1 3814 gy se 901003 is03 technical especification

TECHNICAL SPECIFICATION COAL HANDLING SYSTEM

Document Identification Code

3814-GY-SE-901003

Sheet 1/43 Issue 03 Client : CDEEE - Corporación Dominicana de Empresas Eléctricas Estatales

Plant : 2x360 MW Coal-Fired Power Plant Location : Punta Catalina, Baní República Dominicana

This document is CDEEE’s property, and cannot be used by others for any purpose, without prior written consent


03 08 JAN 2015 ISSUE FOR ORDER R. Ramella Pezza

S. Gaiani

S. Gaiani

02 15 JUN 2014 FINAL ISSUE R. Ramella Pezza S. Gaiani S. Gaiani

01 30.APR.2014 PRELIMINARY ISSUE R. Ramella Pezza S. Gaiani S. Gaiani

Issue Date Reason for Issue – Revision Description Prepared Checked Approved

OWNER DOCUMENT CLASSIFICATION CODE

IN – INTERNAL ISSUANCE

FI – FOR INFORMATION ONLY

FA – FOR OWNER’S REVIEW AND APPROVAL

X

FC – FOR CONSTRUCTION OR FOR PURCHASE

FR – FOR RECORDS



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CONTENTS

1 FOREWORD .................................................................................................................................. 4

1.1 GENERAL INFORMATION ...................................................................................................... 4

1.2 MATERIAL TO BE HANDLED .................................................................................................. 4

1.3 AREA CLASSIFICATION ......................................................................................................... 4

2 COAL HANDLING DESIGN BASIS ........................ ....................................................................... 5

2.1 COAL CONVEYING FROM SHIP UNLOADING TO BULK WAREHOUSE .................................................. 5

2.2 COAL CONVEYING FROM BULK WAREHOUSE TO BOILER SILOS ....................................................... 6

3 SCOPE OF SUPPLY AND BATTERY LIMITS ................ ............................................................... 7

3.1 EXTENT OF PREFABRICATION AND STATUS OF EQUIPMENT AT SHIPMENT........................................ 8

4 MINIMUM REQUIREMENT FOR EQUIPMENT ............................................................................. 9

4.1 OPERATING CONDITIONS ..................................................................................................... 9

4.2 MAIN DESIGN CHARACTERISTICS ....................................................................................... 9

4.3 BELT CONVEYORS .............................................................................................................. 10

4.4 PIPE CONVEYOR ................................................................................................................. 14

4.5 TRIPPERS ............................................................................................................................. 14

4.6 SKIRT BOARDS .................................................................................................................... 14

4.7 FEEDER ENCLOSURES ....................................................................................................... 15

4.8 CHUTES AND HOPPERS ...................................................................................................... 15

4.9 BELT ENCLOSURES HOODS ............................................................................................... 18

4.10 MAGNETIC SEPARATORS AND METAL DETECTORS ....................................................... 18

4.11 ELECTRIC DRIVEN FLOP DIVERSION VALVES .................................................................. 19

4.12 FEEDERS .............................................................................................................................. 20

4.13 COAL CRUSHERS ................................................................................................................ 20

4.14 DUST CONTAINEMENT ........................................................................................................ 21

4.15 DUST SUPPRESSION SYSTEM: WATER SPRAY TYPE ...................................................... 24

4.16 COAL SAMPLING SYSTEMS ................................................................................................ 25

4.17 WEIGHING SCALES ............................................................................................................. 26

5 BELT CONVEYOR STRUCTURES AND AUXILIARY SYSTEMS .... ........................................... 26

5.1 TRANSFER TOWERS AND GALLERIES .............................................................................. 26

5.2 MAINTENANCE EQUIPMENT ............................................................................................... 29

5.3 PIPING NET INSIDE GALLERIES AND TOWERS ................................................................. 30

5.4 FIRE FIGHTING ..................................................................................................................... 31

6 INSTRUMENTATION EQUIPMENT ............................................................................................. 33

6.1 INSTRUMENTATION FOR BELT CONVEYOR CONTROL .................................................... 33



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6.2 INSTRUMENTATION CABLES AND JUNCTION BOX ........................................................... 33

7 ELECTRICAL EQUIPMENT .............................. .......................................................................... 34

7.1 ELECTRICAL DESIGN CRITERIA ......................................................................................... 34

7.2 ELECTRICAL MOTORS ........................................................................................................ 34

7.3 LIGHTING AND SOCKET ...................................................................................................... 34

7.4 MCC AND ADDITIONAL ELECTRICAL EQUIPMENT ............................................................ 35

7.5 GROUNDING SYSTEM ......................................................................................................... 35

7.6 LIGHTNING PROTECTION SYSTEM .................................................................................... 35

7.7 EQUIPOTENTIAL BONDING ................................................................................................. 35

7.8 MODES OF CONTROL .......................................................................................................... 36

8 PLANT 3D VIEWS .................................... ................................................................................... 37

ATTACHMENTS:

Attachment 1 – Preliminary arrangement top of bunker area Attachment 2 – Preliminary arrangement pipe conveyor on jetty Attachment 3 – Preliminary arrangement conveyor & hopper on pier Attachment 4 – Typical section of belt conveyors installed in galleries



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1 FOREWORD

This specification summarizes the design and engineering prescriptions for the supply of the Coal Handling System installed on Coal Power Plant located in the Dominican Republic. The purposes of coal handling are the followings:

• Transfer the Coal from ship to the coal bulk warehouse and boiler bunkers at the same time • Transfer the Coal from the coal bulk warehouse to the boiler bunkers

To optimize the spare parts Vendor shall consider as much as possible the standardization of all equipment, particularly for motors, reducers, pulleys, coupling, idlers, belt cleaners, etc. also if this approach can cause the over sizing in the design parameters of some components. The selection of components has also to be carried taking into consideration reliability, safety and easy maintenance of the system.

1.1 GENERAL INFORMATION

The coal for the new boiler plant at Santo Domingo power plant will be delivered by self discharging ships 80000 tons displacement. HandyMax and le Supra Max that download the coal into hoppers located on dedicated jetty. Unloading facilities have to be designed to accept ships equipped with unloading boom. Under the hoppers troughed belt conveyors extract the coal and deliver it to conveyors that provide the connection with the coal bulk warehouse or directly to the coal bunkers located over the mills.

1.2 MATERIAL TO BE HANDLED

The material to be handled is Thermal coal having characteristics as per specification 3814-YZ-SG-000001 “Design basis and site conditions”.

1.3 AREA CLASSIFICATION

All items included in the supply will be located in areas classified by NEC as per area classification drawings attached to the Material Requisition. All electrical equipment included in the scope of supply will be: Class II, Division 1, Group F / T3B



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2 COAL HANDLING DESIGN BASIS

2.1 Coal conveying from ship unloading to bulk warehous e

The coal, transported from boom equipped self unloading ships, is transferred from the jetty to the power plant by means of belt conveyor chain composed by the following items:

• Movable hoppers 00EAA10BR001; • belt conveyors 00EAC10AF001; • pipe conveyors 00EAC11AF001; • belt conveyors 00EAD10AF001 equipped with movable tripper 00EAD10AF002;

The motorized hopper 00EAA10BR001 located on the jetty can be moved along the belt conveyor 00EAC10AF001 match the position of ship unloading boom and allow a correct coal discharge. In the middle of the hopper will be installed a net necessary to avoid the passage of big lumps. The size of holes will be determined during the detail engineering. The main purpose of this net is the protection of the pipe conveyor. In any case max allowed hole dimensions are 200 x 200 mm. The conveyors 00EAC10AF001 will be equipped with the weighing scale 00EAT10CW001 in order to verify the real quantity of coal discharged from the ships. The coal sent to the tripper conveyor 00EAD10AF001, through the pipe conveyors 00EAC11AF001, reaches the tripper 00EAD10AF002 that provides the coal stacking in the coal bulk warehouse. The closed coal bulk storage is sized considering the recovery of 30 days of two boilers operation at rated capacity. To allow the refilling of boiler bunkers directly with the coal discharged from ships the following items are installed:

• Splitter valve 00EAC12AA101 at the discharge of pipe conveyor 00EAC11AF001;

• Diverter valve 00EAC12AA102 downstream the splitter valve 00EAC12AA101;

• Weighing scales 00ECT11CW001 & ECT21CW001 installed on belt conveyors 00ECD010AF001 & 00ECD20AF001;

The splitter valve (pneumatic actuators are recommended) 00EAC12AA101, (type will be defined by vendor and will be subjected to Contractor approval during detailed engineering) will split the coal flow as per the following:

• Delivery of 3000 t/h to the coal yard when it’s not requested coal in the bunkers

• Delivery of up to 1500 t/h to the bunkers (flow rate will be taken within a range that will absorb the flow rate fluctuations without continuous adjustment of the splitter valve) measured by weighing scales 00ECT11CW001 & ECT21CW001. Coal exceeding the settled flow rate will be sent to coal storage



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2.2 Coal conveying from bulk warehouse to boiler silos

The coal reclaimed from bulk warehouse by means of portal reclaimers 00EAF10AE001 & 00EAF20AE001 will be delivered to the boiler bunkers through a belt conveyor chains composed by the following items:

• Portal reclaimers 00EAF10AE001 & 00EAF20AE001; • Belt conveyors 00ECB10AF001 & 00ECB20AF001; • Belt conveyors 00ECD10AF001 & 00ECD20AF001; • Intermediate hopper 00ECF01 BB001; • Extractor feeders 00ECF10AF001 & 00ECF20AF001; • Coal crushers 00ECF10AJ001 & 00ECF20AJ001; • Belt conveyors 00ECG10AF001 & 00ECG20AF001; • Belt conveyor 00ECH10AF001 equipped with travelling trippers 10ECH10AF001 &

20ECH10AF001; • Belt conveyor 00ECH20AF001 equipped with travelling trippers 10ECH20AF001 &

20ECH20AF001. The coal stored in the bulk warehouse will be recovered by the portal reclaimers 00EAF10AE001 & 00EAF20AE001 that discharges it in the belt conveyor 00ECB10AF001 & 00ECB20AF001. Each conveyor is connected and dedicated to a portal reclaimer. Each portal reclaimer shall be able to work for all warehouse length. Both reclaimed coal conveyors will be located on the same side of the warehouse. In the belt conveyors 00ECB10AF001 & 00ECB20AF001 are installed the weighing scales 00ECT10CW001 & 00ECT20CW001 that provide a feedback to the reclaimer in order to regulate the reclaiming flow rate of the machine. Weighing accuracy shall be enough to guarantee a correct reclaiming flow rate from the portal reclaimers. On conveyors 00ECD10AF001 & 00ECD20AF001 will be installed the devices to clean the coal from magnetic and non magnetic metal debris. The buffer hopper 00ECF01BB001, installed downstream conveyors 00ECD10AF001 & 00ECD20AF001 is used as intermediate capacity during the positioning of the bunkers trippers to avoid the start and stop of the reclaimer. At the outlet of the hopper will be installed the belt feeders 00ECF10AF001 & 00ECF20AF001 and the crushers 00ECF10AJ001 & 00ECF20AJ001 used to destroy all possible residual lumps (lumps breaker will be installed also on the reclaimer chutes) and to reduce the coal size. On the conveyors 00ECG10AF001 & 00ECG20AF001 are installed the coal sampling system 00ECU10 used to analyze the coal recovered from coal storage. The sampling system shall be located on the tower 00UEF50. Belts conveyors 00ECH10AF001 & 00ECH20AF001, located above the boiler bunkers, are equipped with travelling trippers 10/20ECH10AF001 and 10/20ECH20AF001.



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The diverter valves 00ECG10AA101 & 00ECG20AA101, installed in the chute of the belt conveyors 00ECG10AF001 & 00ECG20AF001, are used for the deviation of the coal flow in one of the downstream tripper conveyors. Dedusting systems will be provided where necessary to confine the powder inside chutes and to keep clean the bunker area. The centralized dry type dedusting systems indicated on the PFD 3814-GZ-DP-901005 are mandatory. For local dedusting on conveyor chutes Vendor can propose the most appropriate technical solution based on his experience.

3 SCOPE OF SUPPLY AND BATTERY LIMITS

The supply of coal handling system includes, but is not limited to, the main equipment that are indicated in the Process Flow Diagram 3814-GZ-DP-901005. The portal reclaimers 00EAF10AE001 & 00EAF20AE001 are part of the system but they are not considered in this specification. They are described on the specification 3814-GY-SE-901004 “Technical specification for portal reclaimers”. Equipment & machines shall be supplied adopting the package philosophy. Each component / unit shall be supplied prefabricated and preassembled as far as permitted by the transport limitations and shall be complete at least with all equipment and materials listed here below. All items necessary for a good and safety operation of the system shall be included in the supply also if not directly listed or mentioned in the specification or in the other specifications attached to the Material Requisition. Vendor is responsible for the design of the whole system. The equipment shall be sized for the following flow rates:

• From ship unloading to bulk warehouse: 3000 t/h • From bulk warehouse to boiler: 1500 t/h

Here below a summary table of the conveyors with main characteristics:

Item Type Flow rate (t/h) Length (m) Elevation (m) 00EAC10AF001 Troughed conveyor 3000 275 5 00EAC11AF001 Pipe conveyor 3000 2105 38 00EAD10AF001 Troughed conveyor 3000 500 8 00ECB10/20AF001 Troughed conveyor 1500 535 / 540 3 00ECD10/20AF001 Troughed conveyor 1500 80 20 00ECG10/20AF001 Troughed conveyor 1500 270 50 00ECH10/20AF001 Troughed conveyor 1500 160 15 00ECF10/20AF001 Extractor belts 1500 8 Horizontal



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Item Type Width (m) Length (m) Height (m)

00UEF10 Tower 10 8 8 00UEF20 Tower 10 10 45 00UEF30 Penthouse 10 8 8 00UEF40 Tower 10 10 20 00UEF50 Tower 10 12 54 00EAC10AF001 Gallery 4.5 36 2.9

00EAC11AF001 Open bridge with walkways 3 (*) 126 (*) 2.7 (*) Closed gallery 5 50 3.5

00ECD10/20AF001 Common Gallery 7 50 2.8 00ECG10/20AF001 Common Gallery 7 220 2.8 00ECH10/20AF001 Common gallery 9 (**) 50 + 44 (**) 4 (**) (*) The portion of pipe conveyor located on jetty will be installed directly on concrete foundations.

Jetty is studied considering lateral concrete walkways for all the conveyor length. The portion of elevated conveyor from ground to tower 00UEF20 is required complete with support structure, lateral walkways and trestles. The transition portions of pipe conveyors shall be installed inside closed gallery.

(**) The gallery is not complete for all the conveyors length but is limited to the portion of conveyors

from tower 00UEF50 to the boiler and the portion between boilers. The gallery shall be designed taking into account the need to contain and support also the tail of the trippers when they are positioned to refill the first silo of each unit.

3.1 Extent of prefabrication and status of equipment at shipment

a) Equipment machinery

Equipment (main machines and conveyor heads) shall be completely prefabricated, pre assembled up to the transportation limit with electric motors, instrumentation, tubing and wiring up to junction box. To optimize the transportation volume, the intermediate portion of conveyors (structures & components) will be delivered loose to be assembled on site. Vendor can avoid the pre installation of tubing, wiring and instrumentation when is evident a possible damage during the transportation and erection Cable and tubing partially installed shall be marked on the not connected side to allow an easy assembly at site.



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b) Structure Steel structure shall be supplied prefabricated, loose, clearly marked and ready for the erection at site. They will be transported inside containers as much as possible. All parts to be assembled on site shall be bolted. Field welding are not allowed. c) Cables Both electric and instrument cables not installed will be supplied loose in coils d) Bulk materials and minor items Shall be supplied loose with clearly identification codes and tags for erection.

4 MINIMUM REQUIREMENT FOR EQUIPMENT

4.1 OPERATING CONDITIONS

The Coal Handling System, including equipment involved in the ship unloading operations, shall be designed for service defined as heavy duty and continuous operation 365 days/year. In particular the elongation of the various services is summarized here below:

• Stacking 24 h/d (during the presence of ships) • Reclaiming 24 h/d • Expected Equipment Life 30 years

4.2 MAIN DESIGN CHARACTERISTICS

Vendor shall design the belt conveyors taking into account the prescriptions here below and the belt conveyors characteristics:

• The width of Conveyor Belts will be expressed in millimeters. • Belt width will be selected choosing between the values standardized by ISO. • Standard Edge Distance of Troughed Belt will be according to ISO Standard. • Filling factor of Troughed belt conveyors will be ≤ 85%. • Troughed Belt Conveyors speed will be ≤ 3.2 m/sec. • The Troughed Belt Conveyor slope will be ≤14°. • Pipe conveyor speed: as per Vendor suggestion (to be agreed with TCM) • Pipe conveyor filling factor: ≤75%



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• Slopes angle of the discharge chutes will be at minimum 65 degrees from horizontal. • Bearings: L-10 life, approx. 90000 hours (Note: bearing of conveyor rollers are not included in

this category but are as per specification CEMA) • Service factor: gear reducers and drives: 1.5 minimum based on calculated motor horse power.

The Coal Handling System will be designed on the basis of Main Dimension and Technical Parameter indicated by TCM. Any deviation proposed by the Vendor has to be justified with technical explanation and approved by CDEEE or CNO.

4.3 BELT CONVEYORS

Belt conveyors shall be designed in accordance with CEMA “Belt conveyors for bulk Materials” and considering the prescriptions of following paragraphs

4.3.1 Rubber Belts:

� Belt and pulleys in accordance with CEMA standard for: • Grade 2 belting or better • Top cover: abrasion, cut and gouge resistant • DIN abrasive rating 90 or better • Over temperature range: 40 to 200 F • Minimum tensile rating: as per K quality • Hardness: 60 Durometer Shore A

� Cover materials: • Chemical resistant (sulfur) • Top cover minimum thickness: 3/16” • Bottom cover minimum thickness: 1/16” • Cover ratio to resist cupping

� Carcass: conventional ply construction � Edges bonded and protected to resist edge abrasion � Elongation: not exceeding 2 % during belt life � Design for start with belt conveyor fully loaded � Splices: Hot vulcanized field splices Note: ONT, according to previous referenced application, consider the rubber belt K quality as per

DIN22102 to take into consideration the need to privilege the antistatic and auto extinguish properties instead to fulfill the request to have wear resistant belt. Coal can be considered “Non abrasive” material



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4.3.2 Belt conveyor splicing kits

Vendor shall include in the scope of supply the splicing kits sufficient for the complete installation of all the rubber conveyors that compose the coal handling. A spare number (around 5%) of splicing kits shall be considered to take into account possible modifications, erection mistakes, belt conveyor replacing, etc.

4.3.3 Pulleys and shafts:

� Designed for 150% maximum running load or maximum acceleration load whichever is greater. � Construction: welded steel, heavy duty, self aligning, anti friction roller bearings with grease seals. � Tapered or curved ends are acceptable � Provide bearing brackets with screw adjustment and locking device for aligning on both sides of

each bearing bracket. � Shaft key for drive and head pulley in accordance to ANSI B17.1 � Lagging as per conveyor belt recommendation. � Pulley total indicated run-out tolerances:

• 12” and under diameter: ±0.063”; • over 12”: ±0.125”

� Pulley manufacture and information about pulley & shaft design shall be provided

4.3.4 Drives:

� Type: Electric motor driven gear reducer directly coupled to head pulley shaft � Gear reducer

• Totally enclosed oil bath type with helical or equal gears and antifriction bearings. • Gears and bearings mounted in oil and dust tight split steel or split cast iron housing; split seals

� Drive motor: Direct connected to drive pulley by means a fluid coupling. Electric motor, fluid coupling and gear reducer shall be shop mounted and aligned on a common steel base plate

� Fluid coupling: Adequate to service intended to provide soft start � Provide removable coupling guards � Provide 2 jacking bolts at each of 4 corners of motors � Provide 2 jacking bolts at each of 4 corners of gear reducer.

4.3.5 Belt cleaners provided for each belt conveyor . Locate for easy maintenance access

� Head pulley access doors: Sizes as required to service new pre-cleaner and secondary cleaner. � Head pulley pre-cleaner and mounting hardware:

• Blade material: Polyurethane. • Slide-in/slide-out blades.

� Head pulley secondary cleaner and mounting hardware: • Arms: Polyurethane, slide-in/slide-out multi arms. • Blades: Stainless steel snap-in/snap-out swivel blades.



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� Tail pulley V-plow: • Torsion arm system. • Blades: Urethane blades.

4.3.6 Back stop:

� To prevent backward movement of inclined conveyors. � Minimum size: 1.5 times drive motor horsepower. � Provide additional equipment, if required, to prevent coal pile-ups due to coasting of belt after

tripping off downstream conveyor, when operating at fully loaded condition.

4.3.7 Belt take-ups

� Type: Vertical automatic gravity take-up whenever feasible. � Provide tail pulley screwed take-ups with hydraulic assist only when gravity take-up is not feasible. � Design for belt tension to control belt sag between idlers to 2% maximum. � Location: As recommended for belt tensions, maintenance, and available space. � Provide necessary pulleys, counterweights, guides, cables, and other equipment required for

complete installation. � Take-up travel: Conform to minimum CEMA requirements plus 2’ and as recommended by belt

manufacturer. � Provide means to confine counterweight in event of belt failure; provide means of resisting impact

loads due to free fall of take-up. � Counterweight steel boxes shall have capacity of at least 130% of required weight. Boxes shall

have bolted removable cover and drain holes in bottom. � Counterweights for vertical take-up assemblies shall be located as close as possible to grade or

elevated platform, as applicable. � Extend lubrication points to access platforms.

4.3.8 Idlers

� Carrying idlers: • Type: 3 equal-length rolls with 35° side roller angle; reduce angle at approaches to terminal

pulleys. • Size: 5” diameter rollers minimum, CEMA Series D minimum.

� Return idlers: • Type: full length single roller. Two roll “Vee” return idler to be used to facilitate maintenance for

belt having width greater than 1200 mm. • Size: Diameter and CEMA series to match carrying idlers. • Use steel return idlers between head pulley and take-up pulley.

� Impact idlers: Support each loading point with at least 6 special impact type carriers. � Idler spacing:

• Carrying:



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o Not more than 4’-0”. (1200 mm) o Under skirt boards: Not more than 2’-0”. (600 mm)

• Return: Not more than 10’-0”. (3000 mm) • Impact: Not more than 1’-0”. (300 mm)

� Rollers: • Seamless steel tubing with rounded ends. • Antifriction roller bearings enclosed in dust tight and moisture tight housings with grease seals.

� Self-aligning training idlers: • Same type as carrying and return idlers, with pivot mounted side guide rollers. • Install maximum 15 belt-widths from each terminal or closer as recommended by belt

manufacturer and at spaces not exceeding 100’-0” on both carrying and return runs. � Installation: Laser align idlers to following tolerances.

• No more than 1/16” misalignment in any direction between adjacent idlers. • No more than 1/8” misalignment between any idlers over entire length of conveyor.

4.3.9 Lubrication:

� External means for lubricating bearings. � Gear trains, etc., arranged for enclosed oil bath lubrication; oil sight gage and train valve with plug

on enclosure. � Grease fittings:

• Location: Extend to allow servicing from access platforms or walkways; plastic extension piping is not acceptable; install for all fittings including training idler rollers.

• Hollow shaft idlers with one fitting serving all bearings are acceptable.

4.3.10 Deck plate:

� Not lighter than 14-gage (2 mm) galvanized steel; provide entire length for conveyors. � Overlap 6” and position to prevent material buildup on belt return run.

4.3.11 Removable safety shield:

� Galvanized chain link fence, framed for mounting. � Install at following locations:

• Tail pulley enclosure. • Gravity take-up bend pulleys along walkways. • Along all conveyor length • Other locations as determined by Contractor’s design engineer.

� Design to prevent coal build-up.



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4.3.12 Vertical curves of belt conveyors

Radius of Concave Vertical Curves of troughed belt conveyors will be determined according to CEMA in order to allow the belt to assume a natural path on the troughing idlers under all conditions. Radius of Convex Vertical Curves (when the center of curvature lies below the belt) will be determined according to CEMA recommendations, in order to avoid over stress of belt edges or buckling in the belt. In accordance with CEMA “Belt conveyors for bulk materials”

4.4 PIPE CONVEYOR

For the design of the pipe conveyor the following will be considered:

• The motors of the pipe conveyor will be located at elevation 100.000 to simplify the maintenance ant to reduce the amount of the heavy equipment installed in elevated position.

• The motors will be suitable for unclassified area • To limit the quantity of structures at elevated quote is accepted the entrance of pipe conveyor in

the tower 00UEF20 with inclination angle less than 14 degrees.

4.5 TRIPPERS

� Location: Above boiler silos and above coal pile inside bulk warehouse. � Type: Movable. Design for belt capacity. Provide direct drive gear reducer electric motor drive

system to move tripper. � Provide discharge chute arranged to allow diversion of coal into silos below. � Chutes: Not lighter than 1/4” thick ASTM A36 steel with ceramic lining. � Pulleys: As specified in paragraph 4.3.3. � Grease fittings: High pressure. Extend to allow servicing from tripper floor. Plastic extension piping

is not acceptable. � Festoon cable or cable reel system with cable for power and control circuits suitable for use in

areas classified by NEC as Class II, Division 1, Group F T3B. as per indicated in the area classification drawing

� Steel wheels and track. � Enclose tripper chute for dust control. Tripper speed for translation: 0.16 m/sec corresponding to 10 m/min

4.6 SKIRT BOARDS

� Provide as required for proper operation of material handling equipment. � Arrangement: To be determined by Vendor on the basis of the configuration shown on Drawings. � Design requirements:

• Construct of not less than 1/4” ASTM A36 steel plate or better.



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• Skirt boards, adjustable seal strips, dust curtains, shaft seals, gaskets, calking, packing, and other accessories required for maximum dust tightness; include dust tight inspection doors where shown and recommended.

• Locate skirt boards to allow for vertical offset of impact idlers, due to uneven loading. • Loading point: Self-adjusting one piece “ribbed” dual skirt board sealing system for use on belts

with 35° idlers. o One-piece seal. o Material: Nitrile Rubber, 60 Durometer. o Free belt area: 2.5” on both sides of exterior chute wall. o Service temperature range: -20º to 160ºF. o Length: 12’ minimum.

• Loading point skirt board liners: o Configuration: Straight. o Material: Type 304 stainless steel. o Mounting holes: 24” intervals.

• Cover plate: o Material: 10 gage (3 mm) galvanized steel. o Use spring clip closures at 1’ spacing. o Calk joints with clear silicone calking.

4.7 FEEDER ENCLOSURES

� Feed chute, stationary skirt, and discharge chute with flexible seals to feeder. � Dust tight inspection doors located where recommended and indicated. � Regulating gate in feed chute to control material to feeder. Construct of minimum 1/4” abrasion

resistant plate. � Other accessories as required for maximum dust tightness. � Provide connections on all feeder enclosures and on all conveyor discharge and loading

enclosures

4.8 CHUTES AND HOPPERS

� Arrangement: As determined by Contractor. � Size chutes for specified capacity. � Design for most direct connection from point to point. � Provide U shaped chutes when drop distance greater than 12’. � Avoid “dog legs” and fast tapers. � Materials:

• Chutes and hopper shells: 1/4” minimum thickness ASTM A312 Type 304 stainless steel. • Liners:

o Hoppers at sloping surfaces subject to wear: 5/8” minimum thickness ASTM A312 Type 304 stainless steel.



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o Abrasion-resistant ceramic wear tile liner for all chutes, except portion under belt cleaners: • Hardness: 400-450 Brinell, minimum. • Chemical composition for corrosion resistance: Minimum 90% alumina ceramic. • Material thickness: 1/2” minimum.

o UHMW polyethylene lining for use under belt cleaners: • Density (Test Method ASTM D792): 0.96 g/cc. • IZOD impact, ft-lb/inch notch at 23ºC (Test Method ASTM D256A): 28 to 30. • Tensile strength (Test Method ASTM D638):

� Yield: Minimum 3,200 psi. � Ultimate: Minimum 5,600 psi.

o Coefficient of friction (Test Method ASTM D1894): Maximum 0.11. o Material thickness: 1/2”. o Mounting: Stainless steel welding washers spaced at 12” maximum any direction and at 12”

center to center 2” from edge of sheet with UHMW polyethylene plugs to provide smooth lining surface.

• Wear plates: o Average Brinell hardness: 400-450 minimum. o Chemical composition for corrosion resistance. o Butt joints: Continuously welded; side joints tack welded. o Use: Impact areas. o Material thickness: 1/2” minimum.

• Provide head chutes with liners as specified above up to centerline of discharge pulley on front and sides or 6” higher than material impact point, whichever is greater.

� Provide exterior stiffeners and bracing to prevent excessive vibration and deflection during operation and when plugged.

� Access doors: • Complete with gasket, dust tight. • Size: Minimum 24” x 24” inside dimensions. • Quick-opening type with hinges and latches. • Type: Handle style lift and turn latch. • Latch to apply compression to pull enclosure tight against frame. • Install deflector angles to protect door seals. • Provide access doors as shown and as required for access to all moving parts, critical wear • Areas, belt cleaners, and equipment inside chutes and hoppers. • Provide adjustable baffle plate at discharge from each conveyor head pulley designed for

material • Impingement, with adjusting bar operable from outside of discharge chute. Construct of

minimum • 1/4” wear liner plate. See “Wear Plates” above. • Provide access doors approximately 4’ above skirt board in loading chute and at 15’ intervals.

� Chute at diversion/flop gates: • Symmetrical about centerline. • Design to eliminate material pocket below shaft.



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• Design to recess top of gate in chute when gate is in operating position. � Minimum valley angle: 60° to horizontal. � Loading chutes: Arrange to enable belts to carry maximum load, avoid spillage, and reduce

abrasion. Arrange loading chutes with V-shaped or rounded bottoms designed to deposit fines on belt before larger lumps.

� Provide chutes in welded segments. Limit segment length for easy removal during maintenance. Bolt segments together and use gaskets to provide connections dust tight.

� Hopper and chute side walls shall be as nearly vertical as possible. � Liners welded in place shall have welds accessible for cutting and re-welding for maintenance

purposes. Liner sections shall not exceed 150 lb to allow easy replacement. � Incorporate means for collection of dribble from belt cleaners with delivery to conveyor discharge

hoppers. � Tramp iron chute:

• From magnetic separator to 3’-0” above ground floor. • Construct of not less than 1/4” stainless steel plate.

� Provide stainless steel silo chute inlet grate 5/8” minimum thickness. Note: The hopper 00ECF0BB001 installed in the crusher building will be equipped with manually operated hammers to be used in case of material bridge creation or clogging.

4.8.1 Ship unloading hopper 00EAA10BR001

The ship unloading hopper will be realized with a half cylindrical roof divided into two parts. One portion is fixed and the other is movable to allow the boom positioning during unloading. When the unloading system is not used the roof is complexly closed to protect the conveyor from rain. The movement of the roof will be motorized with push buttons located on board of the hopper. The hopper will be equipped with inspection / maintenance walkways and stairs. Arrangement will be developed during the detail engineering. Rail and bumpers, as well as retaining devices are included in the scope of supply. The hopper will be designed taking into account the following wind speeds as per FEM regulation: � Normal operation: < 20 m/sec � Under operator responsibility: from 20 to 25 m/sec � Retaining: > 25 m/sec (mandatory!) The part of hopper in contact with coal will be realized in Carbon steel. The chute between hopper and conveyor will be made in SS AISI 304



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4.8.2 Crusher hopper 00ECF01 BB001

The hopper is used to guarantee a constant feeding to the crushers The part of hopper in contact with coal will be realized in Carbon Steel. The chute between hopper and extractors will be lined with SS AISI 304 The hopper shall be equipped with explosion venting panel in accordance to the prescriptions of NFPA68 complete with sensor for broken panel.

4.9 BELT ENCLOSURES HOODS

Belt conveyors installed on pier have to be supplied complete with weather protection that consists in movable metallic covers. The movement of the covers is controlled by the movable hopper that is equipped with driving beams that provide the opening and take care the closing of the panels without need of manual operations Belt conveyors installed in the galleries will be covered with protection panel to confine any powder. The preliminary configuration of the protections is shown on Attachment 4.

4.10 MAGNETIC SEPARATORS AND METAL DETECTORS

As per Process Flow Diagram 3814-GZ-DP-901005 the magnetic metal separators 00EBE10AT001 & 00EBE20AT001 and metal detectors 00EBE11CQ001 & 00EBE21CQ001 will be installed along conveyors 00ECD10AF001 & 00ECD20AF001 between tower 00UEF20 and tower 00UEF40 to remove possible metal debris contained in the coal stored in the bulk warehouse or arriving directly from the ship unloading through by-pass. The magnetic separators shall be electrical powered to create a stronger magnetic field. They will be positioned in such a way to facilitate access for maintenance. Self cleaning cross belt type, or in alternative in line type with conveyor belt width minus 6” (150 mm), shall be used. Downstream the magnetic separators metal detectors for ferrous and nonferrous metal debris are installed. The installation position is suitable for easy maintenance. When metal debris are detected the diverter valves 00ECD10AA101 & 00ECD20AA101 switch and discharge coal contained metals, through a chute pipe, to a bin at the base of the tower 00UEF40. Discharge piping are in vendor scope of supply.



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4.11 ELECTRIC DRIVEN FLOP DIVERSION VALVES

The diverter, installed in conveyor chutes and in bunker tripper chutes, shall be driven by electric motor, pneumatic actuator is not allowed, except for by-pass diverter gate 00EAC11AA101 preferred pneumatic actuated. Diverter valves shall be provided with: � Manual wheel operator, chain wheel operator if they are positioned more than 6’ (1.8 m) from floor

or platform. � Position indicator / switch � AISI 304 wearing plates minimum thickness 5 mm � Suitable access panel/s for maintenance � Every moving part (bearings, shafts) dust sealed

The slopes shall be minimum 65 degrees from the horizontal � Construction:

• Electric operator: Motor operator or electric cylinder operator, complete chain wheel operator if they are positioned more than 6’ (1.8 m) from floor or platform.

• Design to withstand stall torque of motor. • Provide local position indicator. • Gate Material: 1/4” Type 304 stainless steel minimum with 3/8” minimum wear plate as specified

for chutes. • Position adjustment capability: 2-position.

� Gate slope in operating position: 65° to horizontal minimum. � Design components to withstand material impingement in all gate positions and permit changing

position while material is flowing. � Access panels: Bolted and complete with gasket, as required for access to moving parts and other

equipment inside chutes and hoppers. � Bearings:

• Pillow block, ball, or roller type; self-aligning. • Dust-sealed. • Support from chute plate with stiffeners to prevent buckling or warping of plates or misalignment

of bearings when operated. • Equipped with lubricating fittings as specified for belt conveyors.

� Shafts: Dust-sealed where passing through material chute plate. � Wear plates: As specified above.



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4.12 FEEDERS

Feeders shall be installed under hoppers to dose the product to the conveyors � Positive displacement rotating spool feeder:

• Feeder output shall be proportional to speed of rotation and material shall be fed at a constant rate.

• Drive system: Variable speed drive and electric motor for a continuously controllable feed rate. • Materials of construction: Housing shall be of ASTM A36 or better, creating stationary support

for rotating elements and drive system. � Belt: Feeder.

• Furnish complete with motors, drives, and other accessories necessary for proper installation and operation.

• Service: Continuous duty at initial and future capacity. • Capable of accepting dry, wet or frozen material. • Controls:

o Variable speed control utilizing a variable frequency drive. o Suitable for manual or automatic adjustment, remote electric operated feed rate control. o Include 4-20 mA DC signals for remote feed rate indication (remote indication by others).

Submit complete feedback signal information. • Design for support on concrete base. • Furnish with lubrication fittings external to housings and frames. • Equipped with adjustable gate for manual control of material flow.

4.13 COAL CRUSHERS

The coal crushers 00EBC10AJ001 & 00EBC20AJ001 are used to destroy all possible residual lumps and to reduce the coal size from 50 to approximately 35 – 40 mm. � Type: double roll mill. � Crusher speed: approx 200 rpm � Construction:

• Frame and housing: Commercially dust tight, welded, heavy-gage, rolled steel plate. Frame liners of carbon manganese steel in areas subject to wear.

• Provide bypass chute of 1 piece steel fabrication with stiffeners and AR400 steel liners. Chute is bolted to frame in lieu of front access panel.

• Adjustable breaker plate assembly to compensate for wear, adjustable from outside of crusher housing. Provide grease fittings for pivot shaft bearings. o Breaker plate support:

• Fabricated steel. • Adjustment by synchronized worm gear jacks outside of frame.



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• Shims not allowed. o Breaker blocks:

• Removable; AR400 or equivalent steel, minimum. • 2 beads of tungsten carbide hard facing at peak of each block.

o Breaker plates: Renewable AR400 or equivalent steel. • Rotor: Balanced statically and dynamically.

o Shaft: Forged alloy steel, sealed dust tight at frame opening. o Rotor breaker plates: Renewable AR400 or equivalent steel

• Bearings: o Anti-friction, self-aligning, dustproof, grease-lubricated. o Equip each bearing with 3-wire RTD detectors rated 100 ohm at 0 °C. Wire and terminate

RTD leads on terminal blocks in externally mounted junction box. Route bearing RTD signals back to motor protection relay. Terminate signals on protective relay on PRT Terminals No. 9 and 10.

o Provide provisions in motor and crusher rotor bearings for future installation of vibration monitoring system; 2 axis each bearing.

• Access door: Hinged frame, sized and arranged to expose entire rotor assembly, breaker plates, and liners; dust tight.

� Drive: Motor-driven through gear-type flexible coupling. � Provide suitable coupling guard. � Provide support attachments for crushers and motors on concrete foundation. � Seal crusher outlet to discharge chute work in accordance with manufacturer’s instructions.

4.14 DUST CONTAINEMENT

The purpose of dust containment system is to minimize the fugitive dust and meet Dominican Republic Environment Agency (SEMARENA) and EPA requirements. Dust collector discrete emission limit is: 0.01 gr/dscf (23 mg/m3)

4.14.1 Product characteristics

Dust to be abated has the following characteristics: � Dust particle size: 2 to 5 microns � Dust bulk density: 80 lb/cu ft. (1280 kg/m3) � Dust temperature: ambient � Air to cloth ratio: 5 cfm/sq ft maximum (1.5 m3/min/m2) � Maximum outlet loading: 0.01 gr/dscf (23 mg/m3) � Service: continuous, uninterrupted.



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4.14.2 Dust collectors system: bag filter type

Coal crushers building and trippers installed over boiler silos shall be equipped with centralized bags dust collector systems Self-cleaning, low-pressure, high-volume, pulse-jet fabric filter dust collectors with exhaust fans. � Maximum fabric filter operating pressure drop: 5” w.g. (127 mm w.g.) � Filter housing:

• Construction: All-welded, round. • Material: 12-gage (2.5 mm) steel, minimum, panel construction designed to withstand up to 20”

(500 mm) minimum w.g. negative pressure. • Explosion venting in accordance with NFPA 68 for collectors for coal handling equipment. • Top bag removal with walk-in plenum. • Safety handrails, platforms, and ladders for units with walk-in plenums. Coordinate with location

and general arrangements. � Hoppers:

• Construction: All-welded, round conical shape. • Material: 12-gage (2.5 mm) steel minimum, panel construction designed to withstand up to 20”

(500 mm) minimum w.g. negative pressure. • 60° slope minimum. • Provide with manufacturer’s standard size hinged access doors, minimum 18” square.

� Bags: • Material: fine denier polyester. • Weight: Minimum 16 oz/sq yard. (540 gr/m2) • Provide grounding in accordance with NFPA 77. • Length: 12’ (4 m) maximum. • Bag cleaning: Compressed air pulse jet. • Same length and diameter bags for all collectors.

� Rotary locks: • Quantity: 1 for each dust collector hopper outlet. • Type: Deep pocket drop-through; capable of discharging collected dust while maintaining

negative pressure within collector and storage hopper during operation. • Size: Minimum 12” • Heavy-duty gear motor. • Valve rotor: Replaceable vanes. • Maximum speed: 22 rpm

� Controls: • Locate unit-mounted electronic controls for easy access. • Control system shall provide options to initiate cleaning cycle based on high differential pressure

and adjustable timer and allow for continuous cleaning. • Solid-state electronic timer with duration and interval adjustments. • Differential pressure indicating switch:

o Provide 1 differential indicating transmitter per dust collector for local indication, high differential pressure control, and high-high differential pressure alarm to monitoring system.

o Provide additional solenoid and connect solenoid output line to each impulse line to be used to keep impulse lines free of any dust particulate build-up. Additional solenoid shall pulse line clean during bag house pulsing.

• Provide broken bag detector.



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• Electrical and instrumentation enclosures: In accordance with NEC requirements for installed location.

� Shop finishing paint: • Interior of dust collector shall be painted at workshop. • Collector shall arrive at jobsite finish-painted. • Field touchup of all surface areas damaged during shipment and installation.

� Accessories: • Access platform:

o Provide access to controls and access doors for inspection and maintenance. o Conform to OSHA requirements. o Size for convenient removal and replacement of bags and cages.

• Diaphragm valves, pulse pipes, solenoid pilot valves, and compressed air header. • Instrument Air line filter: Provide regulator and flow control valve for plant air. • For walk-in plenum, provide upper access door in clean air plenum.

o Size: Minimum 24” wide by 60” high; hinged. o Arrange to allow maintenance and change out of bags.

• External caged ladder and catwalk shall be provided complete with grating, kick plates, and handrails.

• Support legs for hopper bottom units.

4.14.3 Exhaust fan

� Design air flow as necessary per system design. � Size: Air flow rating shall match dust collector air flow at 13” (325 mm) w. g. � Construction:

• Housing: Welded steel; flanged inlet and outlet connections • Wheel and shaft: Dynamically balanced to comply with median value of Quality Grade G6.3 of

ISO 1940 (ANSI S2.19) • Provide quick-opening access doors • Manual outlet damper • Provide casing drain and plug

� Drive: direct drive � Guards:

• Conform to OSHA requirements. • Belt guard:

o Material: Wire mesh. o Size: Minimum 10-gage (3 mm) o Frame: Angle iron.

• Shaft guard. � Bearings: Grease-lubricated, ball or roller.

4.14.4 Ductwork

� Ductwork fabrication and installation shall be in accordance with latest edition of SMACNA Round Industrial Duct Construction Standards and NFPA 91 standards.

� Minimum duct air velocity: 3,500 fpm (17.78 m/s).



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� Ductwork arrangements shall provide adequate clearances for maintenance. � Materials: Galvanized steel conforming to ASTM 526. � Fabrication:

• Ductwork: 16-gage (1.5 mm) steel minimum thickness in 15’ (5 m) sections (maximum) using welded construction with gasket and flanged connections.

• Elbows: 12-gage (2.5 mm) steel minimum thickness with centerline radius of 2 times duct diameter.

• Branch entries: 12-gage (2.5 mm) steel minimum thickness. • Hoods: 10-gage steel minimum thickness. Included angle shall be 90º and face area minimum

of 2 times duct area. Hoods may be either bolted or welded in place. • Clean out doors: 12-gage (2.5 mm) steel minimum thickness; locate on top or sides of ductwork.

Doors hinged and held with snap locks or clamps. Space in accordance with NFPA 91. • Blast gates: 12-gage (2.5 mm) steel minimum thickness; locate in accordance with NFPA 91.

Slides shall be locked, or drilled and bolted in place after final adjustment.

F. Permanent test fittings may be installed in ductwork. Cover test holes drilled in ductwork with welded patches.

4.15 DUST SUPPRESSION SYSTEM: WATER SPRAY TYPE

Each conveyor chute shall be equipped with a water spray abatement system suitable to restrain coal dust emission using available raw water as per specification 3814-YZ-SG-000001 “Design Basis & site conditions”. The water is pumped to the spray systems thanks to a pumping stations mounted on enclosed skid, shipped preassembled and installed at the base of the towers complete as minimum with: � running pumps + spare (N+1) � water filter � water tank � Instrumentation wired to enclosed skid Junction Box. Raw water piping battery limit is at the inlet of the skid pumping station. All piping from pumping skid to spray systems has to be considered included in vendor scope of supply. The dust suppression system shall be equipped with a local control panel to control locally each dust suppression system item in manual mode during start-up / commissioning phase and during maintenance; Logics will be implemented in the main coal handling system PLC.



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4.16 COAL SAMPLING SYSTEMS

The Coal Sampling System 00UEC10 shall be installed along the conveyors 00ECG10AF001 & 00ECG20AF001 downstream the reclaimer to provide the sampling of coal recovered from the coal yard. The equipment composing the system will be located inside tower 00UEF50. The Sampling system will be designed in accordance to: � ASTM D-2013 – Standard Practice for Preparing Coal Samples for Analysis � ASTM D-2234/D-2234M – Standard Practice for Collection of a Gross Sample of Coal. The system will take automatically samples of coal, reduce them to the required size in two steps and prepare aluminum 20 liters containers ready to be sent to the test laboratory. Sampling process data: Lot size: 300 t (sublot) Sample taker – slot width: 125 mm (mind.) Weight of primary increment: 14.9 kg Final sample per lot: appr. 10-30 kg The Coal Sampling Systems shall be composed of the following items: � 00ECU10/20AE001 Primary Sampler, cross cut type � 00ECU01AF001 Primary Belt Feeder. � 00ECU01AJ001 Sample Crusher � 00ECU01AF002 Secondary Belt Feeder � 00ECU01AE002 Secondary Sampler (Vezin Type) � 00ECU01BB001 Sample container storage � 00ECU01AF003 Bucket Elevator � 00ECU01AA101 Diverter valve return elevator � Local control panel. Sampling system shall be equipped with a local control panel to control locally each sampling item in manual mode during start-up / commissioning phase and during maintenance; Logics will be implemented in the main coal handling system PLC.



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4.17 WEIGHING SCALES

Weighing scales are installed along conveyors at least as per indicated on the PFD 3814-GZ-DP-901005. They shall be complete with weighbridge and speed sensor in order to give a rate output visual available locally and at PLC Human Machine Interface in the control room. Multi-idler system is requested in order to reach an accuracy of 0.5 % as minimum. Wiring to local panel is included in vendor scope of supply.

5 BELT CONVEYOR STRUCTURES AND AUXILIARY SYSTEMS

The supply of coal handling includes all the steel structure necessary for the support and maintenance of the belt conveyors and other equipment, moreover includes the auxiliary systems described in the next paragraphs. Calculation of all structures shall be subjected to the approval of Seismic Revisor. The main conveyor structures, auxiliary systems and accessories are: � Transfer Towers & penthouse � Crusher building � Conveyor galleries � Lateral walkways for elevated portions of pipe conveyors � Alarm and Firefighting System to protect the Transfer Towers, belt conveyors etc. � Water distribution net � Plant air distribution net � Gallery and towers illumination

5.1 TRANSFER TOWERS AND GALLERIES

All troughed belt conveyors not installed in closed buildings (warehouse, top of bunkers, etc.) shall be located inside closed galleries. The belt conveyors will be equipped with inspection walkways to ensure a correct maintenance along all the length. Pipe conveyor located on jetty and shore will be placed on concrete foundations. Lateral walkways will be in concrete. The portions of pipe conveyors raising to the top of tower 00UEF20 shall be complete with lateral steel walkways for inspection and maintenance and closed gallery in the transition points at the start and at the end of pipe conveyors.



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The troughed conveyors installed on the pier will be equipped with movable weather protections and closed gallery or open conveyor bridge with fixed weather protection for the portion of conveyors raising to the tower 00UEF10 Tripper conveyors installed on the top of warehouse shall be complete with rails. Support beams and inspection / maintenance walkways will be supplied by bulk warehouse supplier. Battery limit is represented by the lower side of the rails and by the lower face of the conveyor legs baseplate. The preliminary layout of all coal handling system is attached to the Material Requisition (See drawing 3814-XX-DG-000001, 3814-XX-DG-000002 and other equipment layouts).

5.1.1 Belt conveyor structure and galleries

The driving units, the tail ends, and all the interconnecting chutes will be installed in dedicated transfer towers. Preferably the belt tensioning units have to be located inside transfer towers to reduce the total amount of structures, simplifying the erection of the system. All structural parts and relevant foundations shall be designed considering the local regulations, the ambient conditions and the following prescriptions for the overloads on walkways and platforms: � Buildings floor 1000 Kg/m2 � Walkways 300 Kg/m2 � Platforms 500 Kg/m2 � Gallery walkways 300 Kg/m2 (*) (*) The design of local walkways supporting beams is done considering 300 kg/m2 but for the

calculation of the complete gallery or truss a distribute load of 100 kg/m2. This is valid for galleries of conveyors, including the portion of pipe conveyor from ground to tower 00UEF20 and the walkways of tripper conveyor inside coal storage.

In the design of the belt conveyors and relevant structures, the Vendor shall considering the following: � Self-supporting preassembled structures shall be provided for driving units, tail ends and snubs for

belt tensioning units � Galleries and supporting structure for belt conveyors � Self standing structure with lateral walkways for pipe conveyor � Maintenance platforms and stairs for all points not served from floors

5.1.2 Transfer towers

The Transfer Towers will be realized by prefabricated steel structures. They shall be supplied complete with the following: � Main steel framework including supports for lateral walls and roof.



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� Secondary steel frameworks suitable for driving unit, tail ends and tensioning units supports. � Floors made by chequered plates. � Side cladding and roofs of Galvanized corrugated sheet. � Supports for Transfer hoppers and chutes. � Stairs and platforms complete with handrails from top up to ground. � Stairways, platforms and emergency ladders if requested by local regulation. � Monorail for Maintenance Bridge cranes or hoists used for maintenance and equipment repair and

will not be in continuous daily use. Under the monorail opening doors suitable for spare parts and equipment passage shall be provided. Power cable trays up to hoists installation position have to be provided.

� Access doors and opening for natural lighting and ventilation. � Lightning system The towers shall be designed considering natural ventilation to reduce the heating generated by the motors installed inside. Vendor in the design of the towers shall take into consideration: � Confining of dust pollution avoiding dispersion to the ambient � Minimizing of the noise released to the ambient to respect the prescriptions of the specification

3814-SZ-SG-000005 “Noise General Specification”

5.1.3 Troughed belts Galleries

The galleries for the belt conveyors shall be realized in prefabricated steel structure. They shall be supplied complete at least with the following: � Main steel framework complete with support for side cladding and roof. � Side cladding and roofs of Galvanized corrugated sheet. � Belt conveyor supports beams � Walkways with steel grating (ant slipping for inclined walkways) � Metal sheet under conveyors (full length) to limit coal dispersion in the ambient � Opening for natural lighting and ventilation. � Intermediate stairways, platforms and emergency ladders if request by local regulation. � Intermediate support trestle complete with hinged support to be fixed on concrete foundation. NOTE: The floor of tripper room located over boilers silos will be realized in concrete and is part of

boiler building. The concrete floor is the battery limit. Beams and / or steel structures necessary for trippers and belts installations inside tripper room are in vendor scope of supply. Galleries from tower 00UEF50 to first boiler room and between the two boiler rooms are included in vendor scope of supply. They shall be designed considered the prescription of this paragraph and taking into consideration the presence of tripper during the refilling of the first silo of each group. The boiler structure will be equipped with cantilevers for the support of the galleries. These cantilevers represent the supply battery limit. All beams necessary to support the galleries and to reach the floor level has to be considered included in the scope of supply.



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5.1.4 Pipe conveyor structures

The portion of pipe conveyor installed on the jetty shall have a structure suitable for the installation of cable racks and as support for road illumination as per shown on Attachment 2. A belt crossing bridge every 100 m with, configuration as per Attachment 2, has to be included in the scope of supply. The horizontal portion of pipe conveyor from jetty to the tower 00UEF20 will be located on ground, on dedicated concrete floor that is designed with lateral walkways for inspection and maintenance. The inclined portion of pipe conveyor, from ground to the top of tower 00UEF20, will be equipped with lateral walkways made by steel grating.

5.2 MAINTENANCE EQUIPMENT

5.2.1 Maintenance hoists

Each tower shall be equipped with monorail/s for the installation of maintenance hoist/s. They are used for maintenance and equipment repair and will not be considered in continuous daily use. The monorails shall be sized on the basis of the heaviest piece to be lifted. Service conditions will correspond to Hoist Manufacturer's Institute (HMI) hoist Class H2 or approved equivalent. All hoist parts will be designed with a minimum safety factor of 1.25, and the equipment will be factory tested to a 125% overload. All parts will be readily accessible for inspection, adjustment, and repair. One or more electrical maintenance winch(s) shall be provided, located in order to lift all the required spare parts at the highest level where those spare parts are required. The winch shall be suitable to lift the heaviest spare part. In particular the large and heavy equipment shall be provided with dedicated winch installed on the relevant monorail. The expected configuration will be:

Installation point Capacity (ton) Lifting height (m) Type of hoist Tower 00UEF10 2 5 Manual Tower 00UEF20 5 40 Electrical (*) Penthouse 00UEF30 2 5 Manual

Tower 00UEF40 5 10 Electrical (*) 2 20 Manual

Tower 00UEF50 2 50 Electrical (*) Boiler area Out of scope Out of scope Out of scope Coal warehouse 2 30 Electrical (*) Pipe conveyor motor installed on ground (**) 8 3 Electrical



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(*) considering the heavy weight the electrical motors will be foreseen both for lifting and translation (**) The installation of this hoist will be evaluated during the detail engineering. Vendor is considering

as basic solution the complete removal of the pipe conveyor driving group box.

5.2.2 Compressed air generation system

Inside tower 00UEF10 Vendor shall provide a compressed air generation system composed by: � Air compressor reciprocating type complete with inlet air filter (capacity & discharge pressure by

Vendor) � Water demister with automatic condensate removal � Air accumulation vessel, at least 1 m3 capacity � Pressure switch � Electrical devices for the automatic compressor start / stop � Safety valve � Local panel / junction boxes All the equipment will be supplied assembled on skid to minimize the erection operations. The purpose of this system is to provide the compressed air necessary for the maintenance and cleaning of the equipment.

5.2.3 Splicing machine/s

Splicing machine/s necessary to provide the complete vulcanizing of the belt conveyors have to be added in the scope of supply as special tools. Vendor shall quote them as option (separate price) but, in parallel have to inform if it is possible to have these equipment for limited time with a renting contract.

5.3 PIPING NET INSIDE GALLERIES AND TOWERS

Vendor shall provide detailed engineering and materials for all piping that have to be installed inside the towers and galleries. Piping Battery Limits shall be at the base of the tower or at the base of trestles. Vendor with offer shall submit general arrangement drawing indicating also, if possible, preliminary position of Battery Limits. The main plants to be engineered and supplied will be: � Filtered water for the feeding of the water spray located on the belt discharge hoppers and feeding

chutes � Raw water for the plant cleaning � Compressed air (instrument air) net where necessary (i.e. for filter bag cleaning)



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� Compressed air (plant air) for belt conveyor maintenance Piping shall be selected taking into consideration the prescriptions of piping classes.

5.4 FIRE FIGHTING

5.4.1 Coal belt conveyor facilities fire protection systems.

Reference standard for coal belt conveyor facilities is NFPA 850 “Recommended Practice for Fire Protection for Electric Generating Plants and High Voltage Direct Current Converter Stations”.

5.4.2 General safety aspects

Coal conveying and handling structures and supports should be of non combustible construction. The accumulation of coal dust in enclosed buildings can be reduced by designing structural members such that their shape or method of installation, minimizing the surface area where dust can settle. Access should be provided to facilitate cleaning of all areas. Provisions should be made for de-energizing both lighting and electrical power circuits without requiring personnel to enter dust-producing sections of the plant during emergencies. Static electricity hazards should be minimized by the permanent bonding and grounding of all conductive equipment, including duct work, pulleys, take-up reels, motor drives, dust collection equipment, and vacuum cleaning equipment.

5.4.3 Fire fighting systems

Reference 3814-SS-SE-901 “Work requisition Coal Belt Conveyor Facilities Fire fighting Systems”

5.4.4 Safety signs

A complete set of safety sign in Spanish language shall be provided for firefighting equipment and escape emergency ways. Safety sign shall be in compliance with local regulations

5.4.5 Fire detection and alarm systems

Fire detection and alarm system for belt conveyor facilities will be connected to Plant Fire detection and alarm system (by Other); interfaces and battery limits to be defined.



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All Linear heat detection cable and JB shall be suitable for hazardous area classification and complete with all necessary supports and accessories for proper installation. Belt coal conveyor enclosed area will be divided in fire zones; extension of fire zone will be 30 m linear. Preliminarily belt conveyor fire zones to be considered are 16.

5.4.6 Linear heat detection cables

Linear heat detection cable loops will be provided for each fire zone to detect fire condition. Three (3) linear heat detection loops will be provided for each belt conveyor fire zone. NOTE: Picture here below has to be used “for refere nce only” the measure indicated are not valid

For updated drawing see specification 3814-SS-SE-000901

5.4.7 Hot spot detectors

System to detect “Hot spot” will be installed on the belts 00ECD10AF001 & 00ECD20AF001 at the tail end just after the loading chute. If the “hot spot’ is detected the belt is stopped, and the material will be removed manually by the operator. Signal are connected to the main handling system PLC



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6 INSTRUMENTATION EQUIPMENT

The design of equipment and components to be installed in the system shall be carried having in mind reliability, safety and easy maintenance. Refer also to instrumentation specifications.

6.1 INSTRUMENTATION FOR BELT CONVEYOR CONTROL

The following instruments will be installed on Belt Conveyors:

• Zero speed switch Inductive sensor connected to a non-driven pulley, to indicate belt or drive failure.

• Belt misalignment heavy-duty switches, operated by the deflection of a side roller, mounted on the switch lever. Pre-alarm signal at angle by Vendor to be defined during detail engineering. Shutdown at angle by Vendor to be defined during detail engineering. Installation points: on both sides of conveyor close the driving drum and tail pulleys. Along conveyor, self-aligning idlers shall be installed every 30 m.

• Emergency stop switches Manually reset emergency stop switches, operable from heavy duty, nylon jacketed, steel cable, running the length of the conveyor on both sides. Installation distance 50 m with cable supports every 3m. Distance of the ropes from the structures ≈80÷100 mm.

• Emergency stop mushroom push button. Manually reset emergency stop. Installation point near conveyor heads and wherever necessary.

• Chute plug-up switch Sensing device, "tilt switch" type. Installation point outside the normal flow of material.

• Start-up alarm: o Electric siren system, along the belt conveyor every ≈200 m. o Sound for 15 sec. before the actual start of the conveyor.

• Limit switches for gravity tensioning unit to detect the reaching of stroke limits. • Limit switches for screw type and spring tensioning unit to detect the reaching of stroke limits. • Switches and encoder for correct positioning of trippers

6.2 INSTRUMENTATION CABLES AND JUNCTION BOX

Instrument cables along the belt conveyors from the electrical (switches, encoders, etc) until the connection borders JB are included in vendor scope. Instrumentation JB also included in vendor scope as well as cable glands and plugs.



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Cable trays, conduits along the belt conveyors and inside the transfer towers are in vendor scope of supply. Power cable trays and instrumentation cable trays shall be separate. Vendor with offer shall submit general arrangement drawing indicating also, if possible, preliminary position of Junction Boxes.

7 ELECTRICAL EQUIPMENT

7.1 ELECTRICAL DESIGN CRITERIA

Electrical equipment installed in classified areas have to be selected according to NEMA standard and with mechanical protection suitable for the installation zone.

7.2 ELECTRICAL MOTORS

All electrical motors shall be manufactured for continuous duty and start-up under full load. Design characteristics are summarized on specifications: � 3814-NN-SG-000023 “MV Electrical motors”. � 3814-NN-SG-000024 “LV Electrical motors”. Terminal box installed on each electric motor shall be delivered holed to allow the installation of the cable. Dimension of the holes will be communicated by TCM during the follow up. Plugs for holes have to be included in vendor scope of supply. Vendor with offer shall submit general arrangement drawing indicating also, if possible preliminary position of Terminal Boxes

7.3 LIGHTING AND SOCKET

The lighting of galleries, towers and closed ambient shall be included in the scope of supply. Lighting shall be provided for all materials handling activity areas, machinery platforms, walkways and stairs, enclosed rooms and cabs and along the belt conveyor lateral walkways in vendor scope of supply. Emergency lighting shall be provided to permit the operator to leave the machine safely in the event that the main circuit breaker trips after dark. All lighting, as well as sockets, shall be wired till JB. Sockets along galleries shall be installed every 30 meters, in the towers at each floor as minimum.



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7.4 MCC AND ADDITIONAL ELECTRICAL EQUIPMENT

The supply battery limits for electrical parts is shown on scheme 3814-NN-SG-000103. “Electrical Particular Requirements - Conveyors” All installation materials (trays, conduits, supports, etc.) indicated in the above scheme has to be considered as integral part of the supply and have to be quoted by Vendor. All cable trays will be routed inside galleries and tower or stiffened to the pipe conveyor structures. Underground installations are not admitted. Variable speed electric motors shall be supplied complete with VFD and special cables for connections. VFD & electric motor should be of the same brand. Motor and VFD from different brands have to be supplied complete with certificate.

7.5 GROUNDING SYSTEM

Secondary grounding system shall be in Vendor scope of supply. Primary grounding system will be realized by Contractor. Further details on specifications: � 3814-NN-SE-000025 “Primary Grounding system – materials and accessories” � 3814-NN-SE-000026 “Secondary Grounding system – materials and accessories”

7.6 LIGHTNING PROTECTION SYSTEM

Lightning Protection shall be as per NFPA 780 Standard for the Installation of Lightning Protection Systems The protection level shall be defined in accordance with the classification of the volume to be protected. Exposed metal structures and equipment shall be grounded in the same way as prescribed for standard down-conductors. The down-conductors shall have cross-section larger than the value specified by standards, and shall be so installed as to provide the shortest, most direct path to ground.

7.7 EQUIPOTENTIAL BONDING

Metal installations inside the structure (size cable 1/0 AWG) shall be made equipotential at ground level, by bonding to one or several interconnected bonding bars, connected to the ground termination system. Equipotential bonding shall be carried out also in the points where the distance between the metal installation and the external protection system is lower than the safety distance defined by the standards.



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7.8 MODES OF CONTROL

Vendor has to consider the following: The Coal Handling System will be equipped with a dedicated PLC able to operate the plant in the following modes of control: a) Local b) Remote Manual c) Remote Automatic The PLC will be installed in the material handling control room located inside the Building 52. For control system characteristics and architecture refer to Automation documentation.

7.8.1 Local mode

This operation mode is foreseen only for maintenance and tests procedures. In this mode, all drives can be controlled locally in the field. The drives are switches to "local" through PLC and thereby completely de-interlocked from the rest of the process. Safety interlocks and equipment protection trips shall not be by-passed.

7.8.2 Remote Manual mode

In the manual mode the operator shall have full control of the machine. All interlocking protections shall be operational in this mode. All events and status shall be monitored and visualized by PLC.

7.8.3 Remote Automatic mode

Vendor shall provide the complete engineering of the fully automatic remote operation (complete with the control of the interfaced systems about the functional sequences start/stop, permissive, alarms/trips status etc.)



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8 PLANT 3D VIEWS

Handling system overview



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Tripper conveyors for the boiler feeding



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Warehouse front view with crusher tower



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Attachment 1 – Preliminary arrangement top of bunke r area



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Attachment 2 – Preliminary arrangement pipe conveyo r on jetty



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Attachment 3 – Preliminary arrangement conveyor & h opper on pier



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Attachment 4 – Typical section of belt conveyors in stalled in galleries

1 3814 gy se 901003 is03 technical especification

Documents

coal conveying

2x360 mw coal

final issue

preliminary issue

coal handling design

gaiani issue date reason

issue revision description

power plant location