SYSTEM DESCRIPTION

UTILITY SERVICES
Utility services cover:
-Dry fog type Dust suppression system
-Plain water Dust Suppression system for crushed coal stock pile.
-Drinking water system
-Service air system
-De-watering system
-Dust Extraction system

Make-up and drinking water shall be made available near co-ordinate A+9398, B+3953 and A + 8550,
B+1500 respectively at a pressure of approximately 0.5 to 1.0 kg/cm2. Pipe size will be DN 150. Make up
water system will include extension of pipelines from the battery limit with isolation valve in a valve pit and
pressure gauge to the various Dust suppression units and service requirement.

DRY FOG DUST SUPRESSION SYSTEM

Dry Fog Dust Suppression System is a combine system of water and compressed air. The Water &
Compressed air system shall be start from the common pump/compressor house to the different Transfer
Point.
The system utilizes compressed air and plain water to produce 1-10 micron droplets (true fog). These
ultra-fine water droplets attach (agglomerate) to like size airborne dust particles, sometimes referred to as
PM-10 (particulate matter 10 microns or smaller). The slightly wetted dust particles are then heavy
enough to be removed from the air by their added weight and fall back into the process.
Dry fog dust suppression (DFDS) system shall be provided in coal handling area at material transfer
points in junction houses, Wagon tippler No 3 Building basement of Bunker building. Pumps for DFDS
system shall be provided in 4 (Four) numbers pumping station (PS-1, PS-1A, PS-2 & PS-3).

Location of DFDS systems

DFDS system shall be envisaged at the following points. The DFDS shall be provided at the following
points.

Table No. 1

Sl No. Location Description of application points

Pumping Station PS-1 near WT-3
1. Wagon Tippler Apron Feeder AF-5 discharge
Apron Feeder AF-6 discharge
Conveyor CC-4 receipt from AF-5
Conveyor CC-4 receipt from AF-6
Conveyor CC-7 receipt from CC-4
Conveyor CC-8 receipt from CC-4
Conveyor CC-9 receipt from CC-4
Pumping Station PS-1A between JH C-202 & JH C-203
2. Jn House C-1 Conveyor CC-8 discharge
Conveyor CC-201 receipt from CC-8
Conveyor CC-14 receipt from CC-8
3 Jn House C-201 Conveyor CC-201 discharge
Conveyor CC-202 receipt from CC-201
Sl No. Location Description of application points
4 Jn House C-202 Conveyor CC-202 discharge
Conveyor CC-204 receipt from CC-202
Conveyor CC-203 receipt from CC-202
5 Jn House C-203 Conveyor CC-203 discharge
Conveyor CC-28 receipt from CC-203
Conveyor CC-29 receipt from CC-203
6 Jn House C-204 Conveyor CC-204 discharge
Conveyor CC-206 receipt from CC-204
Conveyor CC-205 receipt from CC-204
7 Jn House C-205 Conveyor CC-205 discharge
Conveyor CC-207 receipt from CC-205
Conveyor CC-25 receipt from CC-207
Conveyor CC-26 receipt from CC-207
Conveyor CC-27 receipt from CC-207
Pumping Station PS-2 near coking coal stockpiles
8 Jn House C-206 Conveyor CC-206 discharge
Conveyor CC-208 receipt from CC-206
9 Jn House C-207 Conveyor CC-208 discharge
Conveyor CC-209 receipt from CC-208
Conveyor CC-210 receipt from CC-209
Conveyor CC-211 receipt from CC-209
Conveyor CC-212 receipt from CC-209
Conveyor CC-213 receipt from CC-210
Conveyor CC-213 receipt from CC-211
Conveyor CC-213 receipt from CC-212
10 Jn House C-208 Conveyor CC-214 receipt from CC-210
Conveyor CC-214 receipt from CC-211
Conveyor CC-214 receipt from CC-212
11 Jn House C-101 Conveyor CC-210 receipt from CC-101
Conveyor CC-211 receipt from CC-102
Conveyor CC-212 receipt from CC-103
12 - Conveyor CC-213 discharge
Conveyor CC-216 receipt from CC-213
Conveyor CC- 215 receipt from CC-213
13 - Conveyor CC-214 discharge
Conveyor CC-216 receipt from CC-214
Conveyor CC- 215 receipt from CC-214
14 Jn House C-209 Conveyor CC- 215 discharge
Conveyor CC-107 receipt from CC- 215
Conveyor CC- 217 receipt from CC- 215
Conveyor CC- 216 discharge
Conveyor CC-108 receipt from CC- 216
Conveyor CC- 218 receipt from CC- 216
14 Jn House C-102 Conveyor CC-108 discharge
Conveyor CC-125 receipt from CC-108
Conveyor CC- 219 receipt from CC-108
15 Jn House C-211 Conveyor CC- 219 discharge
Conveyor CC- 220 receipt from CC- 219
Conveyor CC-221 receipt from CC- 219
16 Jn House C-210 Conveyor CC- 217 discharge
Conveyor CC- 221 receipt from CC- 217
Sl No. Location Description of application points
 Conveyor CC- 220 receipt from CC- 217
Conveyor CC-221 receipt from CC-218
Conveyor CC-218 discharge
Conveyor CC- 220 receipt from CC-218
17 Jn House C-212 Conveyor CC- 220 discharge
Conveyor Y- 201 receipt from CC- 220
Conveyor CC-221 discharge
Conveyor Y- 202 receipt from CC-221
Pumping Station PS-3 near Blending Bunkers (C-215)
18 C-213 Conveyor Y-201 discharge
Conveyor Y-203 receipt from Y-201
Conveyor Y-202 discharge
Conveyor Y-204 receipt from Y-202
19 C-214 Conveyor Y-203 discharge
Conveyor Y-205 receipt from Y-203
Conveyor Y-205 discharge (left side)
Conveyor Y-205 discharge (right side)
Conveyor Y-207 receipt from Y-205
Conveyor Y-208 receipt from Y-205
Conveyor Y-204 discharge
Conveyor Y-206 receipt from Y-204
Conveyor Y-206 discharge (left side)
Conveyor Y-206 discharge (right side)
Conveyor Y-207 receipt from Y-206
Conveyor Y-208 receipt from Y-206
20 . C-215 (Blending Bunker) Bunker BB-201 feeding point from Y-207
Bunker BB-203 feeding point from Y-207
Bunker BB-205 feeding point from Y-207
Bunker BB-207 feeding point from Y-207
Bunker BB-209 feeding point from Y-207
Bunker BB-211 feeding point from Y-207
Bunker BB-202 feeding point from Y-208
Bunker BB-204 feeding point from Y-208
Bunker BB-206 feeding point from Y-208
Bunker BB-208 feeding point from Y-208
Bunker BB-210 feeding point from Y-208
Bunker BB-212 feeding point from Y-208
Weigh feeder WF-201 discharge
Weigh feeder WF-202 discharge
Weigh feeder WF-203 discharge
Weigh feeder WF-204 discharge
Weigh feeder WF-205 discharge
Weigh feeder WF-206 discharge
Weigh feeder WF-207 discharge
Weigh feeder WF-208 discharge
Weigh feeder WF-209 discharge
Weigh feeder WF-210 discharge
Weigh feeder WF-211 discharge
Weigh feeder WF-212 discharge
Receipt on conveyor Y-209 from WF-201
Receipt on conveyor Y-209 from WF-203
Sl No. Location Description of application points
 Receipt on conveyor Y-209 from WF-205
Receipt on conveyor Y-209 from WF-207
Receipt on conveyor Y-209 from WF-209
Receipt on conveyor Y-209 from WF-211
Receipt on conveyor Y-210 from WF-202
Receipt on conveyor Y-210 from WF-204
Receipt on conveyor Y-210 from WF-206
Receipt on conveyor Y-210 from WF-208
Receipt on conveyor Y-210 from WF-210

Receipt on conveyor Y-210 from WF-212

21 C-216 (Coal Crushing Conveyor Y-209 discharge
Plant)
Conv Y-211 receipt from Y- 209
Conv Y-212 receipt from Y- 209

Conveyor Y-210 discharge

Conv Y-211 receipt from Y-210
Conv Y-212 receipt from Y-210
Conv Y-211 discharge (left side)
Conv Y-211 discharge (right side)
Conv Y-212 discharge (left side)
Conv Y-212 discharge (right side)
Conveyor Y-214 receipt from HM-201
Conveyor Y-214 receipt from HM-202
22 Jn House C-217 Conveyor Y-214 discharge
Conveyor Y-215 receipt
23 Jn House C-218 Conveyor Y-218 discharge
Conveyor Y-215 receipt

PLAIN WATER DUST SUPPRESSION SYSTEM FOR CRUSHED COAL STOCK PILE

Plain water (sprinkler type) dust suppression system shall be provided for 4 nos. Coking coal stock piles
(four half-piles). The approximate dimensions of the Stockpiles are as indicated below:-

Sl.No. Stockpile designation : Stockpile dimensions (W x L)

1 Stockpile – 1 (at one side of Stacker cum Reclaimer 30 m x ~290 m (Half pile)
201)
2 Stockpile – 2 (at other side of Stacker cum Reclaimer 30 m x ~290 m (Half pile)
201)

3 Stockpile – 2 (at one side of Stacker cum Reclaimer 30 m x ~290 m (Half pile)
202)
4 Stockpile – 3 (at other side of Stacker cum Reclaimer 30 m x ~290 m (Half pile)
202)

Plain water at high pressure is sprinkled over the stockpile area. This system is envisaged to suppress
the generated dust due to stacking / reclamation and wind blowing. Water header shall be provided along
the side(s) of the stockpile. Sprinkler at regular interval shall be provided (to cover the entire stock pile
area by water spray) on vertical pipe risers from the main header pipe. The sprinklers shall be swiveling
type.
Each sprinkler operation cycle shall be controlled by a solenoid valve (enclosed in a box) operated
sequential timer to achieve optimum consumption of water. The solenoid shall be energized by receiving
signal from a sequential control panel which can be set to operate certain set of sprinklers for a fixed time
in sequence in a cyclical order.
Sprinkler post of 1200 mm height from top of Track top level (TTL) (Y Coordinate) at a distance of 1500
mm (X-Coordinate) from track top level (TTL) shall be installed on the header pipe along the side(s) of the
stockpile. Before each sprinkler, ball valve & solenoid valve shall be provided to enable manual control as
well as automatic control of Sprinkler operation.
Sectionalizing valves shall be provided for meeting the manual operation / control of sprinkler in a pre-
selected section of a particular stock pile. The sectionalizing valves shall enable manual operation so that
spraying of water can be shifted from one section to another section. It shall be possible to start the
pumps locally using the selector switch position in “Local” and Start / Stop (Lockable) buttons available at
local panel for maintenance purposes.
Water for stacker cum re-claimer shall be drawn by PWDS pump & shall be supplied to its reservoir
through a tapping from the main header & for this necessary quick release coupling shall be provided.

DRINKING WATER SYSTEM

Drinking water facilities shall be provided at all ECR buildings with Polyethylene water storage tanks at
roof of the buildings separately for drinking and sanitary purposes.

SERVICE AIR SYSTEM

Service air tapping shall be provided from the main header of DFDS system compressed air line . In each
Transfer house & Junction Tower & crusher house, we shall consider one no tapping point at each floor.
At gallery the tapping point shall be consider at an interval of 30 m. Each tapping point consists of one
No. ball valve with nipple. One (1) no hose having length 15 m shall be considered for each floor of
transfer point & each gallery. At a time maximum 5 point will work.

DE-WATERING SYSTEM

The sump pumps are to be provided for drainage system for following underground buildings & conveyor
tunnels:-
a) Take-up building of conveyor CC-215 & CC-216
b) CC-215 & CC-216
c) Junction house C-209
d) CC-217 & CC-218
e) Junction house C-210
f) Junction house C-211
g) CC-219
h) Coke Storage bin.
g) All the pump houses

Minimum two drainage pumps (one working and one standby) of submersible / vertical non-clog type
centrifugal pumps, of suitable capacity shall be provided to drain out the leakage/seepage water in each
of the above mentioned underground buildings & conveyor tunnels. The drainage pumps shall operate
automatically based on water levels in the sump. Sump pumps shall be provided with high level/low level
switches for automatic operation.

DUST EXTRACTION SYSTEM

The dedusting facilities are intended to remove the dust generated during the process and keep the work
environment clean. The dust laden air shall be sucked from the dust generating points through suction
hoods and duct work, filtered in a pulse jet bag filter and discharged to the atmosphere with the help of ID
fan through stack / exhaust duct.
Suction hoods shall be provided at head conveyor discharge point and bottom conveyor receipt point.
Electrically operated open-close damper may be provided (where ever required) at Hoods to prevent idle
suction. The ID fan shall suck the dust laden air from hoods at different dust generating points and shall
be cleaned in bag filter before being discharged into atmosphere through stack. The ID fan is to be
provided after bag filter for suction.
The bag filter shall be cleaned by the reverse pulse jet of compressed air. Hopper shall be provided below
cleaning chamber. Air to cloth ratio of bag filter shall be ≤ 1.20 m3/min/m2. Bags shall be of polyester
needle felt with Anti static treatment. Pent house (weather shed) shall be provided over bag filter. Service
platform & staircase shall be provided for operation & maintenance of bag filter. Self supported stack
height shall be minimum 30 m or 2-3 m above the nearest highest building. Exhaust duct (supported from
junction house building) shall also raise 2-3 m above the junction house. Dust concentration at outlet of
stack shall be less than 50 mg/ Nm3. ix. Small Unitary Dust control systems can be provided to suck the
dust generated during process operations like conveyor transfer points at JH- 104 (refer table no.5). The
discharge of the dust collected in the bag filter can be on to the process stream itself – depending on
system capacity.
The clean air from the bag filters is let into atmosphere above building roof level through exhaust stack
limiting dust concentration in the outgoing gases to within the statutory limits. The (clean-gas) exhaust
duct shall rise at least 2 to 3 m above the nearest building & can be supported from the nearby building as
per site conditions.
The dust extraction system shall be interlocked with the technological equipment / conveyors. The
sequence of operation shall be such that the dust extraction system shall start 5 minutes before start of
the technological equipment and shall stop 5 minutes after stoppage of the technological equipment.

Location of Dust generation points Dust Extraction system shall be envisaged for the following areas of
coke handling facility:-

a. Dust Extraction system DE-1 for coke sorting station, coke screening station & coke storage bin
b. Dust Extraction system DE - 2 for JH-101& JH- 105
c. Dust extraction system DE - 3 for JH- 104
d. Dust extraction system DE - 4 for JH-103 & JH- 102

Dust Extraction system shall cover all the generation points

Sl No. Location Dust Extraction Point
Dust Extraction System DE-1 near coke screening station
1 Coke Sorting Station Conv K-105 discharge
Vibrating Screen (VS-101)
Conv K-107 receipt (screen under size)
Conv K-107 receipt (crusher discharge)
Conv K-107 receipt (Screen by pass)
Conv K-106 discharge
Vibrating Screen (VS-102)
Conv K-108 receipt (screen under size)
Conv K-108 receipt (crusher discharge)
Conv K-108 receipt (screen by pass)
2 Coke Screening Station Conv K-107 discharge
Vibrating Screen (VS-103)
Conv K-109 receipt (screen over size)
Conv K-110 receipt (screen over size)
Conv K-109 receipt (VS-103 by pass)
 Vibrating Screen (VS-105)
Conv K- 118 receipt (screen over size)
Conv K- 120 receipt (screen under size)
Conv K-108 discharge
Vibrating Screen (VS-104)
Conv K-109 receipt (screen over size)
Conv K-110 receipt (screen over size)
Conv K-110 receipt (VS-104 by pass)
Vibrating Screen (VS-106)
Conv K- 118 receipt (screen over size)
Conv K- 120 receipt (screen under size)
3 Coke Storage Bin Conv K-109 discharge
Conv K- 111 receipt from K-109
Conv K-110 discharge
Conv K-112 receipt from K-110
Conv K- 117 receipt from K-109/K-110
Conv K- 118 discharge
Conv K- 119 receipt from K- 118
Conv K- 119 discharge (left side)
Conv K- 119 discharge (right side)
Conv K- 120 discharge
Bunker SB-101
Bunker SB-102
Bunker SB-103
Bunker SB-104
Bunker SB-105
Bunker SB-106
Conv K-121 discharge (left side)
Conv K-121 discharge (right side)

Conv K-122 discharge (left side)

Conv K-122 discharge (right side)

Conv K-123 discharge (left side)

Conv K-123 discharge (right side)

Receipt on conveyor K- 125 from Bunker (SB 101)

Receipt on conveyor K- 125 from Bunker (SB 102)
Receipt on conveyor K- 125 from Bunker (SB 103)
Receipt on conveyor K-126 from Bunker (SB – 101)
Receipt on conveyor K-126 from Bunker (SB – 102)
Receipt on conveyor K-126 from Bunker (SB – 103)
Coke Storage Bin (contd) Receipt on conveyor K-126 from K-
121
Receipt on conveyor K-126 from K-122
Receipt on conveyor K-126 from K-123
Receipt on conveyor K- 124 from K-121

Receipt on conveyor K- 124 from K-122

Receipt on conveyor K-124 from K-123

Dust Extraction System DE-2 located near JH-101
4 Junction house JH-101 Discharge of K- 111
Receipt on conv K- 114 from K- 111
Receipt on conv K- 127 from K- 111
Discharge of K-112
Receipt on conv K-114 from K-112
Receipt on conv K- 127 from K-112
Discharge of conv K- 127
Receipt on conv K-128 from K- 127
Discharge of K-126

Receipt on conv K- 113 from K-126

Receipt on conv K-114 from K-126

Receipt on conv K- 128 from K-126

5 Junction house JH-105 Junction house JH-105 Discharge of K-37A

Receipt on conv K-114 from K-37A

Receipt on conv K-113 from K-37A

Dust Extraction System DE-3 for JH- 104

6 Junction house JH-104
6. Discharge of K-128
Receipt on conv K-129 from K-128

Receipt on existing conv from K-129

Receipt on existing conv from K-129

Dust Extraction System DE-4 located near JH- 102

7 Junction house JH-103 . Discharge of K- 115

Receipt on conv CK- 4A from K- 115

Discharge of K-116

Receipt on conv CK- 4A from K-116

8 Junction house JH-102 Discharge of K- 114

Receipt on conv K-116 from K- 114
Discharge of K- 113
Receipt on conv K-115 from K- 113

The dust collected at bag filter hoppers shall be taken to storage hopper and from there dust shall be
disposed by truck. Clear height below storage hopper shall be 4.5 m to facilitate truck entry. Storage
hopper capacity shall be designed for three days dust storage. Rack and pinion sliding gate (motorized)
arrangement shall be provided at the hopper discharge. Vibrator if required in the hopper is to be
provided. Discharge of dust to the Dust disposal truck shall be done through telescopic chute.
The Dust disposal system shall include rotary air lock valve below the Bag-filter hopper, screw conveyors,
rotary feeder, Storage bins / silos with mounted bag-filters for control of fugitive emissions, discharge end
conveyors / Rotary air-lock valves, Telescopic discharge chute etc., depending upon the size / (volume)
capacity of De-dusting system to be envisaged.
Zero speed switches shall be provided for all dust disposal system drives. Screw conveyors shall have
bearings with outside greasing terminal, protected from dust by packing around the glands. All the
vulnerable parts requiring frequent attention shall be readily accessible. If two flights of a screw is coupled
then, overlapping of each flight at center point shall be made for smooth flow of material.

SCOPE OF WORK
DRY FOG DUST SUPRESSION SYSTEM

Scope of Work
The system comprising of the following equipments -
1. 2 Nos. horizontal centrifugal (multistage) pumps (1W+1S) with motor and other
accessories for each zone.
2. The pumping system comprising with the inlet gate valve, float valve, Pressure gauge
and pressure switch.
3. Level switch in the MS tank.
4. Y-type strainer shall be provided at suction line of pump inlet.
5. Dual fluid dry fog atomizing nozzle
6. Flow Activation Station
7. Y- type strainer
8. Pressure regulating Unit
9. Compressor (1 W+1S) (Compressor shall be common for DFDS system, Service air
system and instrument air).
10. Cooling Tower
11. The system comprises with 2 Nos. horizontal centrifugal (end suction back pullout type)
pumps (1W+1S) with motor and other accessories for recirculation water of compressor
cooling.
12. Piping network including valves, fittings and support.

Tentative capacities and location of Pumping Stations for DFDS systems

Sl.No. Pump Station Type of Pump capacity Water Storage tank

System (Tentative) capacity
. PS-1 DFDS 0.75 CMH (1W + 1S) 0.75 m3
PS-1A DFDS 1.75 CMH (1W + 1S) 1.75 M3
PS-2 DFDS 4.50 CMH (1W + 1S) 4.5 M3
PS-2 DFDS 5.0 CMH (1W + 1S) 5.0 M3

The Total static head shall be considered as 100.0 m WC (Minimum)

During detail engineering if arrived capacities are found to be higher than the above, the same shall
be considered and provided without any price implication. However, if the arrived capacities are lesser
than the above, the minimum capacity and quantity of DFDS & PWDS systems as mentioned in the
above table shall be envisaged.

PLAIN WATER DUST SUPPRESSION SYSTEM FOR STOCK PILE

1. 2 Nos. horizontal centrifugal (multistage) pumps (1W+1S) with motor and other
accessories.
2. The pumping system comprising with the inlet gate valve, float valve, Pressure gauge
and pressure switch.
3. Level switch in the RCC tank having capacity 150 m 3.
4. Full circle sprinkler
5. Solenoid valve
6. Sequential control panel.
7. Duplex strainer has been provided at suction line of pump inlet.
8. Piping network including valves, fittings and support.

Tentative capacity of pump shall be 150 CMH and pump shall be located at PS-2.
DRINKING WATER SYSTE

Drinking water systems comprises of

1. 2 Nos. horizontal multistage type centrifugal pumps (1W+1S) with motor and other
accessories.
2. The pumping system comprising of the inlet gate valve, float valve, level switch in the
RCC tank.
3. Pressure gauge.
4. Y-type strainer has been provided at suction line of pump inlet.
5. Water cooler for each ECR building
6. PVC Over Head tank for ECR building
7. Piping network including valves, fittings and support.

SERVICE AIR SYSTEM

The system consists of

1. One (1) no hose of 15 m length at each floor & gallery

2. Piping network including valves, fittings and support.

DE-WATERING SYSTEM

2 nos. (1W+1SB) sump pump shall be provided for each building mentioned in system description.
Sump pumps shall be provided along with local control panel, limit switch, pipe, fittings and valves.

DUST EXTRACTION SYSTEM

Dust extraction system for each zone consists of

1 no. Bag Filter complete with
 Modular shell
 Hopper for each module with manual slide gate & motorized RAV
 Inlet & outlet manifolds
 Manual damper at inlet & outlet of each module
 Access door
 Tube sheet
 Filter bags & cages
 Solenoid operated pulse valves (24 V DC)
 Pulse controller (Sequential timer)
 Bag filter control panel
 Compressed air line with valve, filter regulator & manifold tank
 Level switch in bag filter hopper & storage hopper
 Pressure switch at compressed air line
 DP switch across bag filter
 Pressure gauge at inlet & outlet of bag filter and at compressed air
 line
 Weather shed over bag filter
 Supporting structure of bag filters with service platforms & approach
 Staircase.

1 no. centrifugal fan consisting of:

 impeller of welded type with main plate, side plate, backward curved blades
  drive shaft,
 self-lubricated bearing
 Flexible coupling with guard,
 fan motor
 fabric expansion joints,
 Variable inlet vane type fan inlet dampers with electro-mechanical actuator
 Rain protection shed for motor only
 Foundation bolts

One lot ducting and duct support & pneumatically operated isolation damper for each
zone.

DESIGN BASIS
DRY FOG DUST SUPRESSION SYSTEM
Concentration of work zone respirable particulate matter (size less than 10 Micron) shall not be
more than 3 mg/Nm3 and the limit on total suspended particulate matter shall not be more than 5
mg/Nm3 to ensure dust free environment. Water line velocity shall be maintained less than 1.5
m/sec.
IS-1239 heavy class, ERW, M.S pipe line shall be used in the compressed air line. Compressed
air pipeline network over ground laying shall be preferred with a minimum slope of 10 mm in 1m
(1: 100) along flow and moisture trap with drain provision at regular interval. Compressed air
pipeline shall be preferably laid along conveyor gallery and can be supported from building super
structure.
Spray Nozzles / Spray bar assemblies for DFDS systems at transfer points (at both conveyor
discharge & receiving points) shall be selected so as to ensure complete coverage. Solenoid
valves shall be mounted on each spray nozzle header at material transfer points. Solenoid valves
shall be interlocked with the operation of conveyor running with material.
The DFDS system nozzles shall have air driven acoustic oscillator capable of producing super
fine atomization of water droplets of size as that of dust particles & blanket of extremely fine fog.
The water addition shall not be more than 0.2% of the weight of material being handled.

PLAIN WATER DUST SUPPRESSION SYSTEM FOR CRUSHED COAL STOCK PILE

We have calculated the system capacity considering the water quantity 500 LPM per spray
nozzle. Two no nozzle shall be in operation at a time.

DUST EXTRACTION SYSTEM

For calculating system capacity suction air quantity shall be considered 2800 m3/hr per meter belt
width. Suction air quantity from screen shall be considered 915 m3/hour/m2 of screen. The dust
extraction system shall be designed based on norms specified in the handbook of American
Conference of Governmental Hygienists (ACGIH).
Electrically operated open-close damper may be provided (where ever required) at Hoods to
prevent idle suction. However, Duct line velocity shall be maintained within 18-22 m/s.
Concentration of work zone respirable particulate matter (size less than 10 micron) shall not be
more than 3 mg / Nm3.

COMPRESSED AIR PLANT (CAP)

SYSTEM DESCRIPTION

To meet the compressed air requirement of Dry Fog Dust Suppression system & Dust Extraction
system (for Bag-filter pulsing) in coal & coke handling system of COB # 5, VSP, a dedicated
Compressed-air Plant
(CAP) is being envisaged. Besides catering for the operation of DE / DFDS systems, the CAP is
intended to meet the Service air requirement at each & every transfer point in junction houses /
Transfer Towers, Wagon Tippler area proper, near Apron feeders, shuttle conveyor, at the tunnel
point of CC-7/8/9 conveying system and at all Material handling facility where DE / DFDS
Systems are provided for control of fugitive emissions. The CAP shall consist of Air-compressors,
Air driers & Air receivers including piping, valves, complete electrics & instrumentation as needed
to generate & supply industrial as well as instrument quality air (near the inlet of consumer) at
needed pressure & quantity.
The 3 No. (2W+1S) Compressors along with heatless desiccant type Air dryers, Air-Receivers,
shall be housed inside compressed air station for DFDS system in the coal & coke handling area
of COB # 5 - VSP. A civil / structural building of suitable size shall be envisaged to house
compressed air station. The inter-connecting water piping along with necessary valves, & fittings,
strainers, pumps, cooling tower/s, etc., for the compressor Jacket cooling, intercooler, cooling
tower make-up, etc shall be included.
As far as possible piping shall be laid above ground. At rail / road crossings a minimum clear
height of 6.5 m and 6.0 m respectively from top of rail / road shall be provided. Pipes should not
be buried underground without specific requirement. Buried pipes, if any, shall be provided with
suitable wrapping & coating for protection against corrosion as per applicable code.
Except where otherwise specified, all pipes shall be provided with butt welded connections and
with flanged joints only at the connections with equipment, vessels and valves. Pipes laid inside
the R.C.C. trenches shall be supported at intervals on steel sections and the arrangement shall
facilitate easy maintenance.
Valves in the air line shall be of gate or globe type. For air-lines, either wafer type butterfly valves
sandwiched between two flanges or double flanged butterfly valves shall be provided. In
butterfly / gate / globe valves, face of the hand-wheel shall be clearly marked with word `open and
„shut' with arrows adjacent to indicate the direction of rotation. In butterfly, non-return & globe
valves, direction of flow shall also be marked on the valve body.
All the globe valves shall be designed to prevent erosion of valve seats when the valves are
operated in throttled conditions. Design of valves shall be such that it will permit packing of glands
while under pressure.

SCOPE OF WORK

The major components / accessories of the proposed compressed-air plant / station are as listed
below:-
i. Three (3) sets of oil flooded, water cooled, rotary screw packaged type air compressors
complete with electric motor of suitable capacity and all its accessories & auxiliaries including
the following units:-
a. Intercoolers, after cooler, moisture separator with auto drain trap station,
b. Suction air filter cum silencer,
c. Lube oil system.
d. Two (2) sets of heatless desiccant type Air drying units.
e. Two (2) Nos. Air Receivers.
f. All necessary interconnecting pipes, valves, fittings including supports and
supporting structures.
g. Drain pipelines from compressed air station to nearest drain/drain pit.
Miscellaneous structures, access platforms for operation and maintenance of
equipment parts, valves, instruments, etc. forming part of the equipment.
h. Cooling water system.
i. Electrics (including earthing, lightning, protection, illumination)
 j. All instrument & controls
k. Piping network

ii. 2 Nos. of Heatless desiccant type air drying unit (1W+1S) consist of
.
a. Activated carbon filter (2 nos.)
b. Prefilter (2 nos.)
c. After filter (2 nos.)
d. Automatic regeneration switching control with pneumatic flow actuator
e. Separate desiccant drain & fill ports
f. Desiccant for each tower with SS internals
g. Full flow safety relief valve (spring operated)
h. Dew point indicator
i. Regeneration fail alarm
j. Temperature and pressure indicators / switches
k. Drain facility
l.
The Dessicant type dryers shall have built in control panel with auto / manual operation.
Indication of outlet air temperature and pressure shall be provided at prominent place. The dryers
shall have failsafe design. In case of power failure inlet valve will open allowing flow through each
chamber Lifting eye bolt shall be provided for installation & maintenance purpose. First-fill of all
consumables shall be supplied along with the dryer unit.

iii. Air Receivers

There shall be 1 No of Air receivers of 8.5 m3 (minimum) capacity for industrial quality air and 1
No. of Air receivers of 1.5 m3 capacity (mimimum) for instrument quality air. Air receivers shall
preferably be vertical cylindrical design of MS welded construction, welded dished ends along
with all accessories including air inlet / outlet connection, safety relief valve, auto drain with
bypass arrangement & vent connection. b. The air receivers shall conform to IS 7938-1991. The
air receivers shall be designed, manufactured and tested according to IS – 2825 – 1969 and shall
be complete with pressure gauge, lifting lugs, manhole, safety valve and foundation bolts. The
material of construction shall be as per IS –2002 – Gr. – 2A.

iv. Cooling Water / Cooling Towers

Compressor (Jacket) cooling water circuit shall be envisaged. b. 2 nos. Dedicated cooling tower
of (1W + 1S) shall be considered. / OR as required by the OEM to meet the cooling requirement
for compressor along with 2 nos (1W + 1S) cooling water pumps. The circuit shall be complete
with necessary piping, valves, fittings along with electrics and instrumentation. c. Induced draft
type, FRP cooling tower shall be provided for the (jacket) cooling water requirement of
compressor. The location of cooling tower may be planned near to the compressed air station.
Pumps shall be installed within the compressor station. Electronic type instruments generally
working on 4- 20 mA DC signal system shall be used.