truck tippler phase1 technical details

Om namo Bhagavate Jagannathaya

Let your Intelligence never fail you in this Kali Yuga

Om namo Bhagavate Jagannathaya

Let your Intelligence never fail you in this Kali Yuga

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Truck Tippler System Phase #1

The Truck Tippler System Phase #1 Comprises various equipments which ultimately feed the

Coal brought through trucks from different mines into the existing Coal Handling Plant system Phase

#1 particularly conveyor 2A & 2B.There are mainly three conveyors , CPP-1A,CPP-2A & CPP-3A.CPP-3A

has a option to dump the coal into 2A & 2B of existing system through Flap Gate.

The various other equipments which comprise the truck tippler system are Apron Feeders,

Single Roll Crusher, Dribble Conveyors, Magnetic Separator, Metal Detector , Flap Gates. There is also

a provision for suppressing coal dust particles through the Dry Fog Dust Suppression System (DFDS

System) which comprises Multistage Pumps, Compressors and Duplex Filter.

The Technical Details of the various equipments are listed in the following pages. The data has

been sourced and in most cases verified from various manuals, drawings and personal consultation

with Project Engineers, Technicians from Vedanta and McNally Bharat Engineering. The author is

solely responsible for typographical errors and not any other. Any comments, wishes are welcome.

The author wishes to thank all of them who were associated in making this manuscript and

help me donate this on the third day of the bright half of the lunar month of Vaishaka celebrated as

Akshaya Trutheeya

1) Dribble Conveyor

Belt Type & Rating N-N FR Grade & 800/5 HD Type-III

Length 13.6m

Width 1800 mm

Thickness 12 mm

Ply 5

Quantity 2

Capacity 60 TPH

Material Conveyed

Material Coal

Maximum Lump Size 300mm

Bulk Density 0.8 T/m3

Conveyor Parameters

Belt Width 1800mm

Length along Belt 6000m

C/C distance (Horizontal) 1200mm

Capacity (Design) 60 TPH

Speed (Nominal) 0.5 m/s

Belting

Type N/N

Rating 800/5

Cover Grade FR

Belt Thickness 12mm

Idlers

Carrying 5

Return 2

Take Up

Type Screw Take- Up

Travel 400mm

Protection Switches

Pull Chord @ 25m 1 pair

Belt Sway @ 50m 1 pair

Zero Speed Tail End

Drive Details

Manufacturer Bonfiglioli Riduttori

Serial No 804509/804510

Voltage 430 V

Frequency 50 Hz

Power 4 kW

Power Factor 0.81

2) CPP 1A Conveyor

Length 240 m

Width 1200 mm

Thickness 12 mm

Ply 5

Capacity 550 TPH

Material Conveyed

Material Coal



Conveyor Parameters

Belt Width 1200mm

Length along Belt 108239mm


Lift 12820mm

Capacity (Rated/Design) 500/550 TPH

No of Feed Points 2

Wrap Angle 210o


Conveyor Inclination 2o & 8o

Belting

Type N/N

Rating 500/4

Cover Grade FR

Actual Tension (Maximum) 38.0 kN

Belt Thickness 12mm

Idlers

Carrying@1m 96

S.A. Carrying@15m 7

Impact@400mm 5

Transition 1+1

Return(Flat)@3m 32

S.A. Return@30m 3

Deflector 1

Counterweight 6500kg

Skirt Board 14m

Take Up

Type V.G.T.U

Travel 2707mm

Protection Switches

Pull Chord @ 25m 5 pairs

Belt Sway @ 50m 3 pairs

Zero Speed Tail End

Gear Box

Manufacturer Premium Energy Transmission Ltd.

Type H2-225 RHB

Gear Ratio 18.9:1 P2 ACW

Serial No HGF-24370

Design kW Mechanical 108/1500 rpm

Design kW Thermal 180/1500 rpm

Nominal Ratio 18.9:1

Actual Ratio 19.111:1

Lubrication Type Splash

Lubricant Greaves Traxol G32

Lubricant Oil Quantity 27 l (approx)

Gearbox Net Weight 470 kg

GD^2 Value 0.060 kgm2

Output Shaft Material 45C8N IS: 1875

Gear & Pinion 815M17/EN353/EQUIV BS:970 Case hardened &

Ground. Hardness 58-62 Rc

Fluid Coupling


Serial No 41569

Type Solid Shaft Delayed Filling Chamber

Fluid Coupling

Size 410

Consumed Power 45.54 kW

Oil Filling Angle 80o

Recommended Oil Servo System 68

Oil Quantity 15.8 l

Max Temperature of Fusible Plug 140oC±5oC

Max Allowable Slip @ demand power 3%

Low Speed Coupling

Manufacturer Rathi Transpower Pvt. Ltd.

Type Gear Flex Coupling double engagement type

Coupling Material Alloy Steel EN-19

Coupling Size LFG-107

Coupling Rating 366kW@100 rpm

Coupling Rating @1500 rpm 5490kW@1500 rpm

Maximum RPM 2100 rpm

Maximum Bore 140 mm

Recommended Grease RSG(Lovejoy Special Grease)

Grease Quantity 1.0 kg

Specific Gravity of Grease 910 kg/m3

Outer Diameter 350 mm

Maximum Operating Temperature 120oC

Dynamic Balancing Standard ISO 1940

Rated Torque 3561 kg-m

Moment of Inertia of Coupling 1.313 kgm2

Weight 103 kg

Drive Details

Manufacturer Marathon Electric Motors (India) Ltd

Manufacture Year 2010

Type Squirrel Cage Induction Motor

Phases 3

Winding Connection Delta

Insulation Class F

Voltage 415 V

Frequency 50 Hz

IP 56

Duty S1

Machine No 105622830002

Frame K2805

DE Bearing N917

NDE Bearing B317

Power 75 KW

Ambient Temperature 50oC

Full Load Current 129.6 A at 40oC

No Load Current 33.5 A

RPM 1480

Efficiency 93.6

Power Factor 0.86

Lubrication Grease Lithium Based

Lubricant Quantity 74 gm

Weight 850 Kg

3) CPP 2A Conveyor

Length 404 m

Width 1200 mm

Thickness 12 mm

Ply 5

Capacity 550 TPH

Material Conveyed

Material Coal



Conveyor Parameters

Belt Width 1200mm



Lift 13740mm


No of Feed Points 1

Wrap Angle 210o


Conveyor Inclination 6o & 0o

Belting

Type N/N

Rating 500/4

Cover Grade FR


Belt Thickness 12mm

Idlers

Carrying@1m 184

S.A. Carrying@15m 13

Impact@400mm 5

Transition 1+1

Return(Flat)@3m 59

S.A. Return@30m 6

Deflector 1


Skirt Board 5m

Take Up

Type V.G.T.U

Travel 4.6m

Protection Switches

Pull Chord @ 25m 8 pairs

Belt Sway @ 50m 5 pairs

Zero Speed Tail End

Gear Box


Type H2-225 RHB

Gear Ratio 18.9:1 P1 CW

Serial No HGF-24371













Fluid Coupling


Serial No 41568

Type Solid Shaft Delayed Filling Chamber

Fluid Coupling

Size 410

Consumed Power 50.42 kW

Oil Filling Angle 75o

Recommended Oil Servo System 68

Oil Quantity 15.8 l

Max Temperature of Fusible Plug 140oC±5oC

Max Allowable Slip @ demand power 3%

Low Speed Coupling








Maximum Bore 160 mm









Weight 138 kg

Drive Details




Phases 3


Insulation Class F

Voltage 415 V

Frequency 50 Hz

IP 56

Duty S1

Machine No 105623710001

Frame K2805

DE Bearing N317

NDE Bearing B317

Power 75 KW




RPM 1480

Efficiency 93.6

Power Factor 0.86



Weight 850 Kg

4) CPP 3A Conveyor

Length 42.8 m

Width 1200 mm

Thickness 12 mm

Ply 5

Capacity 550 TPH

Material Conveyed

Material Coal



Conveyor Parameters

Belt Width 1200mm



Lift 2200mm


No of Feed Points 1

Wrap Angle 210o


Conveyor Inclination 6o

Belting

Type N/N

Rating 500/4

Cover Grade FR


Belt Thickness 12mm

Idlers

Carrying@1m 13

S.A. [email protected] 2

Impact@400mm 6

Transition 2+2

Return(Flat)@3m 5

S.A. Return@0m 3

Deflector 1


Skirt Board 5m

Take Up

Type Screw

Travel 600mm

Protection Switches

Pull Chord @ 0m 1 pair

Belt Sway @ 0m 1 pair

Zero Speed Tail End

Gear Box


Type H2-125 RHB

Gear Ratio 18.9:1 P1 CW

Serial No HGF-24400













High Speed Coupling




Coupling Size LGF-144 Type V

Coupling Rating 1.5kW@1000 rpm







Weight 5 kg (with maximum bore)

Low Speed Coupling








Maximum Bore 110 mm









Weight 57 kg

Drive Details




Phases 3


Insulation Class F

Voltage 415 V

Frequency 50 Hz

IP 55

Duty S1

Machine No 105623160410

Frame D160L

DE Bearing N309

NDE Bearing B209ZZ

Power 15 KW


Full Load Current 27 A at 40oC

No Load Current 10 A

RPM 1450

Efficiency 89.4

Power Factor 0.87



Weight 140 Kg

5) Truck Tippler Assembly

Manufacturer Jaypee Hydraulics Pvt. Ltd.

Make HTU-40 MARK-II

Quantity 2

Serial No JP40-0910-G3G/JP40-0911-G3G

Maximum Capacity 40 T

Year of Manufacture 2009

Hydraulic Pump

Manufacturer Rexroth

Serial No C232290, C232289

Quantity 2

Pump Type Positive Displacement Pump

Oil Delivery 43 l/min @ 1440 rpm

Oil Tank Capacity 100 l

Hydraulic Oil Servo System 68

Drive Details


Serial No A320858,A320857

Quantity 2

Power 15KW/20HP

RPM 1440 rpm

Voltage 415V

Amperage 28.0A

Phase 3

Connection Delta

Power Factor 0.82

Frequency 50Hz

Supply AC

Insulation Class F

Duty S1

Ambient Temperature 500C

IP 55

Efficiency 89.0%

Weight 160Kg

Exhaust Fan

Manufacturer Usha International

Model 0904

Serial No AYTX1825

Quantity 2

Size 230mm

RPM 1325

Supply AC

Phase 1

Frequency 50Hz

Power 48W

6) Magnetic Separator

Model Oil Cooled

Manufacturer Electro Zavod India Pvt. Ltd.


Type SM

Quantity 1

Serial No M-434/SM-1

Size 1340mm(L)*1340mm(W)*760mm(H)

Operating Height 400mm

Voltage 144V DC

Current (Hot) 48.0A

Current (Cold) 62.0A

Power (cold) 8.9 KW @ 144V DC

Power (Hot) 6.9 KW @144V DC

Insulation Class H

Total Weight 6 T (approx.)(With Oil)

Transformer Oil As per IS:335

Magnetic Strength 1000 Gauss @ 400mm OH

Force Index 100000

Force Index(Hot) 128538 Gauss sq/Inch

Force Index(Cold) 177505 Gauss sq/Inch

Conductor Double fiber glass covered Class-‘H’ insulated Aluminum

conductor

Magnet Core Material Low Carbon Steel as per IS: 4491

Max. Temp of Coil 140oC

DC Resistance of Magnet Coil@ 36oC 2.11 ohm

Insulation Resistance of Magnet Coil 80M ohm

@ 36oC (with 1000V Megger)


7) Metal Detector

Manufacturer Prayas Engineering Ltd.(MHE Division)

Manufactured Year APR 2010

Quantity 1

Serial No 860

Equipment Type 120X45

Supply AC

Voltage 15 V

Frequency 16 kHz

Metal Detector Control Panel

Voltage 230±10%

Frequency 50Hz±3%

Phase 1

Power Consumption 30VA Maximum

Protection Grade IP-54

Mounting Wall Mounting

Weight 33kgs

Protection F-Glass Cartridge slow blow fuse rating 0.315 A

Output/Interlocks N/O Contact (5A)

Distance between search coil center

line and adjacent idler 600mm

8) Apron Feeder

Equipment Name Heavy Duty Apron Feeder

Serial Number 2010-I-05 to 2010-I-06

Quantity 2

Size - Length 13920mm (Centre to Centre)

Size – width 1800 mm (Inside Pan)

Inside Skirt 1660 mm

Inside Skirt Liner 1640 mm

Inclination Horizontal

Speed Variation Through VVVF Controller(AB)(Max Speed 15m/min)

Material Bed Depth 1300 mm (approx.)

Motor Rating 132 KW/1000 rpm

Chain Crawler Type, 215.9 mm(8.5”),Pitch*Two Strands

Gear Box Helical Gear Reducer,Ratio-40:1

Open Gearing Spur, Ratio—4.68:1

H.S. Coupling Geared Coupling

L.S. Coupling Geared Coupling

Take Up Manually Operated Screw Take Up

Lubrication Manual Grease Lubrication (Servogem EP2)

Material Handled Coal


Material Bulk Density 0.8 T/m3 (For Vol. Calculation)

1.0 T/m3 (For Power Calculation)

Moisture Content 10% (Max)

Capacity 1200 TPH

Location Below Truck Tippler Side Hopper

Hopper Opening 1640*9000 Lg. (Bottom), 5100*14500 Lg.(Top)

Total Weight 46T (Approx.) Without Drive, Dribble Conv. Assembly &

Discharge Chute

Pan Material SAILMA 350 HI

Total No of Links in Chain 142

Gear Box


Type H3-280 RHB

Gear Ratio 106:1 P1

Serial No HGF-23986


Drive Details




Phases 3


Insulation Class F

Voltage 415 V

Frequency 50 Hz

IP 55

Duty S1

Machine No 105623170005/105623170006

Frame VD180L

DE Bearing N310

NDE Bearing 6210ZZ

Power 15 KW




RPM 965

Efficiency 89

Power Factor 0.83

Weight 208 Kg

9) Single Roll Crusher

Manufacturer McNally Sayaji Ltd

Quantity 2

Type Single Toothed Roll Crusher

Roll Diameter 1400 mm

Roll Width 1600 mm

Roll Tip Speed 4.7 m/s

Material to be Crushed Coal


Feed Size -500mm; Average -1000mm Max.

Product Size -300mm@80%

Capacity 250 TPH

No of teeth on Breaker Plate 60

No of teeth on Crushing Ring 102

No of nibs on Crushing Ring 56

V-Belt 106 SCO 7500 (8 SPC)

V-Groove Pulley

Machine 8 Groove; ‘SPC’-SEC; - 1660 PCD

Motor 8 Groove; ‘SPC’ –SEC; -310 PCD

Drive Details




Phases 3


Insulation Class F

Voltage 415 V

Frequency 50 Hz

IP 55

Duty S1

Machine No 105622840005/105622840006

Frame D315L

DE Bearing N319

NDE Bearing 6319

Power 132 KW


Full Load Current 236 A at 40oC


RPM 1485

Efficiency 94.7

Power Factor 0.85



Weight 1220 Kg

10) Flap Gate

Manufacturer Precision Processing Equipment Pvt. Ltd.

Quantity 2

Location JHCPP-2,JHCPP-3

Equipment ACTUATOR

Equipment No 5178/5179

Type P4

Thrust Torque 2500 kg

Motor Rating 5.5 kW

Output Speed 50 mm/s

Travel 450 mm

Drive Details

Manufacturer NGEF


Make AMKW132S4

Serial No 69134033/69134034

Quantity 2

Power 5.5 kW/7.5 hp

RPM 1430 rpm

Voltage 415V

Amperage 11.0A

Phase 3

Connection Delta

Power Factor 0.82

Frequency 50Hz

Supply AC

Insulation Class F

Duty S4-40


IP 55

11) Sump Pump

Manufacturer SAM Turbo Industry

Quantity 2

Serial No 16569/10, 16570/10

Type VO65/340-FF

Size 80*65

Capacity 20 m3/hr

Total Head 30 mwc

RPM 1450

Efficiency 16%

Specific Gravity of Slurry 1.09

Maximum Solid Size 40mm

Pump Weight 725 kg

Drive Details



Phases 3


Insulation Class F

Voltage 415 V

Frequency 50 Hz

IP 55

Duty S1

Machine No K1035616/K1035617

Frame D160L

DE Bearing NU309C3

NDE Bearing 6209ZZCC3

Power 15 KW



RPM 1450

Efficiency 90.2

Power Factor 0.8

Weight 113 Kg

12) Dry Fog Dust Suppression System

Pump Details

Manufacturer SAM Turbo-machinery Pvt. Ltd.

Quantity 2

Serial No 165667/165668

Type 8MD80/205

Flow Characteristics Centrifugal, Radially Splitted,Barrel type

Suction Flooded

No of Stages 7

Size 100*80

Capacity 22m3/hr

Head 105 m

RPM 1450

Efficiency in % (W/L) 62

BKW (KW)(W/L) 10.15

Flange Standard DIN ND16/DIN ND40

NPSH (R/A) 1.0 m

Lubricant Servogem 3

Pump Drive Details

Manufacturer Bharat Bijlee Ltd.


Quantity 2


Phases 3


Insulation Class F/B

Voltage 415 V

Frequency 50 Hz

IP 55

Duty S1

Machine No K1027874/ K1027875

Frame VD180L

DE Bearing N310

NDE Bearing 6210ZZ

Power 15 KW




RPM 1450

Efficiency 90.3

Power Factor 0.84

Weight 113 Kg

Compressor

Manufacturer Kirloskar Pneumatics Company Ltd.

Quantity 2

Model No. KES37-7.5

Free Air Delivered 6.94m3/min

Operating Pressure 7.0 kg/cm2

Maximum /Unloading Pressure 7.5 kg/cm2

Cut-in/Reloading Pressure 6.5 kg/cm2

MPVL Opening Pressure 4.0 kg/cm2

Capacity Control System LOAD-UNLOAD

Discharge Temp (at air end outlet) 850C to 1000C

Air Temp at Compressor Outlet Ambient +100C

Air Outlet Port Size and Quantity 1 ½ inch BSP *1 No

Sound Pressure Level of the

Compressor @ 1m distance 75 ± 3 dB(A)

Overall Dimensions of the Unit 1730mm*925mm*1530mm

Weight of the unit without oil 845 kg

Oil fill Capacity 16 l

Type of Coupling & size/model Flexible Claw Coupling - SW 226

Reference standard for FAD and SPC ISO 1217:1996 Annexure C

Reference standard for Sound

Pressure level Cagi Pneuerop PN8NTC2.2

Drive Details (Compressor Main Motor)

Make LHP

Quantity 2


Mounting Type B5 with single point support

Phases 3


Insulation Class F

Voltage 415 V ± 10%

Frequency 50 Hz ± 5%

IP 55

Duty S1

Frame 200L

Power 37 kW

RPM 2950

Efficiency 90.3

Overload Relay Setting 47 A

Type of starting Wye-Delta

Drive Details (Compressor Fan Motor)

Quantity 2


Mounting Type B5

Phases 3


Insulation Class F

Voltage 415 V ± 10%


IP 55

Duty S1

Frame YS-2200-4

Power 2.2 kW

RPM 1440

Efficiency 83

Overload Relay Setting 3.2 A

Type of starting DOL

Air Receiver

Manufacturer Kirloskar Pneumatics Co. Ltd.

Quantity 1

KPCL Part No 138010325

Capacity 1.2 m3

Maximum Working Pressure 10.6 kg/cm2

Design Pressure 11.66 kg/cm2

Hyd. Test Pressure 17.49 kg/cm2

Design Code IS 2825

Manufacturer Serial No R10031007

Manufacture Year 03/2010

Vendor Code 86938

Date of Test 21.03.2010

Ventilation System

Area of Application UG of Truck

Tippler,TT-7,TT-8

CPP Substation Toilet at CPP

Substation

Manufacturer DustVen DustVen Marathon

Model No. DCLLS 6.5 DCLLS 6 300Ø

Duty Continuous Continuous Continuous

Quantity 1 1 2

Capacity,m3/hr 37500 28000 1000

Operating Temp,0C 45 45 45

Operating Air Density,

kg/m3

1.1 1.1 1.1

Static Pressure, mmwc 75 60 5.0

Operating Speed, rpm 815 825 1400

Static Press at 1.2

kg/m3 air density,

mmwc

82 65 5.5

Shaft Power at

Operating Density, kW

10.1 6.4 0.055

Shaft Power at

200C,kW

11.0 7.0 0.06

Shaft Power at 40C,kW 11.6 7.4 0.063

Type of Drive V Belt V Belt Direct

Fan Total Efficiency,% 80 80 N/A

Motor Rating , kW/rpm 15/1460 9.3/1460 0.08kW single phase

Casing 3.15mm MS 3.15mm MS 1 mm MS

Impeller Blade 3.15mm MS 3.15mm MS 1 mm MS

Shaft 40C8 40C8 N/A

Bearing Type Ball/Roller Grease

Lubricated

Ball/Roller Grease

Lubricated

N/A

Filter Type 4Ply HDPE 4Ply HDPE N/A

Efficiency 90% down 10µm 90% down 10µm N/A

Size of each Filter 610*610*150 610*610*150 N/A

No of filters 16 12 N/A

Static Weight, kg 720 750 25

Dynamic Weight

inclusive of motor and

accessories, kg

1440 1500

Ventilation Fan Details

a)

Manufacturer DustVen Pvt.Ltd.

Fan Model DCLLS.6.D.L3

Serial No 010.648.VSF2CPP

Location Above Truck Tippler Control Room Building

Drive Details

Manufacturer ABB


Make HX +160ML B4

Phases 3


Insulation Class F

Voltage 415 V±10%

Frequency 50 Hz

IP 55

Duty S1

Machine No A334011

DE Bearing 6309ZZC3

NDE Bearing 6308ZZC3

Power 9.3 KW


Full Load Current 18.8 A

RPM 1455

Efficiency 88

Power Factor 0.81

Weight 125 Kg

b)

Manufacturer DustVen Pvt.Ltd.

Fan Model DCLLS.6.D.L3

Serial No 010.648.VSF1CPP

Location Near Truck Tippler

Drive Details

Manufacturer ABB


Make HX +160ML E4

Phases 3


Insulation Class F

Voltage 415 V±10%

Frequency 50 Hz

IP 55

Duty S1

Machine No A334000

DE Bearing 6309ZZC3

NDE Bearing 6308ZZC3

Power 15 KW


Full Load Current 28 A

RPM 1450

Efficiency 89

Power Factor 0.82

Weight 160 Kg

13) Belt Scale

Manufacturer IPA Weighing & Automation Pvt. Ltd.

Model No BCW55L0

Quantity 1

Location On CPP-1A Conveyor near Magnetic Separator

Power Supply 230V/110V ±10%, 50Hz ±3%

Mounting Wall

Operating Temperature 5oC to 50oC

Excitation to loadcell ± 5V DC, 120 mA

Inputs 0-15mV from Loadcell

Pulses from Speed Sensor

Outputs 4-20 mA corresponding to rate

(Loop Resistance: Maximum-1kΩ, Minimum-100Ω)

Display Annunciation 7-Digit 7-Segment red LED Display

Load Cell Specifications

Model No BR0-H0

Quantity 4

Rated Output 1.5 ±0.01mV/V

Combined Error ±0.1%

Repeatability ±0.05%

Creep on Load (30 minutes) ±0.1%

Zero Balance Voltage ±0.2 mV

Input Resistance 390±10 ohms

Output Resistance 350±2 ohms

Compensated Temperature Range 5-55oC

Operating Temperature Range 5-70oC

Temperature Effect on Span 0.006%/oC

Temperature Effect on Tare 0.008%/oC

Excitation Voltage 10V DC/AC (Maximum 12V)

Safe Overload 200%

Ultimate Overload 300%

Insulation Resistance, Bridge to Case

@ 30V DC @30oC >1000 M ohms


Cable 4m, 4core shielded PU sheathed

14) Belt Sway Switch

Manufacturer Jayashree Electrodevices Pvt. Ltd.

Location 1 each @ every 50m of belt length

Quantity 20

Serial No 41006107 (last 3 digits change for other switches)

Type SW-4028H22

Contact Rating 10 A Resistive @ 240V AC,50 Hz

Contact Combination 2NO+2NC

Enclosure Die Cast Aluminum


15) Pull Chord Switch


Location 1 each @ every 25m of belt length

Quantity 30

Type SW-4037HL22

Contact Rating 10 A Resistive @ 240V AC,50 Hz




Actuation (1-0-1) Bidirectional by Pull Rope

Reset Manual

LED bulb indicating lamp

Supply Voltage 110V AC

Supply Frequency 50 Hz

16) Zero Speed Switch


Location Tail end of individual belt

Quantity 5

Serial No S5032

Type RME261-NITD-CA-22-B60

Contact Rating 5 A Resistive @ 240V AC, 50 Hz




Paint Light Grey Epoxy(631 of IS 5)

Gasket Nitrile Rubber Moulded

Supply Voltage 240V AC ±10%

Supply Frequency 50 Hz ± 5%

Speed Setting Range RPM 10 to 100

Range Calibrated for 4 in/REV

Sensor Probe details

Type SP12B60

Enclosure Nickel Plated Brass Tube

Probe Size M60*1.5P*65L

Supply 12V DC±20%

Protection Grade IP 67

Sensing Distance 25mm ± 10%(Nominal)

15mm ± 10%(Effective)

Cable 3Core,PVC Flex,0.4 sq mm

Ambient Temperature 55oC Maximum

Weight 350 gm

17) Chute Block Switch

Manufacturer Protocontrol Instruments (India) Pvt. Ltd.

Location @ each transfer chute

Quantity 4

Type RFLS R 400 1I1

Rod Probe

Mounting Screwed 1.5 inch BSP

Operating Temperature 150oC

Rod Length 400mm/600mm

Control Unit

Supply 230 V AC


Contact Rating 5 A Resistive @ 230V AC

Output 2 C/O Relay Contact

Switching Delay 2 to 20 seconds

Ambient Temperature 60oC Maximum

Enclosure Housing Die Cast Aluminum


Housing Integral with Probe Housing

18) Transformer

Manufacturer Crompton Greaves Ltd.

Quantity 2

Maker’s Serial No DT2514/1 & DT2514/2

KVA 1600

Phases 3

Frequency 50 Hz

Volts at no load (H.V.) 6600 V

Volts at no load (L.V.) 433 V

Amperes (H.V.) 140.0 A

Amperes (L.V.) 2133.4 A

Impedance (Volts) 6.10%

Core and Windings 1900 kg

Weight of Oil 1130 kg

Total Weight 5200 kg

Quantity of Oil 1290 liters


19) OFF Load Isolator

Manufacturer A Bond Strands Pvt. Ltd. Switchgear Division

Manufacturer’s Designation OFF Load Isolator Switch


Quantity 2

Serial No P4813/P4814

Type of Switch Air

Type of Reference TKL3/12 KV/630 A

Construction Fixed type

No of Poles Three

Method of Operation Quick Make and Gang Operated

Method of Closing Manually Operated

Method of Opening Manually Operated

Operating Mechanism Handle Mounted on Front

Rated Voltage (Normal/Maximum ) 6.6 KV/7.2 KV

Rated Frequency 50 Hz ± 6%

Rated Current 630 A

Rated Duty Continuous

Short Time Withstand Current 40KA/3 second

Peak Withstand Current 100 KA Peak

Rated Making Capacity 100 KA Peak

Temperature Rise above 50oC ambient

@rated current 40oC

Clearance (Minimum as per Panel)

Phase to Phase 127 mm

Phase to Earth 76 mm

Fixed Contact to blade in open position 140 mm

Rated Insulation Level

Standard Impulse Withstand Voltage

Positive and Negative Polarity

Across the Isolating Distance 70 KV Peak

To Earth and between Poles 60 KV Peak

One Minute Power Frequency

Withstand Voltage

Across the Isolating Distance 23 KV RMS

To Earth and between Poles 20 KV RMS

Torque Required to Operate

the switch 18 Kg-m

Main Contacts

Type of Contacts Snap Action

Auxillary Contacts :Main

Spare Contacts (Minimum)

Normally Open 4 nos

Normally Closed 4 nos

Auxillary Contact Rating

Continuous (Make) 10 A

Break (Inductive) 5 A

No of Operation –Switch can

Withstand without deterioration

of Contacts 1000

Type of Interlock- Mechanical a) between Earth Switch and OFF Load Switch

b) Door Interlock

Reference Standards IS: 9921

20) UPS

Input

Nominal Voltage 415V AC Three Phase, 3 wire (± 10%)

Nominal Frequency 50 Hz (±5%)

Input Power Factor >0.92

Rectifier

Type Full Wave, Advance PFC Rectifier

Charger

Type IGBT based

Nominal Voltage Regulation ±1%

Ripple (Without Battery) <1%

Charging Method Constant Voltage Constant Current (CVCC) Auto &

Manual

Battery

Battery Voltage 240 V DC

Type & Rating SMF, 12V, 65AH,20 Nos. Exide Make

Output

Power Capacity 10 KVA/8 KW

Load Power Factor 0.7 lag to Unity within KVA & KW rating

Nominal Voltage 240 V, 1 Phase

Voltage Regulation ± 1%

Frequency 50 Hz (± 0.1 Hz) in Free Running Mode,50 Hz (± 2.5

Hz) in Synchronous Mode

Waveform True Sine Wave

Total Harmonic Distortion < 2% Maximum for 100% linear load

<5% Maximum for 100% Non-Linear Load (Ref : IEC

62040-Part III)

Overload Capacity 125% for 15 minutes. 150% for 60 seconds

Inverter IGBT based PWM with INSTANTANEOUS SINEWAVE

CONTROL

Dynamic Response For 0 to 100% step load change the output shall remain

within ±5% & recover to 98% within < 3 cycles

Crest Factor 3:1

Duty Continuous

Static Switch

Frequency Synchronisation Band ± 2.5Hz

Slew Rate 0.2 Hz/Sec

Transfer (Inverter to Bypass) In Synchronous Mode-No break in transfer

In Asynchronous Mode-<10mSec

ReTransfer (Bypass to Inverter) In Synchronous Mode-No break in ReTransfer

In Asynchronous Mode-Not Applicable

Overload Capacity 1000% for 100mSec

Manual Bypass Make before Break

System Configuration Parallel Redundant UPS with Common Battery Bank &

SCVS in Bypass Path

Environmental

Acoustic Noise Level <68 [email protected] m

Ambient Temperature 0 to 40oC

Storage Temperature 0 to 55oC

Humidity Upto 95% RH, Non Condensing

Altitude <1000m above sea level

Physical

Enclosure Protection & Grade IP-41

Cooling Forced Air

Color Hawells Gray-RAL7035 Structure Finish

Panel Dimension UPS 1&2:- W800*D900*H1850+20mm(With Plinth,

Name Plate Canopy & Anti-Vibration Pad)

SCVS:- W500*D900*H1850+20mm(With Plinth,

Name Plate Canopy & Anti-Vibration Pad)

Cable Entry Bottom

Testing Standard IEC 62040-Part III

21) Electric Hoist

a)

Manufacturer Brady & Morris Engineering Company Ltd.

Capacity 10.0 T

Location Truck Tippler

Quantity 1

Height of Lift (Hoist) 14.0m

Cross Travel 23.0 m

Class of Duty Class II, Indoor Duty as per IS:3938

Hoist Speed 6.0 meters per minute

CT Speed 15.0 meters per minute

Power Supply Voltage 415 V AC±10%

Frequency 50Hz ±5%

Phases 3

Control Supply Voltage 110 V AC

Control Through Pendant from Floor


Hoist Brake ACEM Disc Type; Make Morris

CT Brake ACEM Disc Type; Make Morris

Hoist Limit Switch

Manufacturer Jai Balaji

Power Supply 415V,50Hz, 1.5A

Contact 1NO+1NC

Wire Rope Ø16mm,6*36,4 Fall as per IS:2266,Fibre Core

Make: USHA MARTIN

Hook Forged Steel as per IS:15560

Rope Drum M.S. Seamless Pipe

Trolley Wheel Cast Steel

Bearing Ball & Thrust Type, Make : SKF

Sheave M.S./C.I.

Hoist Motor

Power 20.0 HP

RPM 960

Poles 6

Duty S4


No of Starts per hour 150

IP 55

CT Motor

Serial No 2400

Power 1.0 HP

RPM 1400

Poles 4

Duty S4

Frame 80

Connection Star

Current 2.2A


Torque 1.1 kg-m


IP 55

b)


Capacity 2.0 T

Location JHCPP-2

Quantity 1


Cross Travel 11.0 m





Frequency 50Hz ±5%

Phases 3






Hoist Limit Switch



Contact 1NO+1NC


Make: USHA MARTIN





Sheave M.S./C.I.

Hoist Motor

Power 5.0 HP

RPM 1440

Poles 4

Duty S4



IP 55

CT Motor

Power 0.5 HP

RPM 1440

Poles 4

Duty S4

Connection Star



IP 55

c)


Capacity 7.5 T

Location Magnetic Separator

Quantity 1


Cross Travel 3.0 m





Frequency 50Hz ±5%

Phases 3






Hoist Limit Switch



Contact 1NO+1NC


Make: USHA MARTIN





Sheave M.S./C.I.

Hoist Motor

Power 15.0 HP

RPM 1440

Poles 4

Duty S4



IP 55

CT Motor

Power 1.0 HP

RPM 1440

Poles 4

Duty S4

Connection Star



IP 55

truck tippler phase1 technical details

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