KUDREMUKH IRON ORE COMPANY LTD

TURNKEY TECHNICAL SPECIFICATION

FOR
PULVERISED COAL INJECTION SYSTEM
AT MANGALORE

11.0 MATERIAL HANDLING FACILITIES

11.01 Brief Description of Coal handling system:

Coal storage is envisaged near the yard. The coal arriving by trucks
is unloaded in the covered storage shed and dosed by Front-end
loaders to achieve the required storage capacity. Then the coal is
reclaimed by front end loader and fed to feed hoppers provided on
Reclaiming conveyor. The reclaiming conveyor C1 in turn feeds to
another belt conveyor C2, which is feeding the coal bunker in the
PCI Building. The coal from bunker is fed to grinding mill through
belt weigh feeder.

CONVEYOR SYSTEM & RELATED EQUIPMENT

a. Conveyor

™ Design Basis

• Shall generally conform to; IS: 11592-2000.

• Utilization of cross sectional area – max 80 % of
theoretical cross sectional are as indicated in IS
11592-2000 (for computation of belt speed)
• Design capacity of belt conveyors- 20% more than rated
capacity to be considered while calculating motor power
• Troughing angle - 35o
• Friction factor (for kW calculation) of belt conveyors-
0.03

™ Belting - EP Grade

• Top cover thickness - 6 mm(min)

• Bottom cover thickness - 3mm(min)
• Fire resistant for conveyors handling Coal.

MEC/01/02/196M/TS-001 Chapter 11 Sheet 1 of 14

“© 2008 MECON Limited. All rights reserved”
 KUDREMUKH IRON ORE COMPANY LTD
TURNKEY TECHNICAL SPECIFICATION
FOR
PULVERISED COAL INJECTION SYSTEM
AT MANGALORE

™ Idlers

• Idler construction shall conform to IS 8598-1987

• Carrying Idlers – 139.7mm; Outer Diameter with 4.85

mm shell thickness
• Return Idlers – 127 mm Outer Diameter with 4.85 mm
shell thickness
• Carrying idler spacing -1000 mm. Spacing in the convex
curve position of conveyor shall be limited to half the
normal spacing of carrying idlers
• Return idler spacing - 3000 mm spacing
• Training Idler (with guide rollers) spacing
a) Carrying side - 15 m
b) Return side - 30 m
• Impact idler spacing - 500 mm or less - (min. 6 Nos.)
• Eccentricity of the idlers shall be such that the total
indicator reading shall not exceed 0.8mm. Eccentricity of
the idlers near belt weigh scale shall be limited to 0.1mm.
• Minimum bearing life of idlers & rollers shall be 30,000
working hours and they shall be grease packed for life.

™ Deck plate - 3.15 mm thick all along conveyor to be provided.

™ Pulleys.

• Drive pulley –12 mm thick. Hot vulcanized rubber

lagging, minimum durometer hardness of 55o shore A
scale and minimum tensile strength of 17 MPa and
elongation 400% at break. Pulley Shell thickness shall be
16 mm minimum. Diamond grooved rubber lagging shall
be provided.

• Tail/ Bend/take-up pulley – 10 mm thick hot vulcanized

rubber lagging, minimum durometer hardness of 45o
shore A scale, and shell thickness 12 mm minimum. Plain
rubber lagging shall be provided for all non drive pulleys.
MEC/01/02/196M/TS-001 Chapter 11 Sheet 2 of 14
“© 2008 MECON Limited. All rights reserved”
 KUDREMUKH IRON ORE COMPANY LTD
TURNKEY TECHNICAL SPECIFICATION
FOR
PULVERISED COAL INJECTION SYSTEM
AT MANGALORE

• Pulley face width - As per IS 8531-1986, Reaffirmed in

1993.

• Pulley Shaft –shaft diameter up to 160mm- class-4 as per

IS 1875-1992. More than 160mm - EN-9/BS 970 or
equivalent forged quality.

• Pulleys having shaft diameter of 200mm and above at

bearing shall be provided with expandable shaft hub
connection (Ring feeder type).

• Pulleys having shaft diameter of less than 200mm at

bearing may be provided with Gib head key or parallel
key.

• Pulleys having shaft diameter 160mm or more at bearing

shall be provided with turbo diaphragm type of end disc
wherein the end disc and hub shall be of integral steel
casting.

• The dimensional tolerance on pulley diameter shall not

exceed ±3mm and out of roundness shall be limited to
±1mm prior to lagging.

• Plummer blocks shall be grease filled and of a triple

labyrinth seal type

• Pulley bearing life shall be minimum 40,000 working

hours.

• Plummer block shall be of cast steel construction for

pulleys having shaft diameter at bearing are 160mm and
above.

™ Gear boxes

MEC/01/02/196M/TS-001 Chapter 11 Sheet 3 of 14

“© 2008 MECON Limited. All rights reserved”
 KUDREMUKH IRON ORE COMPANY LTD
TURNKEY TECHNICAL SPECIFICATION
FOR
PULVERISED COAL INJECTION SYSTEM
AT MANGALORE

• All gears shall be of hardened and ground and made of

suitable alloy steel with machine cut teeth.
• Splash lubrication shall be used in the gear boxes.
• The housing for gear boxes shall be of cast steel or
fabricated. Fabricated gear boxes shall be stress relieved.
• Double V-lip type seal shall be provided on input and
output shaft.
• Gear box mechanical rating shall be 1.5 times of
consumed KW or 1.25 times of motor KW rating which
ever is higher for all conveyors.
• Worm gear box shall not be used.

™ Brakes

• D.C. electromagnetic brakes on conveyors wherever

required to prevent roll back or where stopping time
regulation is required.

™ Roller type hold back device.

• On all inclined conveyors to prevent roll back. Rating

minimum 1.5 times the maximum calculated torque.

™ Take up

• For Conveyors up to 40 m length. - Screw take up with

protected thread – Screw of stainless steel with brass nut.

• For Conveyors of length 40 m and above – Vertical /

Horizontal gravity take up.

™ High speed coupling:

• Gear coupling / resilient coupling for drive less than 30

kW and for all drives with hydraulic / VVVF Drives.

MEC/01/02/196M/TS-001 Chapter 11 Sheet 4 of 14

“© 2008 MECON Limited. All rights reserved”
 KUDREMUKH IRON ORE COMPANY LTD
TURNKEY TECHNICAL SPECIFICATION
FOR
PULVERISED COAL INJECTION SYSTEM
AT MANGALORE

• Fluid coupling for drives with 30 kW & above.

• Pin bush coupling - Not Acceptable

™ Low speed coupling:

• Gear coupling / resilient coupling

™ External scraper

• Multi sprung blade (in segments) mounted on elasto

mount system.
• Primary and Secondary type at Discharge pulleys of
Conveyors and Trippers.
• Blade material – metallic blade with tungsten carbide tips
• Material scraped shall fall into main chute.

™ Internal scraper

• V shaped for unidirectional conveyors and diagonal type

for reversible conveyor.
• Mounted on carrier assemblies with elasto-mount and
non-metallic polyurethane blade.
• To be provided on the return belt prior to Tail pulley,
Take-up pulleys.

™ Belt sway switch

• A pair of switch shall be installed near the head end and a

pair near the tail end.
• Pair of switch shall be installed at 100 m interval
thereafter.
• A pair of switches shall also be provided before the belt
weighing scales.

MEC/01/02/196M/TS-001 Chapter 11 Sheet 5 of 14

“© 2008 MECON Limited. All rights reserved”
 KUDREMUKH IRON ORE COMPANY LTD
TURNKEY TECHNICAL SPECIFICATION
FOR
PULVERISED COAL INJECTION SYSTEM
AT MANGALORE

™ Zero speed switch – on non driving pulley

™ Pull cord switch

• 30 m interval on both sides for each conveyor, starting at

4000 mm from drive end.
• All pull cord switches shall have individual local
indication lamps to indicate when operated.

™ Discharge Hood

• 6mm thick mild steel plate for portion above the pulley
centerline. 10 mm for the balance portion.
• Easily adjustable baffle plates in the hood to control
trajectory of materials.

™ Guards

• Guards on the conveyor shall comply with the relevant

IS/IPSS Standard. The guards shall be of expanded metal
conforming to IS: 412 (current)
• Safety guards shall be provided for all couplings, brakes
etc. of the conveyor drive and screwed on the above base
frame.

™ Skirt Boards

• Skirt boards of minimum 3000 mm length at the loading

points of all conveyors, however wherever dust-
suppression system with water spraying arrangement is
provided – the length & height of the skirt shall be
suitably designed.
• The thickness of skirt plate shall be minimum 10 mm.
The top cover plate where provided shall be minimum 3
mm thick.

• The arrangement for fixing rubber curtain and rubber on

MEC/01/02/196M/TS-001 Chapter 11 Sheet 6 of 14

“© 2008 MECON Limited. All rights reserved”
 KUDREMUKH IRON ORE COMPANY LTD
TURNKEY TECHNICAL SPECIFICATION
FOR
PULVERISED COAL INJECTION SYSTEM
AT MANGALORE

skirt boards shall be such as to ensure quick adjustment.

The thickness of rubber curtains shall be minimum 10
mm.

• Skirt rubber shall be in segments and the design shall

ensure automatic flexing of rubber for proper sealing.
Shore hardness of skirt rubber shall be min. 55o A. Skirt
rubber shall be minimum 10 mm thick.
™ Liners

• Chutes:

Chutes shall be provided with minimum 16mm thick

UHMWPE liner.

Dribble Chutes below the snub pulley shall be provided

with 5mm thick stainless steel liners.

• Skirt board:

Skirt plate shall be provided with minimum 12mm thick

UHMWPE liner.

™ Chute Jamming Detectors

• Chute jamming detectors shall be provided on each chute.

™ Motors

• Motor for conveyors shall be of continuous duty energy

efficient squirrel cage type. The motor speed shall be
restricted to 1500 RPM for all conveyors.

11.02 ELECTRIC HOIST

• Electric hoists shall conform to class-I duty as per IS:

3938-1983.

MEC/01/02/196M/TS-001 Chapter 11 Sheet 7 of 14

“© 2008 MECON Limited. All rights reserved”
 KUDREMUKH IRON ORE COMPANY LTD
TURNKEY TECHNICAL SPECIFICATION
FOR
PULVERISED COAL INJECTION SYSTEM
AT MANGALORE

• Electrical hoists with electrically movable trolley shall be

provided in the junction houses for the maintenance of
the equipment. The capacity of the hoist shall be decided
based on the heaviest item to be lifted.

• Hoisting speed shall be 3-5m/min and CT speed shall be

15-20m/min.

• Brakes of Hoists of SWL of 5.T and above, only DC

Electromagnetic shoe Brake of BCH Make. For lower
capacities DC electromagnetic disc brakes acceptable.

• All flexible trailing cables shall be clamped with PVC or

non metallic clamps.

• The wheels shall be mounted on anti friction ball/roller

bearings & shall be easily removable for repair and
maintenance. The wheel diameter shall be selected such
that skidding does not take place even under unloaded
condition.

11.03 MANUAL HOISTS.

• The Chain Pulley Block shall conform to class-I duty as

per IS: 3832-2005.

• Ball and roller anti friction bearing only shall be used.

• Only triple -spur geared type shall be considered.

• Swiveling type standard shank hook mounted on grease

lubricated anti-friction thrust bearing shall be used.

• Only ball and roller anti-friction bearing shall be used.

• Load chain shall conform to Grade 80 as per IS: 6216 –

MEC/01/02/196M/TS-001 Chapter 11 Sheet 8 of 14
“© 2008 MECON Limited. All rights reserved”
 KUDREMUKH IRON ORE COMPANY LTD
TURNKEY TECHNICAL SPECIFICATION
FOR
PULVERISED COAL INJECTION SYSTEM
AT MANGALORE

1982.

• Hand chain shall be of 6.0 mm nominal size and shall

conform to Grade 30 as per IS: 2429 (part – 2) – 1970.

• Geared traveling trolley for the chain pulley block shall

be supplied along with the chain pulley block wherever
specified.

11.04 GROUND HOPPER:

• Hopper mounted on conveyor shall be fabricated from

minimum 10mm thick steel plate.
• Plate inside shall be lined with minimum 5mm thick
stainless steel liner.
• Hopper shall be provided with rod gate at bottom.
• Hopper shall be designed such that the material shall flow
freely on to the conveyor. Minimum slant angle of
hopper plate shall be 70degree.
• Hopper effective storing capacity shall be minimum
10m3.

11.05 INLINE MAGNETIC SEPARATOR & METAL

DETECTOR:

• Inline magnetic separator with one number metal detector

shall be installed on belt conveyor C-1 for removal of
stray iron.

• The Inline magnetic separator shall be complete with

belt, magnet, rectifier, control push buttons, suspension
bars, frame and drive unit. The magnetic separator shall
be used for separating magnetic particles from the
material being conveyed. The separated magnetic
materials shall be discharged at a suitable place away
from conveyor to the ground through a suitable chute.

MEC/01/02/196M/TS-001 Chapter 11 Sheet 9 of 14

“© 2008 MECON Limited. All rights reserved”
 KUDREMUKH IRON ORE COMPANY LTD
TURNKEY TECHNICAL SPECIFICATION
FOR
PULVERISED COAL INJECTION SYSTEM
AT MANGALORE

• The magnetic separator shall be trolley mounted with

locking arrangement so as to have provision for moving
the magnetic separator during maintenance of Conveyor
C-1 drive pulley. The magnetic separator shall be
suspended from the top through turnbuckles and D-
shackles of suitable capacity. The minimum adjustment
in turnbuckles shall be 200mm.

• The following shall be considered for design / selection

of Inline magnetic separator

1. Type Inline magnetic separator

(4 pulley type)
2. Weight to be lifted Min. 50mm long nail and
Max. 1000mm long rod
(max.15kg)
3. Coil winding Double fibre glass
covered copper strips
4. Cooling Air cooled
5. Class of insulation Class – H
6. Min. operating height 500 mm
to be considered
7. Duty Continuous duty

• Non-magnetic pulley shall be provided for the discharge

pulley of conveyor C-1.

• Technical Parameters
1. Material:

a. Size : (-) 30 mm
b. Moisture (maximum) : 15%
c. Bulk density : 0.85 t /cu.m

MEC/01/02/196M/TS-001 Chapter 11 Sheet 10 of 14

“© 2008 MECON Limited. All rights reserved”
 KUDREMUKH IRON ORE COMPANY LTD
TURNKEY TECHNICAL SPECIFICATION
FOR
PULVERISED COAL INJECTION SYSTEM
AT MANGALORE

2. Belt conveyor: 650mm (Belt width)

(35 deg. troughed)

11.06 BELT WEIGH FEEDER:

• The belt weigh feeder shall be complete with all

mechanical components, drive motor with VFD for speed
control, weighing device, structural framework, skirt
board assembly, discharge chute, belt scraper, feed chute
etc. and control panel with display.

• Belt weigh feeders shall be designed for heavy duty

capable of extracting, weighing and conveying specified
material under specified environmental conditions.

• The belt weigh feeder shall incorporate highly reliable

weight measuring system and the drive unit shall be shaft
mounted geared motor with VVVF speed control. The
housing of the gearbox shall be cast steel or fabricated
steel. The gear reducer service factor shall be minimum
of 1.25 based on installed motor power. Worm gear
reducers are not acceptable.

• Conveyor belting shall be of EP, with fire resistance

cover grade and shall conform to relevant clauses of IS:
1891 - (Part1) - 1988 or any other standard of
International repute acceptable to Owner. The belt shall
have adequate number of plies to handle the tensions
likely.

• Belting shall be free from longitudinal and traverse

buckling, wavy cords or other unevenness that would
cause localized points of flexing when belt is in service.

• Top and bottom cover thickness shall be minimum 6 and

3 mm.
MEC/01/02/196M/TS-001 Chapter 11 Sheet 11 of 14
“© 2008 MECON Limited. All rights reserved”
 KUDREMUKH IRON ORE COMPANY LTD
TURNKEY TECHNICAL SPECIFICATION
FOR
PULVERISED COAL INJECTION SYSTEM
AT MANGALORE

• All components of the idler assemblies shall be designed,

manufactured and tested as per IS : 8598 - 1987 or any
other standards of International repute acceptable to
Owner.

• Pulley shall be of extra heavy-duty type. The pulley

assemblies shall be completely balanced before assembly.
Pulley shall be made of welded steel and stress relieved
before machining. Pulley shall be rubber lagged of
diamond type construction for the drive pulley. Other
pulleys shall have plain rubber lagging. Lagging
thickness shall be minimum 12mm for drive pulley and
10mm for other pulleys.

• The weigh feeder is provided below the bunker. The

inlet-connecting chute between the bunker and the weigh
feeder is included in the scope. The chute shall be
provided with manually adjustable vertical gate for
adjusting the bed height.

• No cast iron part shall be used except for electrical

equipment and no wood or other combustible material
shall be used.

• LINER

UHMWPE liners of minimum 16mm thick shall be

provided in the inlet connecting chute, skirt board and
discharge chute of the belt weigh feeders.

• CONTROL SYSTEM

MEC/01/02/196M/TS-001 Chapter 11 Sheet 12 of 14

“© 2008 MECON Limited. All rights reserved”
 KUDREMUKH IRON ORE COMPANY LTD
TURNKEY TECHNICAL SPECIFICATION
FOR
PULVERISED COAL INJECTION SYSTEM
AT MANGALORE

The total belt weigh feeder system shall be controlled from

- Control panel to be located at a convenient location.

- Local control box mounted near the Belt feeder.

• CONTROL PANEL

The control panel shall consist of variable voltage variable

frequency drive for the belt motor. The panel shall consist
of Feed rate setting potentiometer, Totaliser circuit, Start,
Stop push buttons. Feed rate and Totaliser indications
(digital display), Fault indications (LEDs), Motor current
Ammeter and voltmeter on the incomer.

The panel shall include necessary control transformer,

electronic circuits, VVVF drive cards, speed setting, I /O
modules for taking Field inputs from Belt sway, LCB, pull
cord and zero speed switches.

11.07 LIST OF PREFERRED MAKES:

SL.
ITEM MAKE
NO.
1 Bearings SKF / FAG
2 Gear reducers FMG / NAW / ELECON.
HICLIFF / CONCORD / WELLMAN
3 Flexible gear coupling INCANDESCENT / DAVID BROWN /
GREAVES / NAW / ELECON

Flexible spring resilient

4 GBM / WELLMAN INCANDESCENT
coupling

MEC/01/02/196M/TS-001 Chapter 11 Sheet 13 of 14

“© 2008 MECON Limited. All rights reserved”
 KUDREMUKH IRON ORE COMPANY LTD
TURNKEY TECHNICAL SPECIFICATION
FOR
PULVERISED COAL INJECTION SYSTEM
AT MANGALORE

5 Fluid couplings VOITH / PEMBRIL / ELECON

PHONEIX YULE / NORTH LAND /
6 Belt
HILTON
7 Idlers KALI / TRF/ ELECON

8 Belt scraper HOSCH / KAVERI

9 LT Motors Alstom / ABB/ CGL

10 VFD panel Siemens/ L&T/ ABB/ Allan Bradley

11 Belt Weigh Feeder SCHENCK / PBL / TRANSWEIGH
12 Electrical Hoist ARMSEL / VOLTAS/UNITEK/TUOBRO
FURGUSON
13 Chain Pulley Block Mechanical Movement / MH BRADY / Armsel
/Tractor- Tirfor
14 Magnetic Separator EMI / POWER BUILD / ELECTROMAG
14 Pull chord, Belt sway , Telemechanic, Jayashree,Technocrat
Zero speed switches
15 DCEM brakes BCH / STROM CRAFT
16 Metal Detecter MR Equipment / PBL

Note:

1) Items for which preferred makes are not indicated shall be procured
only after approval of the make by owner / consultant.

2) Specific approval shall be taken from the Owner/ its Consultant after
checking its merit for the additional makes as suggested by the tenderer.

MEC/01/02/196M/TS-001 Chapter 11 Sheet 14 of 14

“© 2008 MECON Limited. All rights reserved”