plant Package wa7A ee~~ MAHAGENCO, Monecastita State Power Generation Co. Ld. 10. 2 13. 14. 15, 16. 17, 48. ‘Sheet Tot? COAL SAMPLING UNIT FROM FOR BELT CONVEYORS. Location ty. of sampling unit Type Material handled Input wnp size Moisture content . Bulk density Material temperature Conveyor eapacty Bett width & deg. of troughing Belt speed Material of sampler chutes Min. valley angle of chutes hoppers ‘Sampling system capacity ‘Sampling collection rate Size of sample particle dosired Hours of operation Control syste DATA SHEET TP-105 One(1) set —tor crushed coal ‘Automatic ‘Crushed coal 20mm 20% (Max} 0.8 TICUM for volume calculation 1.0 T/CuM for weight calculation 50 deg. Max. & 5 deg.G Min. 1800 TPH 400mm & 35 deg. 3.2 WSes. Staines steet 80 deg, Chute. material 6mm.thick SS-304. By bidder, preferably as per ASTM:D-2234 ‘but not less than 2M TPH. 2 Kofi (Approx. (350m As required for 24 hours of operation of Plant pes dary. Local Starter-Panal ‘Bhusawal TFS Expansion Project Vobmne =i 1 2.500 MW, Batang of Pant Package MWA Pageww MAHAGENCO Mabarashica Stote Power Gersration Co. Ltd. — Sheet 2 of 3 COAL SAMPLING UNIT FOR BELT CONVEYORS DATA SHEET 19, Primary Sompler - > Type Sweep we i) Capacity ‘As above i) Material AIs1-308 jy) Quantity 2 Nos (one on each stream of bot conveyor BC- 107A & 1078 The eydle time shell be axjustotle through timer. 20, Bell Conveyor - i) Location ' For primary sample i} Capacity [AS per system if} Belt width & speed By bidder iv) Quanity + To suit system requirement. ¥) Components By bider. 21, Screw Conveyor - : ) Location For Rejects i) Capacity 2 AS per sysiem ii) Material Trough & sorew Ms. bShett - ENS ™ Quanity To sul system requiement. 1 Belt conveyor may be offered by bidder. if fet necessary. 22 Crasher « Type 2 RoWHammer Mi i) Frame Ms. Rol 1 Mn-Steel or equivalent, iv) The product cutout size shall be adjustable type. Capacity ‘As per system vw) Ovantiry > By bigser 23. Secondary Sompler - i Tye VeziniMoving Hopper i) Frame MS. i) Cutter tip 2 AISESO4 ) Output cepacity 2 Kg. (Approx) yy Quantiy 2 to, pes ayster. ‘Bhaszwal TPS Expansion Project Voume = page: 2 2X 100 MW, Balance of Plant Pacage MITAMAHAGENCO. Manerashere Sate Pome Generasion Ca. Lid a ‘Sheet 3 of 5 COAL SAMPLING UNIT FOR BELT CONVEYORS: DATA SHEET 24, Sample collection bins S$ Material (6mm thick) 25, Type of bearing BallRolet anti-friction type. 26. Lubrication OWGreaee 27, Sample collection bins To be provided {$5-304) 2a Motor + As per motor specification, NOTE 1. The primary samples taken from either of two Conveyors shall be fed to crushers by a bell conveyor. For rejects bet/screw conveyors will be provided with flap gate arrangement to Teed any of two outgoing conveyors operating. 2. The reject coal to be tetumed to downstream conveyors inrough belt/serew conveyor and chutes. 3. The system shall be dust-proof and free from externa contamination. TEST 1. Alltest as per relevant Coaes & Stancaras, 2 Alltests as por manufacturer's standards. ‘Bhusawil TPS Exparnion Project Yoke =i Pager 3 2X 200 MW, Babine of Plant Paciage MIA 90a MAHAGENCO Maharashira Stace Power Generation Co. Lid AUGER COAL SAMPLING UNIT DATA SHEET + Location of unit Betnzen Ral Tracks for Wagon Tipler-t 2. Oly. of sampling unit One(1} sat - for sampling as received raw coal in rail wagons. 3. Type : Automatic, mounted on truck trailer and operated by boom crane. 4. Material handled : Raw coal. 5. input lomp size (9.300 mm 6. Moisture content ‘ 20% (Max.) 7. Bulk density of coat 0.8 TéGum for volume calculation 1.0 T7Cu.m for weight calculation 8. Materiattemperatore > 50 deg.6 Max. & 5deg.C Min, 9. Wagon Type + BOX! BOXN 10. Auger probes barrel size 2 Suitable for coal lump up to 300 mm, 71. Accessories + The eystem shall include: ‘Solid material Coal Extractor by auger and ‘enclosing auger tube ‘Separating device for the sample from Extractor with outlets for further sampling ‘and for rejecting the unused sample back into the wagen ‘Coal crushers: Crushed coal sample retainar/ collector ‘Truck trader mounted boom with hydraulic lift and elongated flexible arm and adequate Supports for holding and operating the sample collecting and separating equipment ‘Bhusawal TPS Expansion Project Volume — 1 Page: 2X 500 MW, Balance of Plan Package wA7A 1~~ MAHAGENCO Maharaskira State Power Generation Co. Lid Means for transporting the crushed Coal ‘Sampies from the samples retainer to the ‘Samples collecting station in operator's cab ‘Transferring the unused crushed coal to the ‘Wagons. 12. Material of sample extractor Stainless steel 43. Sampling system capacity ‘The sample collecting agsembly shall be suttable for about 3m deep bed of coal in wagons 14, Sampling collection cycla time + Not more than 2 minutes 46. Size of sample particles desired About (-) 42 mim 12. Crushers - i) Type Roll Jaw ii) Frame : MS? fi) Rol 2 Mn-Steel or equivalent. 'y) The product output sizes shall be adjustable type. 18. Control systom + Locat Panel in Operator's Cab 19, Sample retainer and collecton : SS - 304 {6 mm thick) bins 20. Type of bearing 2 BalVRoller anti-ftiction type. 24. Lubrication : Oi Grease Bhuszwal TPS E*pantion Project 2X 600 MW, Balance of Ptant Packagej 1 Sats lap aera ge = — zea a aoe eee are TT =“ amon sa FE (ro cane) rains amar T09| { ee uv eremee Poo Sr ten Shee i Ream = way = a enna WOU THOS eR some = nt eer mee ele