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L& T Wagon Tippler Mannual - HMEL Site PDF

The document provides an operation and maintenance manual for a Wagon Tippler (SUT) and 50T Side Arm Charger used at a 2x660 MW supercritical thermal power plant. It describes the general arrangement of the system including the incoming train of full wagons, side arm charger, SUT wagon tippler, and empty wagon exit track. It provides details on the functions of the side arm charger and components of the SUT wagon tippler such as the tippler cage structure, end frames, rail platform, grippers, side beam, and drive racks. The document contains sections covering general description of machines, control write up, maintenance instructions, general arrangement drawings, safety instructions, and storage instructions.

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100% found this document useful (3 votes)

6K views156 pages

L& T Wagon Tippler Mannual - HMEL Site PDF

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ranajoy71971

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LARSEN & TOUBRO LIMITED

CONSTRUCTION DIVISION
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

DOCUMENT NO DATE
PROJECT : 2 x 660 MW SUPER CRITICRAL TPS
(SURATGARH, STAGE – V, UNIT # 7 & 8) (SUT L&T - O14195-M-BM-EQ-DC-5027 07.03.16
& SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER. 1 OF 1
SAB/PHL AN/RG

CONTENTS

VOLUME-I

SECTION I GENERAL DESCRIPTION OF MACHINES

SECTION II CONTROL WRITE UP FOR WT, SAC

SECTION III MAINTENANCE INSTRUCTION

SECTION IV LIST OF GA DRAWINGS

SECTION V SAFETY INSTRUCTION

SECTION VI STORAGE INSTRUCTION

VOLUME-II
(Buy-out Manuals)
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS DOCUMENT NO DATE

(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER. 1 OF 12
SAB/PHL AN/RG

SECTION – I

GENERAL DESCRIPTION OF MACHINES

LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS DOCUMENT NO DATE

(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER. 2 OF 12
SAB/PHL AN/RG

WAGON TIPPLER (SUT) Train Unloading System

Description of Wagon Tippler and Side Arm Charger:-

In the marshalling yard of 2x300 TPH Coal Pet coke fired steam generators at SURATGARH, Rajasthan,
coal loaded in Broad Gauge open wagons will be unloaded to four nos. of wagon tippler hoppers by
four nos. SUT type wagon tippler (named as WT-1, WT-2, WT-3 & WT-4) on main track. 4 nos. of 50T
Side-arm-charger has been provided to work as wagon-marshalling machine for 4 nos. of WT hopper.
This charger runs on its own track alongside & parallel to main track. In-haul wheel chock is provided
on inhaul side of the main rail track to prevent "rolling" of wagons onto tippler platform during
tipping cycle. Wheel chocks are provided at the wagon tippler named as WT-1, WT-2, WT-3 & WT-4.
From R.C.C made hopper beneath tippler, coal will be reclaimed by Apron Feeder below WT and will
discharge to conveyor.
Just after Wagon Tippler, SAC pushes the empty wagons towards exit track. Out-haul wheel chock is
provided on outhaul side of the exit rail track to prevent "rolling" of wagons onto tippler platform
during tipping cycle.

The primary functions of Side Arm Charger is mentioned below:-

1) Hauling of the incoming train of 59 full wagons by one wagon length at a time, up to a
position adjacent to the Tippler.

2) After manual uncoupling of the lead wagon, hauling the separated lead wagon onto the
Tippler platform for unloading.

3) After completion of tippling operation, SAC pushes the empty wagon clear of the unloading
system on to the exit track.

This typical combination of SUT Wagon Tippler & Side Arm Charger arrangement is employed to
achieve an efficient and mechanized working cycle of wagon unloading.
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS DOCUMENT NO DATE

(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER. 3 OF 12
SAB/PHL AN/RG

Plant Arrangement :-

Direction of Unloading Side Arm

Charger

Incoming Train – Full Wagons Separated Empty Wagons

Train SUT wagon Tippler
Wagon
Holding &
Devices Hoppers

1. Description of SUT Wagon Tippler:-

The Wagon tippler is a simple and compact machine. It unloads one wagon at a time by
inverting the loaded wagon over a ground hopper and discharges material into the ground
hopper located beneath the Tippler.

Independent hydraulic locking cylinders are used to support the side of the car and clamp
the car securely during Tippler rotation.

The Tippler is designed to be fully compliant with the latest requirements of RDSO
Technical Pamphlet G-33; Revision-1, dated May 2010. The general description and major
parameters of the machine are mentioned in subsequent pages.

The Tippler is of rugged construction and mainly comprises of:

Tippler Cage Structure

The Tippler is a cylindrical shaped cage structure, and consists of an Entry and Exit End
Frame, Clamp Beam, Side Beam and Rail Platform. This forms a rigid open cage structure;
each End Ring is mounted on one pivot shaft, the supports are positioned at the side of the
Tippler at ground level.

End Frames

Two End Frames, one positioned at each end of the Tippler, are fabricated as heavy steel
shaped structures. The End Frames are connected together by the Clamp Girder, Side Beam
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS DOCUMENT NO DATE

(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER. 4 OF 12
SAB/PHL AN/RG
and Rail Platform. The design of End Frame allows the arm of Side Arm Charger to move
through the tippler, thus helping efficient handling and unloading of wagons.

An open segmental gear rack is mounted around part of the circumference on both the End
Frame, which engages with the Tippler drive pinions.

Rail Platform & Walkway

The Rail Platform is a heavy steel fabricated box section, which carries a section of rail track
through the structure, and is of sufficient length to accommodate the longest wagons to be
handled. The Platform acts as a bridge between the End Frames and is designed to support
the heaviest wagons on a cyclic basis during unloading and the passage of locomotives on
an infrequent basis as required.

Walk and access ways are mounted on both sides of the Rail Platform to facilitate foot
traffic and maintenance activities.

SUT Platform Grippers

The SUT Platform Grippers uses 4 hydraulic cylinders which extend until the gripper bars
contacts the inner & outer sides of the wagon wheels. Pressure in the circuit is
maintained to secure the wagon to the SUT Platform.

A land mounted hydraulic power pack driven by an AC electric motor and pump unit
provides the hydraulic supply to the Platform Grippers. This unit can be common with the
Clamp Gear / Moving Side Pad unit.

Side Beam

The Side Beam is a long heavy steel fabricated box section, which connects the End
Frames at the mid-vertical point. The Side Beam accommodates the mounting of an
integral moveable Side support beam and is designed as the ultimate support for the
heaviest wagons on a cyclic basis during the unloading operation.

In conjunction with the Rail Platform and Clamp Girder, the Side Beam acts to transmit
vertical and torsional loads throughout the Cage Structure and ensure the Cage acts as a
homogeneous structure during rotation. Similar to the function of the Rail Platform,
connections of the Side Beam to the End Frames are carefully designed to avoid high
stress concentrations and minimize the effects of fatigue.
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS DOCUMENT NO DATE

(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER. 5 OF 12
SAB/PHL AN/RG
Drive Racks

Cast drive gear racks are fitted to the periphery of driven side End Frame via a heavy
fixing plates fabricated into the Frame structure. These racks engage with the ground
mounted Drive Unit to facilitate the controlled rotational movement of the Tippler.

Moving Side Support Beam

The SUT Moving Side Pad uses 4 hydraulic cylinders which extend at low pressure until
the pad contacts the side of the wagon. When the pad stops moving the hydraulic circuit
will lock preventing movement in both directions.

A land mounted hydraulic power pack driven by an AC electric motor and pump unit
provides the hydraulic supply to the Moving Side Pad cylinders. This unit can be common
with the Clamp Gear.
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS DOCUMENT NO DATE

(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER. 6 OF 12
SAB/PHL AN/RG
Clamp Gear

The SUT clamp gear uses 2 cylinders to lower the clamp beams onto the top of the
wagon. The cylinders are locked to restrain the wagon in the SUT.

Each of the 6 clamp beams is equipped with hydraulic cylinders to compensate for any
un-evenness in the top of the wagon and to relieve the bogie spring force that is released
when the load is tipped from the wagon.

A land mounted hydraulic power pack driven by an AC electric motor and pump unit
provides the hydraulic supply to the Clamp Gear. This unit can be common with the
Moving Side Pad.

Drive Units

The SUT rotation drive uses 4 pinions (2 at each end frame) engaging with racks around
the end frame. Each pinion is directly coupled to a Poclain braked hydraulic motor. A land
mounted hydraulic power pack driven by an AC electric motor and pump unit supplies
hydraulic fluid to the drives. Closed loop speed control is incorporated in the power pack.
An encoder is fitted to supply positional information to the drive system.

Wheel Chock Assembly

To ensure safe handling of wagon there will be wheel choke arrangement at inhaul &
outhaul side of Wagon Tippler pit. The main objective of wheel chock is arrest the
movement of loaded rake (at inhaul side) so as to prevent moving towards tippler pit
during wagon tippling operation. Arresting the movement of empty wagon rake towards
tippler pit from outhaul side is also done by wheel chock at outhaul end. Each wheel
chock unit has a pivoted arm which is moved into engagement with the wagon wheel by a
hydraulic cylinder. The hydraulic cylinder operates the arm using a link mechanism which
travels slightly over centre which prevents the restraining force from acting directly on
the cylinder.

Tippler Control

The Tippler is furnished with photocells and limit switches to determine the motions and
extents of travel of the Tippler during operation.

There are two photocell transmitter/receiver systems set diagonal across the platform to
indicate that Tippler Entry and Exit points are clear.
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS DOCUMENT NO DATE

(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER. 7 OF 12
SAB/PHL AN/RG

The limit switches are heavy-duty type and are at ground level at the Entry end of the
Dumper. Striker levers are mounted on the End Frame. These limit switches are provided
as hardwired safety measures to backup the normal limits detected by the encoder
mounted on one Drive Unit.

Basic machine functions and all the interlocks are automated and controlled by an
engineered PLC system, which integrates multiple devices to fully automate the
coordination of the complex functions of Tippler, Indexer and Side arm charger.

2. Side Arm Charger

The Side Arm Charger is a hydraulically powered reciprocating train hauling device
designed to marshal a loaded train up to a maximum of 58 wagons with a gross weight of
up to 140 tones. Additional functions include positioning wagons onto the Tippler and
pushing previously unloaded wagons onto the exit track ready for collection by the
locomotive at the end of the unloading operations. The Side Arm Charger travels on its
own rail track located to the side of the main train tracks and Tippler. The Side Arm
Charger track rails are set to 1500mm centres and have a rack/spine bar drive assembly
mounted between the rails. It is fitted with an extended arm, which carries at its outer end
an automatic coupler (on rear face). Thus, it couples onto the front of the wagon to draw a
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS DOCUMENT NO DATE

(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER. 8 OF 12
SAB/PHL AN/RG
single loaded wagon to position onto tippler platform, or to draw the entire rake of loaded
wagons. SAC is comprises of following components:

Main Frame

The Side Arm Charger Main Frame is a heavy duty fabricated box section structure. The
design will cater for the loads and stresses induced from hauling the rake of fully loaded
rail wagons into the Tippler.

Machined interfaces are provided on the frame for mounting the main arm, support/guide
rollers and drive units.

The Main Frame will also include lifting lugs and these will be sized to allow lifting of the
assembled Side Arm Charger within a workshop and during site installation.

Luffing Arm

The pivoted Luffing Arm is a robust structural box member raised and lowered by two
hydraulic cylinders. The raise/lower operation is controlled in a manner that minimizes the
inertia effects of lowering a large mass. The Arm is lowered for all wagon hauling and
pushing operations and raised to clear the Tippler and waiting wagons during its reverse
travel operations.

Located at the head end of the arm is a standard rail wagon coupler which will be used to
connect the Side Arm Charger to the rail wagons. Release of the coupler mechanism is
achieved by a small hydraulic cylinder mounted on the Luffing Arm. A shock absorbing
mechanism is mounted within the Arm Head to reduce the shock loading effects
experienced in hauling the train of full wagons into the plant and also pushing the empty
wagons from the Tippler station.

Coupler proximity switches are also attached to the coupler end of the arm. These detect
that the Side Arm Charger couplers are engaged and locked.

Drive Assembly

The Side Arm Charger is driven by means a set of individual hydraulically powered drives.
Drive System comprises a hydraulic motor and machined pinion. The pinions are located
beneath the Main Frame and mesh with the land mounted drive rack.

The hydraulic power pack for the drives is located on the Main Frame. Travel motions and
associated train/wagon hauling loads are carefully calculated and controlled during
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS DOCUMENT NO DATE

(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER. 9 OF 12
SAB/PHL AN/RG
operation both automatically by the plant PLC and from an operator's deck in Tippler
control room.

Support & Guide Rollers

The Support Rollers, which are vertical wheel assemblies are mounted on each corner of
the Side Arm Charger Main Frame. One of the total four units incorporates a spring
assembly which ensures that all four wheels make contact with the running rails. The four
Guide Rollers, which are horizontal wheel assemblies, are located on the underside of the
Side Arm Charger Main Frame and contact the ground mounted Track Spine Bar. These
Guide Rollers react the horizontal forces generated in the Luffing Arm when the train of rail
wagons is hauled forward by the Side Arm Charger. Both the Support Roller and Guide
Rollers incorporate anti-friction bearings and seals. These are superior railway cartridge
type bearings for reliability.

Track, Rack & Spine Bar

The Side Arm Charger Track, Drive Rack and Spine Bar are a proven design and are sized to
accommodate the driving forces and reaction forces generated when hauling a train of 59
fully loaded wagons, weighing up to maximum 140 tone.

All horizontal transverse loads are reacted by a central Spine Bar via the Guide Rollers, and
for the hauling forces by the continuous Drive Rack. The Spine Bars will have machined
surfaces for contact with the Side Arm Charger Guide Rollers and Racks and be mounted on
supports equally pitched along the total length of travel. Racks will be cast steel with a
machined mounting face for seating onto the Spine Bars.

Festoon Cable System, Travel Limit Switches & Track Switches

Power and control circuits are connected to the Side Arm Charger by means of a Festoon
Cable System suspended on an overhead track adjacent to and running parallel with the
Side Arm Charger Rail Track. The cables are hung on festoon trolleys. Limit switches are
mounted on the Festoon Track to control the stopping position of the Side Arm Charger
and to provide a safety interlock during movement. A track side limit switch is also used to
monitor and control the movement of the rail cars.
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS DOCUMENT NO DATE

(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER. 10 OF 12
SAB/PHL AN/RG

Technical Data Sheets:

Wagon Tippler

1. Make and Type Larsen & Toubro Limited - SUT Type.

2. Type of Wagons Handled BOX, BOXN, BOXN MARK-II, BOX MODIFIED,

BOXNHL, BOXN 25 ETC & DFC (32.5 T axle
load) (As per RDSO G33 rev-1)

3. Mode of Placement of By Side Arm Charger

Wagons

4. Maximum Gross Weight of Up to 140 T

Loaded Wagon

5. Rail Gauge 1676 mm

6. No. of Tips / Hour 25 (with Single Train Hauling Device)

7. Average Cycle Time 70 to 75 Seconds Tip & Return to Achieve 25

Tips / Hour.

8. Angle of Rotation 160 Degree

9. Type of Drive (Main Hydraulic

Rotation)

10. Type of Motor, Brake etc. Hydraulic Motor Operated by Power Pack
fitted with integral brake.

11. Type of Drive (Clamping) Hydraulic

12. Type of Clamping & No of 6 clamp beam is connected to main beam by

Clamps Provided 6 cylinders. Two clamp arm cylinders are
lowering the main beam by 2 cylinders
mounted on End Frame.
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS DOCUMENT NO DATE

(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER. 11 OF 12
SAB/PHL AN/RG
13. Hydraulic Transmission Arrgt. Via Pivot Mounted Hose Loop to Rotating
Cage.

14. Diesel Loco Passage Yes.

15. Clearance Profile RDSO G-33 revision-1, Annexure ‘A’

16. Mode of Control Semi-Automatic from Remote Control Room

PLC & Local.

17. Safety Features as Envisaged Over Rotation Protection

Wagon Clamp Interlocking
Wagon Clamp pressure relief

18. Type of Lubrication Arrgt. Manual Centralized Lubrication at Specified

Periodic Intervals.

Side Arm Charger

1. Make and Type Larsen & Toubro Limited - Rail Mounted

Type.

2. Tractive Effort for Pushing and To Haul 59 nos. Loaded Wagons & Hauling
Pulling capacity: 50T.

3. Mode of Control Semi-Automatic from Remote Control Room

& Local.

4. Mode of Power Supply Via Cable Festoon System on to Mobile m/c.

5. Type of Drive Arrgt. Hydraulic Motors Operated by Power Pack,

Driving a Set of Pinions onto Ground
mounted Drive Rack.

6. Arm Raise/Lower Arrgt. Hydraulic Cylinder operated by Power pack.

7. Safety Features Over Travel Protection.

LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS DOCUMENT NO DATE

(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER. 12 OF 12
SAB/PHL AN/RG
8. Type of Lubrication Arrgt. Manual Centralized Lubrication at Specified
Provided Periodic Intervals.

9. No. of Carriage Wheels Four.

LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS (SURATGARH, STAGE – V, UNIT # 7 & 8) (SUT & SAC) DOCUMENT NO DATE: 05.02.16 REV. - A
L&T - O14195-M-BM-EQ-DB-5105
TITLE : CONTROL WRITE UP OF WAGON TIPPLER AND DESIGNED CHECKED SHEET
SIDE ARM CHARGER SAB / PHL AN / RG Page 1 of 38

LEVEL 2

DESCRIPTION OF OPERATIONS

WAGON TIPPLER & SIDE ARM CHARGER SYSTEM

SURATGARH SUPERCRITICAL TPS STAGE-V, UNIT 7 & 8, INDIA

L&T- Rev A
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

CONTENTS
1. INTRODUCTION ............................................................................................................................................................................ 4
1.1 CONTENT........................................................................................................................................................................................................................................ 4
1.2 DEFINITION OF TERMS ...................................................................................................................................................................................................................... 5
1.3 REFERENCE DOCUMENTS & DRAWINGS ............................................................................................................................................................................................... 5
1.4 DEVICE (SWITCH/SENSOR) ABBREVIATIONS & TYPES .............................................................................................................................................................................. 7
1.5 TRAIN CONFIGURATION .................................................................................................................................................................................................................... 8

2. BRINGING IN TRAIN & LOCO DESPATCH (MANUAL) ....................................................................................................................... 9

2.1 PLANT CONDITION PRIOR TO TRAIN ARRIVAL ....................................................................................................................................................................................... 9
2.2 LOADED TRAIN ENTRY .................................................................................................................................................................................................................... 11
2.3 COUPLE SAC TO TRAIN ................................................................................................................................................................................................................... 11

3. SAC TRAIN & WAGON INDEXING CYCLE (AUTOMATIC)................................................................................................................. 12

3.1 PLANT SET UP ............................................................................................................................................................................................................................... 12
3.2 SAC AUTOMATIC OPERATION.......................................................................................................................................................................................................... 13

4. TIPPLER TIP & RETURN CYCLE (AUTOMATIC)................................................................................................................................ 16

4.1 TIPPLER AUTOMATIC OPERATION ..................................................................................................................................................................................................... 16
4.2 LAST WAGON AUTOMATIC OPERATION ............................................................................................................................................................................................. 21

5. PLANT OPERATIONS (MANUAL) .................................................................................................................................................. 23

5.1 CYCLE INTERRUPT .......................................................................................................................................................................................................................... 23
5.2 CYCLE RESET ................................................................................................................................................................................................................................. 23
5.3 EMERGENCY STOP PUSHBUTTONS .................................................................................................................................................................................................... 24
5.4 PLC WATCHDOG ........................................................................................................................................................................................................................... 24
5.5 OVER TRAVEL LIMIT SWITCHES ......................................................................................................................................................................................................... 24
5.6 SAC MANUAL OPERATIONS ............................................................................................................................................................................................................ 25
5.7 TIPPLER MANUAL OPERATION ......................................................................................................................................................................................................... 26

L&T- Rev A
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

5.8 ENTRY AND EXIT WHEEL CHOCK MANUAL OPERATION ........................................................................................................................................................................ 27

5.9 PLANT SET-UP FOR COLLECTION OF EMPTY TRAIN ............................................................................................................................................................................... 28
5.10 ANNUNCIATOR ON HMI ............................................................................................................................................................................................................ 29

6. TIPPLER GENERAL ....................................................................................................................................................................... 31

7. SAC GENERAL .............................................................................................................................................................................. 33
8. WHEEL CHOCK OPERATION (MAINTENANCE)............................................................................................................................... 34
10. DEVISE SCHEDULE: ...................................................................................................................................................................... 35
A. WAGON TIPPLER ......................................................................................................................................................................... 35
B. SIDE ARM CHARGER .................................................................................................................................................................... 36
C. SIDE ARM CHARGER DRAG CHAIN ............................................................................................................................................... 37
D. ENTRY WHEEL CHOCKS................................................................................................................................................................ 38
E. EXIT WHEEL CHOCKS ................................................................................................................................................................... 38

L&T- Rev A
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

1. INTRODUCTION

1.1 This document provides a high level description of the operating processes of the Side Unloading Tippler (SUT), Side Arm Charger (SAC) and
Train Holding Equipment to ensure safe and continuous operation at the Suratgarh Thermal Power facility in India.
1.2 This document should be read in conjunction with reference documents outlined in Section 1.8 below.

1.3 There are a total of four systems at this facility. Drawings and device types (switch references) noted in this document reflect the WT-2
System. The WT-4 System is identical in operation to WT-2. The other systems, WT-1 and WT-3, are similar except for being opposite
handed as identified on key diagrams located on the appropriate plant general arrangement drawing.

1.4 Each system consists of One Side Unloading Wagon Tippler (SUT), One Side Arm Charger (SAC), One Set of Entry Track Wheel Chocks and
One Set of Exit Wheel Chocks.

1.5 The Wagon Unloading System is designed in the ‘Long System’ configuration. This is reflected in Time Cycle calculations.

L&T- Rev A
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

1.6 Definition of Terms

Term Definition
SAC Side Arm Charger
SUT Side Unloading Tippler
Entry Track The main rail track on which the rake of full wagons approach the SUT
Exit Track The main rail track on which the rake of empty wagons leave the SUT
LCS Local Control Station
PLC Programmable Logic Controller

1.7 Reference Documents & Drawings

Drg/Doc No Title

O13057-M-BM-EQ-_______
O13057-M-BM-EQ-GA-5452, GA of SUT Wagon Positioning Photocells
O13057-M-BM-EQ-GA-5453
O13057-M-BM-EQ-GA-5321 GA of SUT Drives
O13057-M-BM-EQ-DD-5250, GA of SUT Limit Switches for Clamp Gear
O13057-M-BM-EQ-DD-5251
O14195-M-BM-EQ-GA-5362 GA of SUT Limit Switches for Moving side pad
O13057-M-BM-EQ-GA-5271 GA of SUT Limit switches for Rotational switches

L&T- Rev A
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

O13057-M-BM-EQ-GA-5270 GA of Platform down limit switches

O14195-M-BM-EQ-GA-5425 GA of Platform Grippers
O14195-M-BM-EQ-GA-5198 GA of SAC Arm
O14172-M-BM-EQ-GA-5210 GA of SAC Drive cartridge
O14195-M-BM-EQ-GA-5512 GA of SAC Arm raise/ lower switches
O14195-M-BM-EQ-GA-5513
O13057-M-BM-EQ-GA-5360 GA of SAC travel magnetic switches
O14195-M-BM-EQ-DD-5589 GA of Coupler Release
O14195-M-BM-EQ-GA-5513 GA of Arm Latch
O14195-M-BM-EQ-DD-5591 GA of Knuckle Switch
O11077-M-BM-EQ-GA-5327,
O11077-M-BM-EQ-GA-5325, GA of Wheel Chocks (Entry & Exit)
O11093-M-BM-EQ-GA-5325
‘HD’ Refers to Hydraulic Equipment Supplier Drawing
O14195-M-BM-EQ-VR-5739,
O14195-M-BM-EQ-VR-5763,
O14195-M-BM-EQ-VR-5786, Hydraulic circuit drawing for Wagon tippler, SAC & Wheel chock
O14195-M-BM-EQ-VR-5776

L&T- Rev A
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

1.8 Device (Switch/Sensor) Abbreviations & Types

Note: Devices types indicated are suggested suitable equipment but not mandatory for the correct functioning of the plant.
Suitable equivalent alternatives may be used. The design of mounting equipment as shown on AB DSOs may need to
be adjusted to suit any alternative devices.

Induction Sensor (IS): Turck Proximity Induction Sensor: Bi25-G47SR- FZ3X2

Magnetic Switch (MS): GO Magnetic Switch 11-31238 + MA1 Magnet
Mill Switch (MLS): Heavy duty Lever Limit switch
Rotating Cam Switch (RCS): Gemco Rotating Cam Switch, NEMA 4, Straight Drive, 2:1 Ratio
Pressure Switch As per Hydraulic Equipment Supplier standard.
Photo-Electric Cell (PEC): Alan Bradley Photo-Electric Cell - Transmitted Beam Type
Absolute Encoder (EN-ABS): Multi-turn absolute encoder.

Local Control Station (PC): Commercially Available Type

L&T- Rev A
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

1.9 Train Configuration

The Train will arrive at the unloading system hauled by either a Single Locomotive or Dual Locomotives. The train comprises up to 59 fully loaded
wagons. All wagons in the train will be of the same type.
1.9.1 The types of wagon to be handled have been categorised for this project into two length groups and two height groups as identified in the
table below:

WAGON TYPE LENGTH GROUP HEIGHT GROUP

1 BOXC Long Low
2 BOX Long Low
3 BOXN Short Low
4 BOXNHA Short Low
5 BOXNLW Short Low
6 BOXNHL Short Low
7 BOXN25 Short Low
8 DFC32.5 (COAL) Short High
9 DFC25 (COAL) Short Low

The length category is used by the SAC Control System to position the wagon approximately central on the Platform. The height
category is used by the SUT Control System to determine the Clamp position during the tipping operation. Two selector switches
capable of selecting any one of the wagons listed in the table above are considered in the control desk to cover all the wagons to be
handled by the SUT.

L&T- Rev A
LARSEN & TOUBRO
MMH IC – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS (SURATGARH, STAGE – V, UNIT # 7 & 8) (SUT & SAC) DOCUMENT NO DATE: 05.02.16 REV. - A
L&T - O14195-M-BM-EQ-DB-5105
TITLE : CONTROL WRITE UP OF CRESCENT WAGON TIPPLER AND DESIGNED CHECKED SHEET
SIDE ARM CHARGER SAB / PHL AN / RG Page 9 of 38

Drawing / IDENT Device

Description of Operation Document
Ref Ref. Type

2. BRINGING IN TRAIN & LOCOMOTIVE DESPATCH (MANUAL)

The sequences given in the text are recommended but not mandatory.
2.1 Plant Condition Prior to Train Arrival

2.1.1 The following conditions must be satisfied before a train can be brought into the SUT system:

• Control System healthy.

• All Hydraulic Systems operating.

• SUT & SAC Photo Cells clear. GA-5452,

PEC-T-1-3 PEC
GA-5453
GA-5360, LS-CF-PP MS
• SAC Stationary at Park Position with Arm Raised. LS-C-AR
GA-5512 IS
DD-5591,
• SAC Coupler Released and Knuckle Fully Open (Loss of knuckle close signal). LS-C-CRE IS
GA-5513
LC-C-ALR
• SAC Arm Latch Released. GA-5512 IS

• SUT Stationary with Platform on weigh scale (Rails Aligned, 0° Rotation) and Drive Brakes Applied. GA-5270 LS-T-RA MLS

L&T- Rev A
LARSEN & TOUBRO
MMH IC – EDRC

Drawing / IDENT Device

Description of Operation Document
Ref Ref. Type

DD-5250, LS-T-CA1-2 IS
• SUT Clamp Gear Fully Raised with Clamp Arm Cylinder and Clamp Beam Cylinders Fully Retracted, LS-T-CBR1-6
DD-5251 IS
and Clamp Releiving Cylinder Reset. LS-T-CRCR1-6
HD Hyd. Splr.
LS-T-SPER1-4
• SUT Moving Side Pad Retracted. GA-5362 IS

• SUT Grippers Retracted. GA-5425 LS-T-GR1-4 IS

LS-WCE-FR1-2
IS
LS-WCE-RR1-2
• Entry and Exit Wheel Chocks Retracted. GA-5429 IS
LS-WCX-AR1-2
IS
The operator selects ‘Locomotive Passage’ to prepare the unloading system for the locomotive to
pass through the SUT. Upon selection, the following operations and checks are carried out
automatically by the Control System:
To eliminate the possibility that the hydraulic cylinders have extended (fallen) under gravity thus HD PT-T-CAE1-2 Hyd. Splr.
lowering the clamps, the Clamps are fully lowered and then raised to the ‘Fully Raised’ position. LS-T-CA1-2 IS
The Control System shall be configured to ignore the first signal which will be from the DD-5251 LS-T-CBE1-6 IS
“intermediate” target. LS-T-CBR1-6 IS
Both upper and lower Side Pad cylinders are pressurised on the annulus side to fully retract them
and pull the side pad away to provide the clearance for locomotive passage through the SUT. The
GA-5362 LS-T-SPR1-4 IS
‘Side Pad Retracted’ switches (mounted at each cylinder) will be activated to confirm the fully
retracted position.

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LARSEN & TOUBRO
MMH IC – EDRC

Drawing / IDENT Device

Description of Operation Document
Ref Ref. Type

GA-5360, LS-CF-PP MS
The Control System checks that the SAC is at the ‘Parked’ position with the Arm Raised.
GA-5512 LS-C-AR IS

2.2 Loaded Train Entry

2.2.1 Upon receiving the Plant Clear signal, the loaded train being pulled by 1 or 2 locomotives at slow speed
is hauled into the system. The driver stops the train when the lead bogie wheel of the first wagon in the
train is located within 1m of the Entry Side Wheel Chocks. With the train stopped, the forward arms of GA-5327,
LS-WCE-FE1-2 IS
the Entry Wheel Chocks are then activated to bring them out in front of the wagon wheels. The diesel GA-5429
locomotive/locomotives are now uncoupled from the first wagon and driven forward at slow speed
through the SUT.

2.3 Couple SAC to Train

2.3.1 With the Control System set to Manual, the operator is required to board the SAC. The SAC Arm is
manually lowered and the Coupler Release cylinder is retracted to the ‘Coupler Ready to Engage’ GA-5512 LS-C-AL IS
condition. The SAC is manually travelled back and at creep speed, couples to the 1st full wagon. The SAC DD-5591, LS-C-CRE IS
travel is stopped when the switch indicating the coupler ‘Knuckle Closed’ condition has been registered. DD-5589 LS-C-KC IS
The operator then off boards the SAC.

2.3.2 Retract Entry Wheel Chocks forward arms. GA-5327,

LS-WCE-FE1-2 IS
GA-5429

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MMH IC – EDRC

Drawing / IDENT Device

Description of Operation Document
Ref Ref. Type

3. SAC TRAIN & WAGON INDEXING CYCLE (AUTOMATIC)

3.1 Plant Set Up

3.1.1 The following conditions must be satisfied before a rake of wagons can be hauled into the SUT system
under automatic control:

• Control System healthy

• All hydraulic systems operating

• SAC Stationary. Arm Lowered and coupled with lead wagon GA-5512 LS-C-AL IS
DD-5591, LS-C-CRE IS
DD-5589 LS-C-KC IS

• SUT Stationary at rail level (rails aligned)and drive brakes applied GA-5270 LS-T-RA MLS

• SUT Moving Side Pad Retracted GA-5362 LS-T-SPR1-4 IS

DD-5250 LS-T-CA1-2
IS
• SUT Clamp Gear Fully Raised with Clamp Arm Cylinder and Clamp Beam Cylinders Fully Retracted, LS-T-CBR1-6
DD-5251 IS
and Clamp Releiving Cylinder Reset. LS-T-CRCR1-6
HD Hyd.Splr.

L&T- Rev A
LARSEN & TOUBRO
MMH IC – EDRC

Drawing / IDENT Device

Description of Operation Document
Ref Ref. Type

LS-T-GR1-4
• SUT Grippers Retracted GA-5425 IS

GA-5327 LS-WCE-FR1-2
LS-WCE-RR1-2 IS
• Entry and Exit Wheel Chocks Retracted. GA-5325 LS-WCX-AR1-2 IS
GA-5429 IS

3.1.2 At the main control room the operator selects the wagon type in the rake (see 1.9.1), switches the
Control System to Automatic and initiates the automatic cycle.

3.2 SAC Automatic Operation

3.2.1 The SAC pulls the rake forward and when the lead wheel of the 2nd wagon passes the Slowdown switch
on the approach to the Wheel Chocks, the SAC decelerates to creep speed. The Slowdown switch is
programmed to ignore the passage of the first 3 wheels and only on detection of the 4th wheel (i.e. lead GA-5327 LS-WCE-CSD IS
wheel of the 2nd wagon) does it initiate SAC Slowdown. The operation of the same switch also LS-WCE-FE1-2 IS
simultaneously initiates the operation of the Entry Wheel Chocks Forward Arms into the path of the
approaching wheels.

3.2.2 The SAC continues to pull the rake forward at creep speed until the lead wheel of the 2nd wagon is
detected by the Forward Stop switch on the approach to the Wheel Chocks at which point, the SAC is GA-5327 LS-WCE-FWD IS
stopped. The operation of the same switch also simultaneously initiates the operation of the Entry LS-WCE-RE1-2 IS
Wheel Chocks Rear Arms behind the rear wheels of the bogie.
Note: On the second and subsequent automatic cycles, the SAC Arm head simultaneously buffs the GA-5325 LS-WCX-RE1-2 IS
empty wagon off the Tippler Platform to join the rake of empty wagons accumulating on the Exit track.

L&T- Rev A
LARSEN & TOUBRO
MMH IC – EDRC

Drawing / IDENT Device

Description of Operation Document
Ref Ref. Type

The Exit Wheel Chocks shall be confirmed as retracted prior to initiation of the pull rake forward
operation on second and subsequent cycles.

3.2.3 When the Entry Wheel Chocks Arms have fully engaged, and the SAC is stationary, the Uncoupling GA-5327 LS-WCE-FE1-2 IS
Operator uncouples the lead wagon from the rake using the wagon coupler release lever between the
LS-WCE-RE1-2 IS
wagons and confirms completion of this operation by pressing a pushbutton on the local control Station
at track side. DD-5591 PB-CF-UN PC

3.2.4 Upon receipt of the signal confirming that the SUT is at rail level with the platform on the weigh scale,
the SAC automatically pulls the uncoupled full wagon forward onto the SUT platform (and weigh scale)
and positions it centrally on the SUT Platform. The stopping position depends on the length group of the EN-C-LWSD EN-ABS
wagon selected, ('Long' or 'Short'); see Section3.1.2. GA-5210 EN-C-LWS EN-ABS
EN-C-SWSD EN-ABS
The position of the wagon on the SUT is checked by the use of 3 sets of photocells. 2 sets EN-C-SWS EN-ABS
work together and check that a 'Long' group wagon has been placed centrally on the
Platform. This will check that a 'Long' wagon has not been placed incorrectly on the
Platform in the 'Short' wagon position (in this case the rear of the long wagon will obscure PEC-T-1 PEC
the rear beam) or a 'Long' wagon has been incorrectly placed too far forward on the
GA-5452 PEC-T-2 PEC
Platform caused by SAC over-run (in this case the front of the wagon obscures the front
PEC-T-3 PEC
beam). The third photocell set checks that a 'Short' wagon has been positioned as a 'Long'
wagon i.e. too far forward (in this case the front of the wagon will obscure the beam).
These 3 sets of photocells ensure that either 'Long' or 'Short' wagons cannot be placed on

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MMH IC – EDRC

Drawing / IDENT Device

Description of Operation Document
Ref Ref. Type

the SUT in a manner that the Grippers, Side Pad, or wagon Clamps could not perform their
intended functions and fail to support and restrain the wagons.

3.2.5 After positioning the full wagon on the SUT Platform, the SAC coupler is released, which is enunciated
by the loss of the 'Coupler Ready to Engage' signal. The SAC travels forward and in doing so uncouples LS-C-CRE IS
GA-5210,
from the wagon. Loss of the Knuckle Closed signal confirms separation of the SAC from the wagon has EN-C-TCSD EN-ABS
GA-5360,
been achieved. The SAC Arm clears the SUT Platform pushing any previously unloaded wagons further EN-C-TCS EN-ABS
along the Exit track and clear of the Exit Wheel Chocks. The Coupler Release cylinder remains extended DD-5591
LS-C-KC IS
to ensure the knuckle stays open and is confirmed by loss of "Knuckle close Switch" signal.

3.2.6 When the SAC Forward Clear Slowdown signal is provided, the SUT Tip Cycle (refer to Section 4) and the EN-C-TCSD EN-ABS
GA-5210
Exit Wheel Chocks Engage operations are initiated. The SAC stops at the SUT Clear Stop position. EN-C-TCS EN-ABS

3.2.7 Exit Wheel Chock Arm Engaged is confirmed prior to further SAC operations. GA-5325,
LS-WCX-AE1-2 IS
GA-5429

3.2.8 The SAC Arm is raised and the SAC commences travels in the return direction. GA-5512,
LS-C-AR IS
GA-5513

3.2.9 During return cycle, when the SAC has reached a position at which the arm is clear of the SUT ‘Entry’
GA-5360 LS-CF-AL IS
End Frame, it is signalled to begin to lower whilst the SAC is in motion.

3.2.10 The SAC continues return travel to the Slowdown and Parked Position. The final stages of arm lowering GA-5210 EN-C-CRSD EN-ABS
are completed after the SAC comes to rest. The travel limit positions ensure that the arm is clear of the EN-C-CRS EN-ABS

L&T- Rev A
LARSEN & TOUBRO
MMH IC – EDRC

Drawing / IDENT Device

Description of Operation Document
Ref Ref. Type

waiting wagon. GA-5360 LS-CF-PP IS

GA-5512 LS-C-AL IS

3.2.11 With The SAC stationary and the arm now fully lowered, the Coupler Release cylinder is retracted in the GA-5360
LS-C-CRE IS
Coupler Ready to Engage condition. The SAC travels back slowly to engage with the rake of wagons. The DD-5591,
LS-C-KC IS
SAC travel is stopped when the switch indicating coupler ‘Knuckle Closed’ has been operated. DD-5589

3.2.12 The Entry Wheel Chocks Retract to release the rake and the cycle is then repeated from 3.2.1. GA-5327, LS-WCE-FR1-2 IS
GA-5429 LS-WCE-RR1-2 IS

4. SUT TIP & RETURN CYCLE (AUTOMATIC)

4.1 SUT Automatic Operation

4.1.1 When the SAC has positioned the wagon on the SUT Platform (reference 3.2.5), the Wheel Grippers EN-C-LWS/SWS EN-ABS
GA-5210
Engage to grip all the wheels of the wagon. Confirmation of Gripper engagement is annunciated by the PEC-T-1,2,3 PEC
GA-5452
loss of the Gripper Retracted signal. Hydraulic pressure is maintained to the Grippers hydraulic LS-T-GR1-4 IS
actuating cylinders throughout the SUT Tip and Return cycle. HD
PS-T-GRE Hyd. Splr.

4.1.2 When the SAC has uncoupled from the wagon positioned on the SUT Platform (reference 3.2.6above)
DD-5591 LS-C-KFO IS
and Grippers are engaged as described in Section 4.1.1, all four Side Pad cylinders extend
simultaneously to move the Side Pad into contact with the side of the positioned wagon. Contact will GA-5362 LS-T-SPR1-4 IS
be annunciated firstly by the loss of the four Side Pad Retracted signals and then activation of the four HD PS-T-SPL1-4 Hyd. Splr.
local pressure switches. All four cylinders are then simultaneously hydraulically locked to provide a solid

L&T- Rev A
LARSEN & TOUBRO
MMH IC – EDRC

Drawing / IDENT Device

Description of Operation Document
Ref Ref. Type

support for the whole wagon side throughout the tipping operation.

4.1.3 At this stage, with the first wagon on the SUT ready to be tipped, the Clamps are in the fully raised DD-5250 LS-T-CA1-2 IS
position (Clamp Arm cylinders and Clamp Beam cylinders are fully retracted) following previous DD-5251 LS-T-CBR1-6 IS
operations.

If the operator has selected a 'High' wagon type, the Clamps remain in the fully raised position at DD-5250 LS-T-CA1-2 IS
this time.
Check sequence: If the wagon selected by the operator falls into the 'Low' wagon category, the PLC
signals the clamp system to lower to the 'Intermediate' position. It is at this stage that a check is DD-5251 LS-T-CA1-2 IS
conducted to ensure that a 'Low' wagon is positioned in the SUT. If the operator has incorrectly HD PT-T-CAE1-2 Hyd. Splr.
selected a 'Low' wagon when there is a 'High' wagon present, the Clamp Arm limit switch will not
detect the intermediate target and the hydraulic cylinder pressure transducers will detect an
DD-5251,
unexpected pressure rise (i.e. wagon contact). This shall indicate a fault and stop the cycle.
When the Clamp Arms are at their selected position, the 6 Clamp Beam cylinders are then fully GA-5225 LS-T-CBE1-6 IS
extended and the Clamp Relieving cylinders (manifold) adopt the Reset Position (ready to relieve HD LS-T-CRCR1-6 Hyd. Splr.
during operation).
4.1.4 On confirmation that the SAC has cleared the SUT and stopped, the Side Pad is still engaged with wagon GA-5362 EN-C-TCS EN-ABS
and the SUT Wheel Grippers are still engaged, the SUT Tip Cycle can commence. At this time the Clamp GA-5425 LS-T-SPR1-4 IS
system is signalled to lower to bring the 6 Clamp Beams into contact with the top of the wagon by DD-5250 LS-T-GR1-4 IS
lowering the Clamp Arms.
Check sequence: If the operator has mistakenly selected 'High' wagon type when in fact there is a
'Low' wagon positioned on the SUT Platform, the clamp "intermediate" position target will be

L&T- Rev A
LARSEN & TOUBRO
MMH IC – EDRC

Drawing / IDENT Device

Description of Operation Document
Ref Ref. Type

sensed before any of the 6 Clamp Beam cylinder pressure transducers indicate Clamp Beam to DD-5251 LS-T-CA1-2 IS
wagon contact. The proximity switch on sensing the target shall signal a fault and the SUT is
decelerated to stop in a controlled manner.
Under normal operation, (i.e. the correct wagon type has been selected), when full contact between
Clamp Beams and the wagon is established (signalled by a predetermined pressure being registered HD PT-T-CBE1-6 Hyd. Splr.
in all 6 Clamp Beam cylinders), the Clamp Arm cylinders are stopped and immediately hydraulically GA-5225 LS-T-CA1-2 IS
locked by disengaging SV/T/CAE1 & CAE2. All 6 Clamp Beams must be in full contact with the wagon
at a SUT tip angle no greater than 45 degrees. From 45⁰ to 75⁰ all clamp beam cylinder flow is on
and pressure has been maintained at full bore side which is sensed by pressure transducers
(PT/T/CBE1 to CBE6). At 80⁰ of tippler rotation of pump flow is stopped by disengaging SV/T/CBE1 &
CBE2 & all cylinders are hydraulically locked now.

4.1.5 With all 6 Clamp Beams in contact with the wagon and locked, and the Clamp Arm cylinders locked, the
Clamp Relieving cylinders (manifold) at each Clamp Beam location are in the Reset Position following
previous hydraulic system operations and available to operate at the point material is discharged from
the wagon and the wagon bogie springs re-exert/extend. The purpose of this relieving operation is to HD PT-T-CBE1-6 Hyd. Splr.
allow sufficient movement of the Clamp Beam cylinders for the force exerted by the bogie springs to
dissipate, preventing an increase in force between wagon and clamp as the wagon is tipped and
emptied.

4.1.6 At 80 degrees of SUT rotation checks are undertaken to ensure that the Wheel Grippers, Side Pad, and
Clamp hydraulic cylinders are pressurised or locked to permit further SUT rotation. If any cylinder does PT-T-GE
not register the anticipated pressure and are potentially not locked, the SUT is decelerated to stop in a HD PT-T-SPL1-4 Hyd. Splr.
controlled manner and an alarm initiated. The SUT will be returned to rail level at slow speed under

L&T- Rev A
LARSEN & TOUBRO
MMH IC – EDRC

Drawing / IDENT Device

Description of Operation Document
Ref Ref. Type

Manual control. Otherwise rotation continues. At this angle a check is also made that signals have been PT-T-CAE1-2
received to indicate that both platform hooks have swung into engagement with the pins in the End PT-T-CBE1-6
Frames. If either of the 2 signals is not received, rotation of the SUT will be halted as previously
GA-5271 LS-T-PH1-2 IS
described.
LS-T-SDT RCS

Monitoring of the sensor pressure continues throughout the rest of the tip cycle until the SUT
reaches 90 degrees tip angle on the return cycle. During the tip period, if any of the pressure
transducers indicate a loss of cylinder pressure, i.e. that a Clamp is no longer locked, the rotation of
the SUT will perform a controlled stop and display a fault indication. The operator will then decide
whether to continue to unload the wagon or return it to rail level at slow speed under Manual
control. During the return period, if any of the pressure transducers indicate a loss of cylinder
pressure, rotation of the SUT will automatically continue back to rail level followed by a fault
indication and plant Auto Cycle interruption.
4.1.7 At approximately 150 degrees of SUT rotation, a signal is provided to initiate Slowdown. The SUT is
decelerated to stop at the full tip angle of 160 degrees rotation (or alternative angle depending on plant GA-5271 LS-T-SDT RCS
configuration).
The hardwired Overtravel switch will initiate an Emergency Stop in the event of a Normal Slowdown GA-5273 LS-T-OTT MLS
signal failure.

4.1.8 As soon as the SUT has stopped, the SUT Return cycle is automatically initiated by the PLC and the SUT
GA-5271 LS-T-TFR RCS
is accelerated to return speed. There is no pause time between the tip and return cycles.

4.1.9 When the SUT reaches 80 degrees from rail level on the return cycle, the Clamp Arms commence DD-5251 LS-T-CA1-2 IS

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MMH IC – EDRC

Drawing / IDENT Device

Description of Operation Document
Ref Ref. Type

retraction and stop raising when the proximity switch detects the first target seen. This will either be LS-T-CBR1-6 IS
the ‘Intermediate’ (‘Low’ wagon group) or ‘Fully Raised’ (‘High’ wagon group) position. When this HD LS-T-CRCR1-6 Hyd. Splr.
position is reached, all 6 Clamp Beam cylinders are retracted and the Clamp Relieving cylinders
(manifold) adopt their Reset Position.

4.1.10 When the SUT reaches 15 degrees from rail level, the Slowdown cycle is initiated. The SUT rotation is
decelerated and reaches creep speed before platform rails are aligned with main rails. The Slowdown GA-5362 LS-T-SDR RCS
signal also initiates the retraction of the Moving Side Pad.

4.1.11 Approaching 0 degrees a striker mounted on the SUT platform actuates the ‘Rails Aligned’ switch which GA-5270 LS-T-RA IS
signals the PLC to stop the drive. Upon receipt of the ‘Rails Aligned’ and ‘Side Pad Retracted’ signals, the
Wheel Grippers are signalled to retract.

4.1.12 After getting "Rail Aligned" signal & "Side pad retracted" & "Gripper Retract signal" 6 clamp beam GA-5362, LS-T-SPR1-4 IS
cylinder will be extended fully. GA-5425, LS-T-GR1-4 IS
The hardwired Over travel switch will initiate an Emergency Stop in the event of a Normal Slowdown DD-5250, LS-T-CBE1-6 IS
signal failure. DD-5251,
GA-5273 LS-T-OTR MLS

4.1.13 When the SUT is stopped at rail level, the SAC is signalled to commence hauling the second and
subsequent wagons forward. All signal checks and interlocks required for SAC operations (Sections 3)
and SUT (Section 4) are to be repeated for all wagon unloading cycles.

L&T- Rev A
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MMH IC – EDRC

Drawing / IDENT Device

Description of Operation Document
Ref Ref. Type

4.2 Last Wagon Automatic Operation

4.2.1 Hauling of the last wagon is detected by the Slowdown switch when counting the passage of bogie
wheels. Normally the 4th wheel passing the switch initiates Slowdown (refer to 3.2.1). However, when As 3.2.1 As 3.2.1 As 3.2.1
the SAC is hauling the last wagon, there will be no 4th wheel. The SAC then automatically continues and & & &
pulls the last wagon onto the SUT Platform, buffing the empty wagon off as described previously (refer 3.2.4 3.2.4 3.2.4
to 3.2.4).

4.2.2 After positioning the full wagon on the SUT Platform, the SAC travels forward and in doing so uncouples
from the wagon. The SAC Arm clears the SUT Platform pushing the unloaded wagons further along the
As 3.2.5 As 3.2.5 As 3.2.5
Exit track and clear of the Exit Wheel Chocks. The Coupler Release cylinder remains extended to ensure
knuckle stays open (refer to 3.2.5).

4.2.3 When the SAC Forward Clear Slowdown signal is provided, the SUT Tip Cycle (refer to Section 4) and the
Exit Wheel Chocks Engage operations are initiated. The SAC stops at the SUT Clear Stop position (refer As 3.2.6 As 3.2.6 As 3.2.6
to 3.2.6).

4.2.4 The SAC Arm is raised and the SAC travels back to slowdown and stop at the SAC Parked Position (refer As 3.2.8 As 3.2.8 As 3.2.8
to 3.2.8 to 3.2.12). to to to
3.2.12 3.2.12 3.2.12

4.2.5 The SAC Arm is lowered. After the SUT has operated to empty the last wagon, the Exit Wheel Chocks are GA-5512 LS-C-AL IS
retracted. GA-5513
GA-5270 LS-T-RA IS

L&T- Rev A
LARSEN & TOUBRO
MMH IC – EDRC

Drawing / IDENT Device

Description of Operation Document
Ref Ref. Type

GA-5325, LS-WCX-AR1-2 IS
GA-5429

4.2.6 The SAC travels forward to push the last empty wagon clear of the SUT Platform and into contact with GA-5210 EN/C/TCSD EN-ABS
the rake of empty wagons. Exit Wheel Chocks are engaged. EN/C/TCS EN-ABS
GA-5325 LS-WCX-AE1-2 IS
GA-5512 LS/C/AR IS
GA-5210 EN/C/CRSD EN-ABS
4.2.7 The SAC raises its arm and travels back until it reaches the 'SAC Parked' position where it stops with the
EN/C/CRS EN-ABS
Arm Raised.
GA-5512 LS/C/AL IS
GA-5360 LS/C/ALR IS
HD PT-T-CAE1-2 Hyd. Splr.
4.2.8 The Wagon Clamps are fully lowered and then raised to the 'Fully Raised' position. The Control System LS-T-CA1-2 IS
recognises that the 'Clamps Raised' switches will activate twice before giving the 'Fully Raised' signal. DD-5250 LS-T-CBE1-6 IS
LS-T-CBR1-6 IS

4.2.9 Both upper and lower Side Pad cylinders are pressurised on the annulus side to fully retract them with GA-5362 LS-T-SPR1-4 IS
the 'Side Pad Retracted' switches confirming all cylinders and the Side Pad are fully retracted. GA-5325 LS-WCE-FR1-2 IS

4.2.10 Entry Wheel Chocks remain retracted. Exit Wheel Chocks remain engaged. GA-5327 LS-WCX-AE1-2 IS

L&T- Rev A
LARSEN & TOUBRO
MMH IC – EDRC

Drawing / IDENT Device

Description of Operation Document
Ref Ref. Type

5. PLANT OPERATIONS (MANUAL)

5.1 Cycle Interrupt

5.1.1 Operator Initiated Cycle Interrupt

At any time during the Automatic cycle, the track side operator must be able to interrupt it by
pressing a 'Cycle Stop' pushbutton on the uncoupling Local Control Station. The operator in the
SUT Control Room may also interrupt the Automatic cycle by activating the 'Cycle Interrupt'
control on the control desk or interface screen. All Automatic operations will be immediately
suspended.
5.1.2 Automatic Cycle Interrupt
In the event abnormal operating conditions are encountered during the unloading process and
detected by the Control System PLC, such as:
• Tipping (and returning) with an empty wagon.
• Tipping and returning with no wagon.
• Returning after prematurely stopping partly through a tip cycle.
All Automatic operations will be immediately suspended.
5.2 Cycle Reset

L&T- Rev A
LARSEN & TOUBRO
MMH IC – EDRC

Drawing / IDENT Device

Description of Operation Document
Ref Ref. Type

5.2.1 Automatic operation can be resumed by the appropriate operator again pressing the 'Cycle Reset'
pushbutton or control on the uncoupling local control station or control desk following investigation of
the reason for the Cycle Interrupt and, in the case of the SUT, returning the SUT to rail level under
Manual Operation. All SUT manual operations shall be performed at slow or creep speed.
Note: An interrupted cycle can only be resumed at the point of interruption. e.g. if the cycle is
interrupted at the uncoupling local control station, automatic operation cannot be resumed from
the control desk; only at the uncoupling local control station.
5.3 Emergency Stop Pushbuttons

5.3.1 Operation of any emergency stop pushbutton must de-energise a main ‘Emergency Stop Relay’. The
Emergency Stop Relay must subsequently energise and remain energised until the operated emergency
stop pushbutton has been manually reset, and the ‘Control Reset’ pushbutton has been pressed on the
control desk in the Central Control Room.

5.4 PLC Watchdog

5.4.1 In addition to the emergency stop pushbuttons, the main Emergency Stop Relay must also be de-
energised if the PLC develops a fault. This will be achieved via a PLC interface relay.

5.5 Over travel Limit Switches

5.5.1 Over travel by the SAC, (in forward and return directions), or SUT (tip direction only), will cause Over
Travel Limit Switches to trip which will signal the PLC to de-energise. Over Travel limit switches have no

L&T- Rev A
LARSEN & TOUBRO
MMH IC – EDRC

Drawing / IDENT Device

Description of Operation Document
Ref Ref. Type

effect on the Main Emergency Stop Relay.

5.6 SAC Manual Operations

5.6.1 The Operator has the ability to 'Single Step' through an entire SAC cycle, using the following
push buttons on the control desk for manual operation:
• Arm Raise PB
• Arm Lower PB
• Charger Uncouple PB
• Charger Forward Travel PB
• Charger Reverse Travel PB
Other functions which are not repetitive shall be done through HMI.
• Power pack motor start
• Power pack motor stop
• Cooler motor start
• Cooler motor stop

All indications shall be on HMI only.

5.6.2 All motions will be on a ‘Push to Run’ basis.

L&T- Rev A
LARSEN & TOUBRO
MMH IC – EDRC

Drawing / IDENT Device

Description of Operation Document
Ref Ref. Type

5.7 SUT Manual Operation

Push buttons on control desk for repetitive operation
• Tippler Tip PB
• Tippler Return PB
• Tippler stop PB
• Cycle Interrupt
• Cycle reset

Following functions will be automatically taken care by PLC logic based on the operation
• Wheel gripper extension/retraction
• Side pad Extension/Retraction
• Clamps raising/lowering
• All control and safety checks during the operation.
Following functions which are not repetitive shall be done through HMI before
starting of the operation.
• Tippler pump on
• Tippler pump stop
• Clamp pump on
• Clamp pump stop
• Apron feeder pump motor start
• Apron feeder pump motor stop

L&T- Rev A
LARSEN & TOUBRO
MMH IC – EDRC

Drawing / IDENT Device

Description of Operation Document
Ref Ref. Type

Track Side LCS

• Change Wagon PB
• Cycle Interrupt PB
• Cycle Reset PB
All indications shall be on HMI only.

5.7.1 All motions will be on a ‘Push to Run’ basis and all Tip and Return drive operations performed at slow or
creep speed.

5.8 Entry and Exit Wheel Chock Manual Operation (On control desk)
• Inhaul Wheel chock front Arm Engage PB
• Inhaul Wheel chock front Arm Disengage PB
• Inhaul Wheel chock rear Arm Engage PB
• Inhaul Wheel chock rear Arm Disengage PB
Exit wheel chock:
• Exit Wheel chock Arm Engage PB
• Exit Wheel chock Arm Disengage PB

Following functions which are not repetitive shall be done through HMI before starting of the
operation.
• Inhaul Wheel chock Pump Start PB

L&T- Rev A
LARSEN & TOUBRO
MMH IC – EDRC

Drawing / IDENT Device

Description of Operation Document
Ref Ref. Type

• Inhaul Wheel chock Pump Stop PB

• Exit Wheel chock pump Start PB
• Exit wheel chock pump stop PB

All indications shall be on HMI only

5.8.1 All motions will be on a 'Push to Run' basis.

5.9 Plant Set-up for Collection of Empty Train

5.9.1 If the empty train of wagons have to return back through the SUT, the following conditions must be
satisfied:
• Control System is healthy.
• SAC is Stationary at its Parked Position
• SAC arm is raised
• SAC Arm Coupler is Unlocked and Knuckle is Open
• SUT is Stationary with Tracks Aligned at Rail Level
• SUT Clamps are Fully Raised
• SUT Moving Side Pad is in the fully retracted position

L&T- Rev A
LARSEN & TOUBRO
MMH IC – EDRC

Drawing / IDENT Device

Description of Operation Document
Ref Ref. Type

• SUT Wheel Grippers are Retracted

• SAC and SUT Brakes are applied
• Entry & Exit Wheel Chocks are Fully Retracted

5.9.2 Providing all the above stated interlocks are satisfied, the empty train can be removed from the SUT
area.

5.10 ANNUNCIATOR ON HMI

Apart from PB’s the following Annunciator window is also mounted on the Control desk, to
give the instantaneous attention of the operator, in case of any fault/trip. And also the
individual alarm for abnormal process & trend display for continuous inputs shall be
programmed & indicated as different colour in HMI.

1. SAC HPP FAULT (W1)

2. WT HPP FAULT (W2)
3. CLAMP HPP FAULT (W3)
4. INHAUL WHEEL CHOCK HPP FAULT
5. OUTHAUL WHEEL CHOCK HPP FAULT
6. WAGON TIPPLER OVER TRAVEL
7. SAC OVER TRAVEL
8. SAC COOLER MOTOR OVERLOAD TRIP

L&T- Rev A
LARSEN & TOUBRO
MMH IC – EDRC

Drawing / IDENT Device

Description of Operation Document
Ref Ref. Type

9. EPB OPERATED(TIPPLER/SAC/WHEEL CHOCK LCS)

10. WAGON TIPPLER MOTOR OVER LOAD TRIP
11. SAC MOTOR OVERLOAD TRIP
12. CLAMP MOTOR OVERLOAD TRIP
13. WHEEL CHOCK MOTOR OVER LOAD TRIP ( INHAUL & OUTHAUL)
14. Spare
15. Spare

L&T- Rev A
LARSEN & TOUBRO
MMH IC – EDRC

6. TIPPLER GENERAL

There are four modes of operation:

This is done by means of the switch on the wagon tippler control desk labelled AUTO, MANUAL,LOCO & LOCAL MANUAL (MAINTENANCE)

Auto
The tippler cycle is initiated by the charger forward position, subject to the wagon being central on the platform (checked by the photocells).
Side pad should extend and touches the wagon side stanchion which will be sensed by pressure switch for 4 side pad cylinder, It will also to be
sensed by “loss of side pad retraction” signal. Also gripper should engage the wheel of wagon this will be sensed by “Loss of gripper retracted
“signal. Pressure switch also confirms that gripper is engaged with the wheel. Both entry wheel chock and exit wheel chock should be in a
retracted condition to get the permissive of AUTO operation of tippler. All the above is required to start “Auto’ operation of tippler.

Manual
This facility allows the tippler to perform normal tip and return cycles and is used when material remains in the wagon, or if AUTO mode is not
available. It is initiated by the selector switch when MANUAL is selected.
Operator can do the manual operation from keyboard (which is mounted on the desk) for HMI or from following pushbuttons on Control desk
based on the HMI/Desk mode selector switch (SS2) selected by operator.
And also the process of the complete tippling cycle are recognized through the below mentioned Indication lamp in all modes of
operation.

Note: Auto & Manual mode utilize all the interlocks for safe operation through PLC

L&T- Rev A
LARSEN & TOUBRO
MMH IC – EDRC

Local Manual (Maintenance)

The Key switch and Local Manual switch will select LOCAL operation which allows operation of the machine from the local control station (0 to
160degree); a minimum number of interlocks will be utilized to ensure personnel and plant safety.
Clamp operation restricted between 0 to 10 degree. No clamping operation can be done in between 10 degree to 160 degree in Local manual
mode. Following push button switch needs to be there on the Local control station to operate Wagon tippler.
• Tip
• Return
• Side Pad Forward
• Side Pad Return
• WT Clamps Lower
• WT Clamps Raise
• Platform Grippers Engage
• Platform Grippers Retract
• Tippler over travel limit switch bypass pushbutton
• Emergency stop

‘DO NOT OPERATE THE TIPPLER WITH LOADED WAGON IN LOCAL MANUAL (MAINTENANCE) MODE’
LOCO MODE :
Loco mode will only use when diesel loco will enter on tippler table. In this mode Inhaul Wheel Chock & gripper should be in retracted
condition. Also movable side beam will be fully retracted, and clamp will be aligned with inhaul track.

L&T- Rev A
LARSEN & TOUBRO
MMH IC – EDRC

7. SAC GENERAL
There are three modes of operation of the charger:
AUTO
Auto operation can be started when charger is at “parked position”. At the desk Auto Operation can be selected through Plant operation
mode selector switch.

MANUAL
This facility allows the charger to perform actions controlled by the control room operator from the push button / keyboard (based on the
selection of HMI/desk mode) on control desk when the charger / desk mode is in desk mode or field operator from the charger LCS when
the charger/desk mode selector is in charger control mode.
Pushbuttons :

LOCAL MANUAL(Maintenance)
This facility allows the charger to perform actions controlled by the operator on the charger using the local control station.
• SAC Forward
• SAC Return
• SAC Arm Raise
• SAC Arm Lower
• SAC Coupler Uncouple
• SAC Coupler De-energise to couple
• Charger over travel back out
• Emergency stop
All control operate as "Push To Run" at low speed from the LCS in maintenance mode.

L&T- Rev A
LARSEN & TOUBRO
MMH IC – EDRC

8. INHAUL WHEEL CHOCK OPERATION (MAINTENANCE)

• Wheel Chock Front Arms Engage
• Wheel Chock Rear Arms Engage
• Wheel Chock Front Arms Retract
• Wheel Chock Rear Arms Retract
• Emergency stop PP

9. OUTHAUL WHEEL CHOCK OPERATION (MAINTENANCE)

• Wheel Chock Arms Engage
• Wheel Chock Arms Retract
• Emergency stop PB

All control operate as "Push to Run"

L&T- Rev A
LARSEN & TOUBRO
MMH IC – EDRC

10. DEVISE SCHEDULE:

A. SUT

IDENT FUNCTION TYPE LOCATION DRAWING

Devices Directly Mounted On or Adjacent to Tippler
Mill Switch
LS/T/RA Rails Aligned (0° Rotation) GA-5270
(L&T Standard)
LS-T-TFR Fully Rotated (160° Rotation) Gemco Rotating Cam
LS-T-SDT Slow-Down Tip Switch, NEMA 4,
GA-5271
LS-T-SDR Slow-Down Return Straight Drive, 2:1
LS-T-CPC Status Check (80° Rotation) Ratio
LS-T-OTT Over Travel Tip Mill Switch
GA-5273
LS-T-OTR Over Travel Return (L&T Standard)
Clamp Beam Cylinders Fully Turck Bi25-
LS-T-CBE1-6 DD-5250
Extended G47SR-FZ3X2
Turck Bi25-
LS-T-CBR1-6 Clamp Beam Cylinders Fully Retracted DD-5250
G47SR-FZ3X2
Clamp Arm Cylinders. Arms at
Turck Bi25-
LS-T-CA1-2 Intermediate Position or Fully DD-5251
G47SR-FZ3X2
Raised Position.
Turck Bi25-
LS-T-GR1-4 Grippers Retracted GA-5425
G47SR-FZ3X2
Allen Bradley Series
Photocell – Exit Clear and Long
PEC-T-1 4000B Transmitted GA-5452, GA-5453
Wagon Positioned
Beam type

L&T- Rev A
LARSEN & TOUBRO
MMH IC – EDRC

Allen Bradley Series

Photocell – Entry Clear and Long
PEC-T-2 4000B Transmitted GA-5452, GA-5453
Wagon Positioned
Beam type
Photocell – Short Wagon Allen Bradley Series
PEC-T-3 Incorrectly Positioned (Too Far 4000B Transmitted GA-5452, GA-5453
Forward) Beam type
Turck Bi25-
LS-T-SPR1-4 Side Pad Retracted GA-5362
G47SR-FZ3X2
Turck Bi25-
LS-T-PH1-2 Platform Hook Engaged GA-5305
G47SR-FZ3X2

B. SIDE ARM CHARGER

IDENT FUNCTION TYPE LOCATION DRAWING

Devices Directly Mounted on SAC
Turck Bi25-
LS-C-AR SAC Arm Raised GA-5512
G47SR-FZ3X2
Turck Bi25-
LS-C-AL SAC Arm Lowered GA-5512
G47SR-FZ3X2
Turck Bi25-
LS-C-CRE SAC Coupler Ready to Engage DD-5591
G47SR-FZ3X2
Turck Bi25-
LS/C/KC SAC Coupler Knuckle Closed DD-5591
G47SR-FZ3X2

L&T- Rev A
LARSEN & TOUBRO
MMH IC – EDRC

SAC Encoder:
EN/C/LWSD - Long Wagon Slow Down
EN/C/LWS - Long Wagon Travel Stop
EN/C/SWSD - Short Wagon Slow Down Asbolute Positional
EN/C/SWS - Short Wagon Travel Stop type fitted to
GA-5360
EN/C/TCSD - Tippler Clear Slowdown hydraulic drive
EN/C/TCS - Tippler Clear Stop motor
EN/C/CRSD - Charger Return Slowdown
EN/C/CRS - Charger Return Stop &
Encoder Check

C. SIDE ARM CHARGER DRAG CHAIN

IDENT FUNCTION TYPE LOCATION DRAWING

SAC ARM LOWER ON RETURN Turck Bi25-
LS/CF/AL GA-5360
TRAVEL G47SR-FZ3X2
LS/C/F NORMAL FORWARD. GO SWITCH GA-5360
V-lever type switch
LS/CF/OTF OVERTRAVEL FORWARD SWITCH GA-5360
by L&T
ENCODER CHECK, PARK & ARM GO 11-31238 + MA1
LS/CF/PP GA-5360
LOWER SWITCH Magnet
V-lever type switch
LS/CF/OTR OVER TRAVEL RETURN SWITCH GA-5360
by L&T

L&T- Rev A
LARSEN & TOUBRO
MMH IC – EDRC

D. ENTRY WHEEL CHOCKS

IDENT FUNCTION TYPE LOCATION DRAWING

Turck Bi25-
LS-WCE-FE1-2 Wheel Chock Front Arm Engaged GA-5327, GA-5429
G47SR-FZ3X2
Turck Bi25- GA-5327, GA-5429
LS-WCE-FR1-2 Wheel Chock Front Arm Retracted
G47SR-FZ3X2
Turck Bi25- GA-5327, GA-5429
LS-WCE-RE1-2 Wheel Chock Rear Arm Engaged
G47SR-FZ3X2
Turck Bi25- GA-5327, GA-5429
LS-WCE-RR1-2 Wheel Chock Rear Arm Retracted
G47SR-FZ3X2
Wagon Wheel at Wheel Chocks Turck Bi25- GA-5327, GA-5429
LS-WCE-CSD
Charger Slow Down G47SR-FZ3X2
Wagon Wheel at Wheel Chocks Turck Bi25- GA-5327, GA-5429
LS-WCE-FWD
Charger Stop G47SR-FZ3X2

E. EXIT WHEEL CHOCKS

IDENT FUNCTION TYPE LOCATION DRAWING

Turck Bi25-
LS-WCX-AE1-2 Wheel Chock Arm Engaged GA-5325, GA-5429
G47SR-FZ3X2
Turck Bi25-
LS-WCX-AR1-2 Wheel Chock Arm Retracted GA-5325, GA-5429
G47SR-FZ3X2

L&T- Rev A
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS DOCUMENT NO DATE REV-A

(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16 dated:
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER. 1 OF 11
SAB/PHL AN/RG

SECTION – III

MAINTENANCE INSTRUCTIONS
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS DOCUMENT NO DATE REV-A

(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16 dated:
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER. 2 OF 11
SAB/PHL AN/RG

INTRODUCTION

The information given in these schedules and by manufacturers of the proprietary equipment elsewhere in
this manual will assist your personnel to establish maintenance procedures that will keep the machines in
a safe and efficient working condition.
All reasonable care has been taken to list the various items requiring servicing when the machines are
being operated under normal working conditions.
We do recommend, however, that as conditions can vary considerably from site to site, the instructions
given in the schedules should be reviewed and if necessary amended by a qualified engineer, after the
equipment has been in operation for approximately one year.

Care should be taken to ensure all the inspection and maintenance work is carried out in a clean
environment. The equipment to be serviced together with nearby plant should be thoroughly cleaned prior
to commencement of work.

Lubrication schedule given under this section should be strictly followed for optimum performance of the
machine.

MAINTENANCE SCHEDULE
SL. ITEM PROCEDURE DAILY WEEKLY MONTHLY EVERY EVERY ANNUALLY
NO. THREE SIX
MONTHS MONTHS
1.1 WAGON
TIPPLER
1. End Frames, (1) Clean down steelwork X
platform, Side & examine for damage or
beam, Movable defects.
side beam, End (2) Examine all bolted X
ring rail of SUT connections and ensure
wagon tippler they are securely fastened
(3) Visually inspect all X
welded connections
(4) Clean down platform X
(5) Examine condition of X
paint work
(6) Check movable side X
beam wear plates.
(7) Movable side pad
cylinder movement & X
Link hinge movement
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS DOCUMENT NO DATE REV-A

(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16 dated:
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER. 3 OF 11
SAB/PHL AN/RG

SL. ITEM PROCEDURE DAILY WEEKLY MONTH EVERY EVERY ANNUALLY

NO. LY THREE SIX
MONTHS MONTHS
2. Drive Gear of Wagon tippler
a) Hydraulic As per Manufacturer's X
motors recommendation (given in
volume II)
b) Rack and Check proper matching of X
pinion tooth and tooth wear.
NOTE: For periodic maintenance of drive pinions & bearings of wagon tippler-drive, "Rotation Maintenance
Lock Assembly" is to be mounted on the drive unit & it is to be used to hold the end-frames into the required
position.
3. Clamp gear of Check level & wear of clamp X
Wagon tippler beam contact pad at clamp
arm.
Check bushes & spherical X
roller bearing at all hinge
joints
a) 2 nos. Clamp As per Manufacturer's X
Beam cylinder & recommendation (given in
Clamp volume II) satisfactory
Hydraulic working of clamp movement
Cylinder (6 nos.) should be checked.
4. Rail of Check its level and alignment X
Platform assly.
5. Limit switches Check for proper function LH X
& Photo Cell End & RH end
Hose Loop Bkt.
For SUT Check the hose clamps X
6. Tippler
7. Inhaul wheel As per manufacturer's X
chock & Out recommendation (given in
haul wheel volume II)
chock Satisfactory working of stop
Hydraulic movement should be checked.
cylinder
8. Hydraulic As per manufacturer's X
power pack recommendation (given in
volume II)
9. Chain & Check freeness in chain X
Sprocket of movement.
Rotary Cam Clean any dust accumulation
Limit Switch
10. Wheel Gripper Check smooth movement of X
the cylinder as per
manufacturers
recommendation.
11. Wheel Gripper Check smooth movement of X
all hinge joint.
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS DOCUMENT NO DATE REV-A

(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16 dated:
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER. 4 OF 11
SAB/PHL AN/RG

12. Platform Hook Check smooth movement of X

Hook.
13. Platform Hook Check bush of platform hinge. X
14. Platform Check bush & smooth X
Roller, V- movement.
Block,
Longitudinal/L
ateral

SIDE ARM CHARGER:-

SL. ITEM PROCEDURE DAILY WEEKLY MONTHLY EVERY EVERY ANNUALLY
NO. THREE SIX
MONTHS MONTHS
2.1 SIDE ARM CHARGER
1 Main Frame, 1) Clean down steel work
Access and examine for damage X
Platform, Arm or defects
& Arm Hoist 2) Examine all bolted
Assembly. connections and ensure
X
they are securely
fastened.
3) Visually inspect all
X
welded connection
2. Travel Drive
a)Hydraulic As per Manufacturer's
motor recommendation(given in
volume II)
b) Rack Check for any wear X
c) Drive pinion Check for any wear. X
3. ARM HOIST
a) Arm Hoist Check the smooth
structure movement and final X
position of Arm-Hoist.
b) Arm Luffing As per manufacturer's
Hydraulic recommendation (given in
Cylinder volume II) satisfactory X
working of luffing should
be checked.
c) Arm Head Proper alignment and
Buffer smooth functioning of
X
rubber springs need to be
checked.
d) Arm As per manufacturer's
uncoupling recommendation (given in
hydraulic volume II). Satisfactory
cylinder working of decoupling X
should be checked.
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS DOCUMENT NO DATE REV-A

(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16 dated:
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER. 5 OF 11
SAB/PHL AN/RG

4. Charger Check proper

Track tightening of fasteners X
and condition of track.
5. Hydraulic As per manufacturer's
Power Pack recommendation (given
in volume II)

SL. ITEM PROCEDURE DAILY WEEKLY MONTHLY EVERY EVERY ANNUALLY

NO. THREE SIX
MONTHS MONTHS

TWO/FOUR WHEEL CHOCK ASSEMBLY:-

3.1
a) Hydraulic Check the smooth X
Cylinder movement and final
position of wheel chock
arm
b) Hydraulic As per manufacturer's
power pack recommendation (given
for wheel in volume II)
chock
c) Four/two Check for water X
wheel choke clogging inside the pit
pit due to jamming of
drainage system.
Because track switches
& other electrical
devices like proximity
switches are attached
with wheel chock &
these items are
damaged at the time
water clogging.
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS DOCUMENT NO DATE REV-A

(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16 dated:
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER. 6 OF 11
SAB/PHL AN/RG

LUBRICATION SCHEDULE:-

The schedule is produced in the form of a table, each assembly heading containing its relevant assembly
title and drawing number. The table is divided into a series of columns, listing: description of item, no. of
units, where applicable, lubrication facility, frequency, lubricant grade, and remarks.
Lubrication interval for each item is entered in the frequency column, and is presented in the following
abbreviated form. Wherever, the abbreviation is preceded by a letter C, a check is all that is normally
required.

Period Abbreviation Remarks

As required A/R
Weekly W
Monthly M
Six Monthly 6M
Annually A
Overhaul O/H Usually at two or three year intervals.

Sl. ITEM Nos. of Facility Frequency Lubricant Remarks

No. Feeding Grade
Points
1. WAGON TIPPLER Drg. No.
O14195-M-BM-EQ-GA-5001
1.1 Clamp Gear
a) SKF Spherical Roller 4 Grease W SERVOGEM Grease Nipples
bearing – Clamp main pivot Gun EP-2 (of at each end of
shaft I.O.C.) cover plate

Sl. ITEM Nos. of Facility Frequency Lubricant Remarks

No. Feeding Grade
Points
1.2. Tippler Drive gear
assembly.
a) Spherical Roller Bearings 4 Grease W SERVOGE Grease Nipples
– pinion shaft Gun M EP-2 (of on upper half of
I.O.C.) bearing housing
O/H Clean out and
repack to 60%
capacity
b) Drive Rack - Brush W SERVOCO Lubricate in
AT – 140 (of conjunction with
I.O.C.) drive pinion.
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS DOCUMENT NO DATE REV-A

(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16 dated:
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER. 7 OF 11
SAB/PHL AN/RG

6M SERVOCOAT Clean off old

– 140 (of
I.O.C.) lubricant &
apply new.
c) Drive Motor (Hydraulic) - - - - No separate
with brake lubrication is
necessary.
d) Drive Pinion - Brush W SERVOCOAT Lubricate in
– 140 (of
I.O.C.) conjunction with
drive rack
sections
6M SERVOCOAT Clean off old
– 140 (of
I.O.C.) lubricant &
apply new.
Note : a) being inaccessible, these points are piped to a common feed point on drive unit. Total 4
such Group lubrication systems, one each for each drive system.
1.3. Tippler Main Pivot
assembly.
a) Spherical Roller Bearings 4 Grease W SERVOGEM Grease Nipples
EP-2 (of I.O.C.)
– pinion shaft Gun on upper half of
bearing housing
1.4. Platform Support
assembly.
a) Support roller & Guide 9 Grease W SERVOGEM Grease Nipples
EP-2 (of I.O.C.)
roller of Platform Support Gun at each end of
assly. pin
b) Platform hook assly. 2 Grease W SERVOGEM Grease Nipples
EP-2 (of I.O.C.)
Gun at one end of
Platform hook
pin

Sl. ITEM Nos. of Facility Frequenc Lubricant Remarks

No. Feeding y Grade
Points
b) Short link chain - Brush W SERVOCOAT Lubricate in
– 140 (of conjunction with chain
I.O.C.) & D-shackle & whole
body of chain
1.5. Rotational Limit As As As All lubrication
Switches recomme recomme recommende procedures to be
nded nded d performed as specified
by manufacturer
(Refer Vol.2 Electrical
item leaflets).
1.6 Wheel Gripper 8 Grease W SERVOGEM Grease Nipples at each
hinge point Gun EP-2 (of end of pin
I.O.C.)
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS DOCUMENT NO DATE REV-A

(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16 dated:
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER. 8 OF 11
SAB/PHL AN/RG

2. SIDE ARM CHARGER:-

(Drg. No. O14195-M-BM-EQ-GA-5002)

Sl. ITEM Nos. of Facility Frequenc Lubricant Remarks

No. Feeding y Grade
Points
2.1 Support Roller
a) Roller Bearing 8 Grease W SERVOGE
Gun M EP-2 (of
I.O.C.)
2.2 Charger Arm
a) Bush-Arm pivot 2 Grease W SERVOGE Grease nipples
Gun M EP-2 at each end of
pivot shaft

Sl. ITEM Nos. of Facility Frequency Lubricant Remarks

No. Feeding Grade
Points
2.3 Charger Arm Head
a) Guide 4 Grease W SERVOGEM Grease
Gun EP-2 Nipples
located on
side faces of
guide
2.4 Guide Rollers
Roller Bearing / Ball 4 Grease W SERVOGEM
bearing Gun EP-2
O/H Clean out then
repack to 60%
capacity
2.5 Travel Drive
a) Drive Motor (Hydraulic) 3 - - - No separate
lubrication is
necessary.
b) Rack Section - Brush M SERVOCOAT Lubricate in
– 140 conjunction
with drive
pinion (three
no.)

Brush O/H SERVOCOAT Clean off old

– 140 lubricant and
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS DOCUMENT NO DATE REV-A

(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16 dated:
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER. 9 OF 11
SAB/PHL AN/RG

apply new.
2.6 Charger Arm Luffing
a) Hydraulic cylinder 1 - - - No separate
lubrication is
necessary.
Arm raise link 6 Grease W SERVOGEM Grease nipples
Gun EP-2 at one end of
link & pivot
2.7 Charger Arm Assly.
a) Coupler spring shaft- Arm 3 Grease W SERVOGEM Grease nipples
end + Buffing arm end Gun EP-2 at one end of
sph. plain
bearing at arm
end & both
end of buffing
arm head
pivot pin at
buffing end
b) Buffing arm hinge point 2 Grease W SERVOGEM Grease nipples
Gun EP-2 at both end of
buffing arm
tail pivot pin

Sl. ITEM Nos. of Facility Frequency Lubricant Remarks

No. Feeding Grade
Points
2.8 Two/Four Wheel chock
arrangement

a) Link pivot pin 1 Grease W SERVOGEM Grease Nipples

Gun EP2 / of at one end of
I.O.C. pivot pin.
b) Arm pivot pin 1 Grease W SERVOGEM Grease Nipples
Gun EP2 / of at one end of
I.O.C. pivot pin.
c) Clevis pivot pin 1 Grease W SERVOGEM Grease Nipples
Gun EP2 / of at one end of
I.O.C. pivot pin.
d) Pivot pin 1 Grease W SERVOGEM Grease Nipples
Gun EP2 / of at one end of
I.O.C. pivot pin.
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS DOCUMENT NO DATE REV-A

(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16 dated:
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER. 10 OF 11
SAB/PHL AN/RG

ELECTRICAL INSTRUCTIONS :

General
The conditions likely to affect the efficient operation of the control equipment are :
(a) The presence of dirt or moisture within the enclosure.
(b) Wear and tear of moving parts and contact surfaces of electro-mechanical
devices.
The maintenance program has been devised to prevent breakdown of any devices by the above conditions
These instructions, however, only generally cover components which are repairable. Any other unit
becoming unserviceable should be replaced in its entirety.
WARNING
BEFORE WORKING ON ANY PART OF THE MACHINES IT IS ESSENTIAL THAT ALL
EQUIPMENT INCLUDING ITS ASSOCIATED CONVEYOR BELOW IS MECHANICALLY AND
ELECTRICALLY ISOLATED IN ACCORDANCE WITH THE HEALTH AND SAFETY
REGULATIONS.

HYDRAULIC INSTRUCTIONS :
In addition to the instructions given in Hydraulic Power Pack & Cylinder Manual (Vol. 2), please check the
following :
1. Oil Level
a) Oil level should not fall below the range of sight glass of oil reservoir. This should be checked
daily.
b) Float switch should be checked periodically for proper functioning.
2. Oil Temperature
Thermostat should be checked periodically for proper functioning by reducing the setting temperature
to atmospheric temperature.
3. Oil Filtration
a) Check the condition of the filters daily. If the clogging indicator is in rcd zone, it indicates that the
filter is clogged and needs replacement. A supply of filter cartridges in their original packaging
should be kept at the machine.
b) In case of frequent clogging of filter either centrifuge the oil or replace the oil. Addition of oil
must be thro' an oil filter. Laboratory test to find out contamination level is recommended.
c) Periodically open the drain valve gradually and drain off any water that might have separated from
oil.
d) When the fluid contamination level is not continuously monitored, change oil every 2000
operating hours or at least once a year or as indicated by laboratory tests. Clean the reservoir
before refilling.
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS DOCUMENT NO DATE REV-A

(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16 dated:
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER. 11 OF 11
SAB/PHL AN/RG

4. Air Breather
a) Never leave the air breather open.
b) As a general rule, carry out maintenance of breather at the same time as oil filter.
5. Oil Cooler
The cooler tubes should be cleaned annually.
6. Hydraulic Lines & Fittings
Visually check daily for wear, damage or any fluid leakage. Tighten, repair or replace as required. Also
check for collapsed suction compensators.

7. Interlock
Check at least once a month that the safety interlocks condition i.e., if the clamps do not engage by
80 deg. tippler rotation, tipping should stop.

NOTE
1. DO NOT RUN THE TIPPLER IN MAINTENANCE MODE WITH WAGON.
2. DO NOT TIP WITH THE CLAMPS IN FULLY RAISED CONDITION IN MAINTENANCE
MODE.
3. DO NOT RE-START THE TIPPLER WHICH IS TRIPPED BY OVER TRAVEL LIMIT SWITCH
WITHOUT INVESTIGATING THE CAUSE; SPECIALLY, CHECK THE CONDITION OF
ROTARY CAM LIMIT SWITCH.
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

DOCUMENT NO DATE
PROJECT : 2 x 660 MW SUPER CRITICRAL TPS
(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER 1 OF 4
SAB/PHL AN/RG

SECTION – IV

LIST OF GA DRAWINGS
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

DOCUMENT NO DATE
PROJECT : 2 x 660 MW SUPER CRITICRAL TPS
(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER 2 OF 4
SAB/PHL AN/RG
LIST OF DRAWINGS FOR WAGON TIPPLER

Sl.No. Description Drg. No. Wt per Parts

M/C List
(in kgs) sheet
no
1. G.A of SUT Wagon Tippler O14195-M-BM-EQ-GA-5001 - -

2. Load data & foundation details of O14195-M-BM-EQ-GA-5003 - -

SUT Wagon Tippler (2 Sheets)
3. GA of LH End Frame O13057-M-BM-EQ-GA-5400 11
24431
4. GA of RH End Frame O13057-M-BM-EQ-GA-5414 24431 12
5. GA of Drive Rack assly. (Sht 1 & 2) O13057-M-BM-EQ-GA-5320 5897 13
6. GA of Drive Gear assly. O13057-M-BM-EQ-GA-5321 7142 14
7. GA of Clamp Gear assly. O13057-M-BM-EQ-GA-5525 17477 15
8. GA of side Beam for SUT WT O13057-M-BM-EQ-GA-5296 16

9.
16809
GA of side Beam for SUT WT O13057-M-BM-EQ-GA-5297 16

10. GA of movable side beam assly for O14195-M-BM-EQ-GA-5362 17

17753
SUT Tippler (Sht 1 & 2)
11. GA of Main Pivot assly. (Sht 1 & 2) O14195-M-BM-EQ-GA-5315
5671 18

12.
GA & detail of platform assly. O14195-M-BM-EQ-GA-5300 19
19084
13.
GA & detail of platform assly. O14195-M-BM-EQ-GA-5301 19
14. GA of Platform Support assly. &
O14195-M-BM-EQ-GA-5305 20
Retaining hook for SUT WT
15.
2045
GA of Platform Support assly. &
O14195-M-BM-EQ-GA-5306 20
Retaining hook for SUT WT
16. GA of Platform & Walkway for SUT
Wagon Tippler O14195-M-BM-EQ-GA-5343 2978 21
17. GA & Detail of hook restraining 22
O14195-M-BM-EQ-GA-5310 74
bracket and end thrust pads
18. Mechanicals for over travel limit 23
O14195-M-BM-EQ-GA-5273 73
switches for SUT
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

DOCUMENT NO DATE
PROJECT : 2 x 660 MW SUPER CRITICRAL TPS
(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER 3 OF 4
SAB/PHL AN/RG
Sl.No. Description Drg. No. Wt per Parts
M/C List
(in kgs) sheet
no
19. GA of wheel grippers for SUT Tippler O14195-M-BM-EQ-GA-5425 4538 25
20. GA of Wagon tippler power pack O14195-M-BM-EQ-VR-5738
21. Hydraulic circuit for Wagon tippler
O14195-M-BM-EQ-VR-5739
power pack for drive & clamp
22. O13057-M-BM-EQ-GA-5570
Manual grease lubrication for WT
& GA-5571
23. Hose & cable loop bracket O13057-M-BM-EQ-GA-5603
24. Chain & sprocket arrangement for
O13057-M-BM-EQ-GA-5271
rotating cam limit switch
25. Platform down limit switch
O13057-M-BM-EQ-GA-5270
arrangement for SUT
26. GA of four wheel chock assly. O11077-M-BM-EQ-GA-5327
27. GA of two wheel chock assly. O11077-M-BM-EQ-GA-5325
28. Hydraulic circuit for four wheel chock
power pack O14195-M-BM-EQ-VR-5786
29. Hydraulic circuit for two wheel chock
power pack O14195-M-BM-EQ-VR-5776
30. GA of four wheel chock power pack O14195-M-BM-EQ-VR-5785
31. GA of two wheel chock power pack O14195-M-BM-EQ-VR-5775
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

DOCUMENT NO DATE
PROJECT : 2 x 660 MW SUPER CRITICRAL TPS
(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER 4 OF 4
SAB/PHL AN/RG

LIST OF DRAWING FOR 50T SIDE ARM CHARGER

Sl.No. Description Drg. No. Wt per M/C Parts List

(in kgs) sheet no.

1. GA of Side arm charger O14195-M-BM-EQ-GA-5002 - -

2. Load data & foundation details O14195-M-BM-EQ-GA-5004
of long arm side arm charger (3 - -
sheets)
3. Fixed support roller assly. for
O14172M-BM-EQ-GA-5178 11
SAC
1324
4. Sprung support roller assly. for
O14172-M-BM-EQ-GA-5179 11
SAC
5.
Guide roller assly. O14172-M-BM-EQ-GA-5252 3157 12
6.
Charger Arm assly. O14195-M-BM-EQ-GA-5198 5178 13
7. Charger drive rack assly. O14172-M-BM-EQ-GA-5210 2081 14
8. Coupler & charger arm head
O14195-M-BM-EQ-GA-5575 342 16
assly.
9. Main frame assly. for SAC O14195-M-BM-EQ-GA-5148 17
10. Main frame assly. for SAC
15633
O14195-M-BM-EQ-GA-5149 17
11. Fixed support roller frame O14172-M-BM-EQ-GA-5180 228 19
12. Sprung support roller frame O14172-M-BM-EQ-GA-5189 243 20
13. O14195-M-BM-EQ-GA-5512
GA of Cylinder support frame 1676 21
& GA-5513
14. Assembly of access & stair way,
power pack support frame & O14195-M-BM-EQ-GA-5244 1059 23
drag chain support
15. Key Plan & G.A of Rack, spine bar
O14195-M-BM-EQ-GA-5284 36899 25
& support
16. Rack for Charger drive O13057-M-BM-EQ-GA-5288 - -
17. Hydraulic circuit of SAC O14195-M-BM-EQ-VR-5763 - -

18. GA of Hydraulic power pack O14195-M-BM-EQ-VR-5761 - -

& VR-5762
19. Track limit switch & bracket O13057-M-BM-EQ-GA-5360
arrangement for sac (2 sheets)
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS DOCUMENT NO DATE

(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER 1 OF 3
SAB/PHL AN/RG

SECTION –V

SAFETY INSTRUCTIONS
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS DOCUMENT NO DATE

(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER 2 OF 3
SAB/PHL AN/RG

INTRODUCTION :
The equipment supplied to this contract has been carefully inspected at various stages during its
manufacture to ensure a satisfactory standard of work. Inspections are also carried out during
assembly, and again at site when erection to ensure equipment is in serviceable condition.
Thereafter, only operating the plant properly and working to a planned maintenance procedure
(under supervision of qualified personnel) will keep it in a safe and efficient working order.

This manual provides the necessary information to establish a routine system of maintenance
based on good common-sense procedures and our own experiences. It must be remembered
however, that each maintenance procedure could carry its own safety hazard, and we expect that
all your personnel should be properly trained in the necessary skills and be able to recognize
safety hazards as and when they exist.
WARNING :
a) BEFORE WORKING ON ANY PART OF THE SUT WAGON TIPPLER & SIDE ARM
CHARGER MACHINE, IT IS ESSENTIAL TO ENSURE ALL EQUIPMENTS BELOW
ARE MECHANICALLY AND ELECTRICALLY ISOLATED IN ACCORDANCE WITH
THE HEALTH AND SAFETY AND SITE REGULATIONS.
b) THE CONTROL PANEL IS PROVIDED WITH COMPONENTS FED FROM SEPARATE
SOURCES. THE PARTICULAR SOURCE MUST BE ELECTRICALLY ISOLATED
BEFORE CARRYING OUT ANY WORK ON THIS SECTION.
c) ENSURE OPERATING INSTRUCTIONS AS GIVEN IN SECTION II (CONTROL WRITE-
UP) ARE COMPLIED WITH WHEN TAKING THE SUT WAGON TIPPLER OR SIDE
ARM CHARGER IN AND OUT OF SERVICE.

GENERAL GUIDANCE ON SAFETY PRECAUTIONS

All operating and maintenance work must be carried out according to the Health and Safety Act
and site regulations.
From our experience we draw your attention to some of the more common precautions that should
be taken to prevent accidents.
( 1 ) Protective equipment, i.e., safety helmets, overalls, footwear, gloves, safety goggles MUST
be worn when carrying out maintenance or repairs.
(2) No machinery should be operated with any guard panels or inspection doors left open.
(3) Temporary guarding or scaffolding required whilst maintenance or repair work is being
carried out MUST be to standards laid down in statutory regulations.
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS DOCUMENT NO DATE

(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER 3 OF 3
SAB/PHL AN/RG

(4) Personnel MUST only use designated platforms and ladders.

(5) Platforms and ladders MUST be kept in a clean condition and free from obstructions.
(6) Any remedial work which involves lifting or dismantling of heavy machinery or making
safe equipment whilst repairs are carried out MUST be supervised by qualified experienced
personnel.
(7) All lifting tackles MUST be approved and tested to withstand loads being raised as laid
down in statutory regulations.
(8) A qualified experienced engineer MUST be consulted before removing or replacing any
major component of the equipment to avoid the possibility of affecting the stability of the
machine or overstressing of any structural member or machinery.
(9) The machines MUST be kept clean and free from any materials which could cause a fire,
dust or explosive hazard.
(10) The safety officer should be consulted before commencing any work which may cause a
fire, i.e. welding, drilling, grinding etc.
(11) After maintenance or repair work has been completed, checks MUST be made to ensure all
tooling, lifting tackles or any articles which could cause injury or damage are removed from
the machines and their working area.
(12) All guarding and inspection panels must be replaced before the plant is put into
commission.
IF IN DOUBT, CONSULT YOUR SAFETY OFFICER.
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS DOCUMENT NO DATE REV-A

(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16 Dated:
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER. 1 OF 2
SAB/PHL AN/RG

SECTION –VI

STORAGE INSTRUCTIONS
LARSEN & TOUBRO LIMITED
ECC Division – EDRC

PROJECT : 2 x 660 MW SUPER CRITICRAL TPS DOCUMENT NO DATE REV-A

(SURATGARH, STAGE – V, UNIT # 7 & 8) L&T - O14195-M-BM-EQ-DC-5027 07.03.16 Dated:
(SUT & SAC).

TITLE : OPERATION & MAINTENANCE MANUAL DESIGNED CHECKED SHEET

OF SUT & 50T SIDE ARM CHARGER. 2 OF 2
SAB/PHL AN/RG

STORAGE OF MATERIAL DURING ERECTION

On arrival at site each component and accessories should be stored as follows :
a) Under cover at a stable temp. (Between 0 and 50 deg.)
b) Away from strong sunlight.
c) In a clean and dry environment.
d) Free from vibration.
e) Heating should be provided if there is a possibility of condensation.

1. It is recommended that the equipment be stored in its original packing and only sufficient
covering be removed to enable necessary inspections etc. to be carried out.
2. After completion of any work the covering should be replaced No unauthorized personnel
should be allowed access to the machine whilst it is in storage.
3. Although the machines and its accessories have been protected for storage, we recommend
that due to possible damage etc., during transit that the following precautions be taken at
regular intervals throughout the storage period :
4. Visually check all components for signs of corrosion. If necessary, treat with suitable
anticorrosion inhibited
5. Should any component be disassembled machine surface must be protected by a suitable rust
inhibitor.
STORAGE OF MATERIAL AFTER COMMISSIONING OF PLANT
The Rotational Maintenance Lock Assembly to be stored near to drive-area when the tippler is in
operation. This item will be used only for maintenance of drive pinion/bearings.
2 x 660 MW, RRVUNL SUPER TPS Unit - 7 & 8
PROJECT :
FIELD QUALITY PLAN PACKAGE
SURATGARH
: CHP - CONVEYOR PACKAGE
Item FQP FOR COAL HANDLING PLANT BHEL FQAP NO IS-4-QP-843-111-M064 CLIENT : RRVUNL
BEVON WAYORS PVT. LTD Order No: 77/14/0209/MVG Revision R1
CLIENT
: TCE, BANGALORE
Corp. off: H-11, IDA, Uppal, CONSULTANT
Hyderabad-500039, Works: EPC
Date 24-08-2015 : BHEL-ISG, Bangalore
139, IDA, Phase-III, CONTRACTOR
Cherlapally, Hyderabad- INSPECTION
Page 1 OF 2 CAT-3
500051 CATEGORY
EQUIPMENT / QUANTUM OF REFERENCE INSPECTION AGENCY
S. NO CHARACTERISTICS TYPE OF CHECK ACCEPTANCE NORMS TYPE OF RECORD D REMARKS
COMPONENT CHECK DOCUMENTS M B C
DELIVERY CHALLAN/ INSPECTION DELIVERY CHALLAN/
1 RECEIPT OF MATERIAL CHECK WITH MDCC 100% SITE PROTOCAL √ √ √ √
INSPECTION REPORT REPORT INSPECTION REPORT
2 STORAGE OF MATERIAL -- -- -- -- -- SITE PROTOCAL √ P W W
INSPECTION
3 FOUNDATION BOLTS ALIGNMENT DEIMENSIONS 100% TEMPLATE SITE PROTOCAL √ P W W
REPORT

ASSEMBLY OF HEAD ORIENTATION ,

4 DIMENSIONS 100% DRAWINGS DRAWINGS SITE PROTOCAL √ P W W
FRAMES & TAIL FRAMES ALIGNMENT

FITMENT OF PULLEYS
5 WITH BEARINGS & ALIGNMENT VISUAL 100% DRAWINGS DRAWINGS SITE PROTOCAL √ P W W
BLOCKS
INSPECTION
6 WELDING WELD FILLET SIZES VISUAL, MEASUREMENT 100% DRAWINGS DRAWINGS √ P W W
REPORT

ASSEMBLY OF STRINGERS
7 ALIGNMENT, STRIGHTNESS VISUAL, MEASUREMENT 100% DRAWINGS DRAWINGS SITE PROTOCAL √ P W W
, SHORT SUPPORTS

ASSEMBLY OF BRACKETS
8 ALIGNMENT, STRIGHTNESS VISUAL, MEASUREMENT 100% DRAWINGS DRAWINGS SITE PROTOCAL √ P W W
& IMPACTPADS/IDLERS

ASSEMBLY OF SKIRT ALIGNMENT , MATCHING

9 VISUAL & MEASUREMENT 100% DRAWINGS DRAWINGS SITE PROTOCAL √ P W W
BOARDS, DECK PLATES OF MATING HOLES
ASSEMBLY OF DRIVES
WITH GEARBOX, HIGH
SPEED COUPLING ,
10 MOTOR, LOW SPEED ALIGNMENT/ LUBRICATION VISUAL & MEASUREMENT 100% DRAWINGS DRAWINGS SITE PROTOCAL √ P W W
COUPLINGS, ELECTRO
HYDRAULIC TRUSTER
BRAKE
INSPECTION
11 WELDING WELD FILLET SIZES VISUAL, MEASUREMENT 100% DRAWINGS DRAWINGS √ P W W
REPORT
ERECTION OF CHUTES, ALIGNMENT , MATCHING
12 VISUAL & MEASUREMENT 100% DRAWINGS DRAWINGS SITE PROTOCAL √ P W W
HOPPERS OF MATING HOLES
ERECTION OF GATES
ALIGNMENT , ORIENTATION
( RACK&PINION GATE,
13 & MATCHING OF MATING VISUAL & MEASUREMENT 100% DRAWINGS DRAWINGS SITE PROTOCAL √ P W W
DIVERTOR GATE, ROD
HOLES
GATE, FLAP GATE )
14 TRAVELLING TRIPPER ALIGNMENT VISUAL & MEASUREMENT 100% DRAWINGS DRAWINGS SITE PROTOCAL √ P W W
CURRENT OUTPUTS,
TRAVELLING TRIPPER NO
15 TRACKING OF BELT , FREE VISUAL , MEASUREMENT 100% DRAWINGS DRAWINGS SITE PROTOCAL √ P W W
LOAD TRAILS
RUNNING,
INSPECTION
16 WELDING WELD FILLET SIZES VISUAL, MEASUREMENT 100% DRAWINGS DRAWINGS √ P W W
REPORT
17 COAL SAMPLING UNIT CONSTRUCTION MEASUREMENT 100% DRAWINGS DRAWINGS SITE PROTOCAL √ P W W
2 x 660 MW, RRVUNL SUPER TPS Unit - 7 & 8
PROJECT :
FIELD QUALITY PLAN PACKAGE
SURATGARH
: CHP - CONVEYOR PACKAGE
Item FQP FOR COAL HANDLING PLANT BHEL FQAP NO IS-4-QP-843-111-M064 CLIENT : RRVUNL
BEVON WAYORS PVT. LTD Order No: 77/14/0209/MVG Revision R1
CLIENT
: TCE, BANGALORE
Corp. off: H-11, IDA, Uppal, CONSULTANT
Hyderabad-500039, Works: EPC
Date 24-08-2015 : BHEL-ISG, Bangalore
139, IDA, Phase-III, CONTRACTOR
Cherlapally, Hyderabad- INSPECTION
Page 2 OF 2 CAT-3
500051 CATEGORY
EQUIPMENT / QUANTUM OF REFERENCE INSPECTION AGENCY
S. NO CHARACTERISTICS TYPE OF CHECK ACCEPTANCE NORMS TYPE OF RECORD D REMARKS
COMPONENT CHECK DOCUMENTS M B C
COAL SAMPLING UNIT
AS PER
18 APPARATUS FOR COAL SET IN ORDER SET IN ORDER 100% AS PER REQUIREMENT SITE PROTOCAL √ P W W
REQUIREMENT
ANALYSIS
IN-LINE MAGNETIC
19 ALIGNMENT VISUAL & MEASUREMENT 100% DRAWINGS DRAWINGS SITE PROTOCAL √ P W W
SEPERATOR
20 METAL DETECTOR ALIGNMENT VISUAL & MEASUREMENT 100% DRAWINGS DRAWINGS SITE PROTOCAL √ P W W
21 BELT WEIGHER ALIGNMENT VISUAL & MEASUREMENT 100% DRAWINGS DRAWINGS SITE PROTOCAL √ P W W
BELT VALCANISING
22 ALIGNMENT VISUAL & MEASUREMENT 100% DRAWINGS DRAWINGS SITE PROTOCAL √ P W W
MECHINE
23 BELT SCRAPPER ALIGNMENT VISUAL & MEASUREMENT 100% DRAWINGS DRAWINGS SITE PROTOCAL √ P W W
24 MONO RAIL & HOIST ALIGNMENT VISUAL & MEASUREMENT 100% DRAWINGS DRAWINGS SITE PROTOCAL √ P W W

VGTU & HGTU

25 ALIGNMENT, STRIGHTNESS VISUAL, MEASUREMENT 100% DRAWINGS DRAWINGS SITE PROTOCAL √ P W W
SUPPORTING STRUCTURE

INSPECTION
26 WELDING WELD FILLET SIZES VISUAL, MEASUREMENT 100% DRAWINGS DRAWINGS √ P W W
REPORT
ASSEMLY OF SWITCHES &
OTHER INTRUMENTS ( ALIGNMENT, ORIENTATION,
VISUAL,
27 BELT SWAY, PULL CORD, LOCATION, 100% DRAWINGS DRAWINGS SITE PROTOCAL √ P W W
CHECKS/MEASUREMENTS
ZERO SPEED) & OTHER ASSEMBLY
INSTRUMENTS

ELECTRICALS LIKE CABLES, ALIGNMENT, ORIENTATION,

VISUAL,
28 CONTROL PANELS, LT AESTHETICS,LOCATION, 100% DRAWINGS DRAWINGS SITE PROTOCAL √ P W W
CHECKS/MEASUREMENTS
MCC & PLC PANNEL ETC ASSEMBLY

CURRENT OUTPUTS,
NO LOAD TRIALS FOR
29 TRACKING OF BELT , FREE VISUAL , MEASUREMENT 100% DRAWINGS DRAWINGS SITE PROTOCAL √ P W W
CONVEYORS
RUNNING
CURRENT OUTPUTS,
30 LOAD TRIALS REQUIRED OUT PUTS OF VISUAL, MEASUREMENT 100% DRAWINGS DRAWINGS SITE PROTOCAL √ P W W
MATERIALS
10 %
31 PAINTING DFT VISUAL. MEASUREMENT DRAWINGS DRAWINGS SITE PROTOCAL √ P W W
RANDOM

Note:D*: 1) Records identified with "Tick" shall be essentially included by Manufacturer/Subcontractor in QA Documentation

2) Material Specification shall be as per Approved drawing/data sheet/manufacturer's drawing only.

3) All inspection/verification/NDT reports along with material certificates shall be reviewed by RRVUNL at the time of witness point.

4) The inspection agency/inspector shall be provided with the latest drawings.

LEGEND
* M: Manufacturer / Subcontractor ; "B" : BHEL / BHEL Nominated Inspection Agency
"C": RRVUNL / RRVUNL Nominated Inspection Agency Reviewd by:
"P" Perform by Mfg "W" Witness & "V" Verification of Records by Customer
TC: Test Certificate
Manufacturer /
MAIN SUPPLIER IR: Inspection Report NDT: Non Destructive Test UT: Ultrasonic Test CUSTOMER USE:
SubContractor
BHARAT HEAVY ELECTRICALS LTD
INDUSTRIAL SYSTEMS GROUP CAT-1 BHEL/RRVUNL OR 3 RD PARTY
CAT-2 BHEL CAT-3 MANUFACTURER
(COAL HANDLING PLANT)

This approval status shall be interpreted as laid down in the contract and
it shall not relive the contractor form the contractual obligation.
Reviewed & Submitted for
CAT I - Approval
CAT II & III - Information
CAT IV - Reference
Name
Lovekush Verma
Engineer
Bharat Heavy Electricals
Limited
ISG-BG 1A-CHP
Bangalore -560012
FIELD QUALITY PLAN

FOR

AIR CONDITIONING SYSTEM

(FABRICATION & ERECTION)

FOR

2 X 660MW SUPERCRITICAL POWER

PROJECT RRVUNL, SURATGARH

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR - EASTERN REGION

DOC. NO: QPE:SRG:660:EL:002

REV. NO: R01
FIELD QUALITY PLAN
FOR

AIR CONDITIONING SYSTEM

(FABRICATION & ERECTION)

FOR

2 X 660MW SUPERCRITICAL POWER

PROJECT RRVUNL, SURATGARH

PREPARED BY APPROVED BY
Dy.Engr./QLY, PSER AGM/QLY, PSER
FQP NO. QPE:SRG:660:EL:002
ORIGINAL DATE OF ISSUE 29.06.2016
REVISION NO. & DATE R01 / 20.10.2016
COPY NO.
ISSUED TO
DATE OF ISSUE
CONTROLLED / INFORMATION COPY
ISSUED BY
(SIGN. & DESIG.)

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR - EASTERN REGION
Performance
Test ( earlier
commented-
include)
Performance
Test ( earlier
commented-
include)
INSTRUMENT REG. NO./TAG NO.

DATE OF INSPECTION

PSER-QLY
DRAWING / DOCUMENT REF.

PROTOCOL

SIGNATURE &
NAME
DATE
FQP NO: QPE:SRG:660:EL:002

RRVUNL, INSPECTED
PROJECT
Suratgarh BY
REV. NO.: R01

CLEARED
UNIT NO.
BY
PROTOCOL NO.

RATING 2X660 MW CUSTOMER PAGE: 1 OF 1

For Piping refer LP
piping
QPE:SRG:660:
PP:72
F
FIELD
D QU
UALIITY PLAN
N

FOR

PRE
R TRE NT PLA
EATMEN ANT
(FA
ABRICAT
TION & ERECTIO
E ON)

FOR

2 X 660MW
6 W SUP
PERCR
RITICA
AL PO
OWER
PROJJECT RRVU
R UNL, SUR RATGA ARH

BH
HARAT
T HEA
AVY ELECT
E TRICA
ALS LIMIT
L ED
P
POWER SEC
CTORR - EA
ASTER EGION
RN RE

DOC
C. NO: Q
QPE:SRG
G:660:BR
R:002
R
REV. NO: R01
F
FIELD
D QU
UALIITY PLAN
N
FOR

PRE
R TRE NT PLA
EATMEN ANT
(FA
ABRICAT
TION & ERECTIO
E ON)

FOR

2 X 660MW
6 W SUP
PERCR
RITICA
AL PO
OWER
PROJJECT RRVU
R UNL, SUR RATGA ARH

PREPA
ARED BY AP
PPROVED BY
Dy.Engr./QLY, PSER AG
GM/QLY, PSER
P
FQP N
NO. QP
PE:SRG:660:BR:00
02
ORIGIINAL DAT
TE OF ISS
SUE 04.07.2016
REVIS
SION NO. & DATE R01 / 04.07
7.2016
COPY NO.
ISSUE
ED TO
DATE OF ISSUE
E
CONTR
ROLLED / INFORM
MATION COPY
ISSUE
ED BY
(SIGN
N. & DESIG
G.)

BH
HARAT
T HEA
AVY ELECT
E TRICA
ALS LIMIT
L ED
P
POWER SEC
CTORR - EA
ASTER EGION
RN RE
INST
TRUMENT RE
EG. NO./TAG NO.

DATE
E OF INSPEC
CTION

LY
PSER-QL
DRAW
WING / DOC
CUMENT REF
F.

PROTOC
P COL

SIGNATURE &
NAM
ME
DATE
FQP NO
O: QPE:SRG
G:660:BR:0
002

R
RRVUNL, INSPECTED
PROJECT
S
Suratgarh BY
REV. NO.:
N R01

CLEARED
UNIT NO.
BY
PROTO
OCOL NO.

RATING 2
2X660 MW CUSTOMER PAGE: 1 OF 1
F
FIELD
D QU
UALIITY PLAN
N
FOR

COM SED AIR

MPRESS I SYS
STEM

(ERE
ECTION & COMM
MISSION
NING)

FOR

2 X 660MW
6 W SUP
PERCR
RITICA
AL PO
OWER
PROJJECT RRVU
R UNL, SUR RATGA ARH

BH
HARAT
T HEA
AVY ELECT
E TRICA
ALS LIMIT
L ED
P
POWER SEC
CTORR - EA
ASTER EGION
RN RE

DOC
C. NO: Q
QPE:SRG
G:660:BR
R:001
R
REV. NO: R01
F
FIELD
D QU
UALIITY PLAN
N
FOR

COM SED AIR

MPRESS I SYS
STEM

(ERE
ECTION & COMM
MISSION
NING)

FOR

2 X 660MW
6 W SUP
PERCR
RITICA
AL PO
OWER
PROJJECT RRVU
R UNL, SUR RATGA ARH

PREPA
ARED BY AP
PPROVED BY
Dy.Engr./QLY, PSER AG
GM/QLY, PSER
P
FQP N
NO. QP
PE:SRG:660:BR:00
01
ORIGIINAL DAT
TE OF ISS
SUE 22.02.2016
REVIS
SION NO. & DATE R01 / 26.02
2.2016
COPY NO.
ISSUE
ED TO
DATE OF ISSUE
E
CONTR
ROLLED / INFORM
MATION COPY
ISSUE
ED BY
(SIGN
N. & DESIG
G.)

BH
HARAT
T HEA
AVY ELECT
E TRICA
ALS LIMIT
L ED
P
POWER SEC
CTORR - EA
ASTER EGION
RN RE
FIELDD QUALITYY PLAN FQ
QP NO. QPE
E:SRG:660:BR:001
For
RE
EV. NO. R01
1
Compre essed Airr System
m
PSER-Q
QLY (Erection & Commmissioning
g) SH
HEET NO. 1 OF 1

TABLE
E OF CON
NTENTS

Sl.No
o. D
Descriptio
on No. of Pages
1.0 Ap
pproval Sh
heet 01

2.0 Tab
ble of Conttents 01

3.0 Status of Reviisions 01

4.0 State
ement of Checks
C 02
FIELDD QUALITYY PLAN FQ
QP NO. QPE
E:SRG:660:BR:001
For
Compre essed Airr System
m RE
EV. NO. R01
1
PSER-Q
QLY
(Erection & Commmissioning
g) SH
HEET NO. 1 OF 1

STATUS
S OF REV
VISIONS

Sl. Referen
nce of Sh
heet(s) Revision No.
R
Rem
marks
No. revised & Datee
Sheeets 1 & 2 o
of 2
R01 Customeer commen nts
01. Sheets of Statem
ment of
2.16
Dtd.26.02 incorrporated
Checks
FIELD QUALITY PLAN

FOR

MISC. PUMPS
(ERECTION)

FOR

2 X 660MW SUPERCRITICAL POWER PROJECT

RRVUNL, SURATGARH

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR - EASTERN REGION

DOC. NO.: QPE:SRG:660:ST:49

REV. NO. : R01

WI:QLY:03-F02/R0
FIELD QUALITY PLAN

FOR
MISC. PUMPS
(ERECTION)

FOR

2 X 660MW SUPERCRITICAL POWER PROJECT

RRVUNL, SURATGARH
PREPARED BY APPROVED BY

Dy.Engr./QLY
Head/QLY
FQP NO. QPE:SRG:660:ST:49

ORIGINAL DATE OF ISSUE 27.09.2010

REVISION NO. & DATE R01 Dt. 08.10.15

COPY NO.

ISSUED TO

DATE OF ISSUE

CONTROLLED / INFORMATION COPY

ISSUED BY
( SIGNATURE &
DESIGNATION )

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR – EASTERN REGION

WI:QLY:03-F03/R0
FIELD QUALITY PLAN FQP. NO.: QPE:SRG:660:ST:49
FOR
REV No.: 01
MISC. PUMPS
N (ERECTION)
SHEET: 01 OF 01
PSER - QLY

TABLE OF CONTENTS

Sl No. Description No. of Sheets

1.0 Status of Revisions 01

2.0 Authorisation for different categories of checks 01

3.0 Statement of checks 04

4.0 Documents referred in Field Quality Plan 01

5.0 Log Sheets (L-00 TO L-01) 02

6.0 Protocol 01

7.0 Feedback on Field Quality Plan 01

WI:QLY:03-F04/R0
FIELD QUALITY PLAN FQP. NO.: QPE:SRG:660:ST:49
FOR
REV. NO.: R01
MISC. PUMPS
PSER - QLY (ERECTION) SHEET 1 / 1 SHEET

STATUS OF REVISIONS

SL. REFERENCE OF SHEET(S) REVISION NO. & REMARKS

NO. REVISED DATE

Sheet 2 to 4 of 4 of Statement Customer comments suitably

1. R01 dtd.08.10.2015
of Checks incorporated
Appended with additional data
2. Log Sheet No. L01 R01 dtd.08.10.2015
recording

Note:
In case of Float of Pump Shaft, Alignment Checks (mentioned in page no.2, 3 & 4 of 4 of Statement of
Checks), ‘A’ Category Check is in order, but in other cases where ‘B’ Category Checks has been
asked to be made ‘A’ – are not required.
As confirmed by us in Page No.1 of 1 for ‘Authorization for Different Categories of Checks’, Customer
has access & freedom to involve in all ‘B’ Category Checks also.

Log Sheet, L01 has been appended suitably with an additional recording of data

Please refer previous comments irrespective

of A/B check Protocol has to be made for the
activities (* wherever mentioned).

WI:QLY:03-F05/R0
FIELD QUALITY PLAN FQP. NO.: QPE:SRG:660:ST:49
FOR
REV. NO.: R01
MISC. PUMPS
(ERECTION)
PSER - QLY SHEET 1 / 1 SHEETS

AUTHORISATION FOR DIFFERENT

CATEGORIES OF CHECKS

Classification of Check Checking Authority Accepting Authority

--------------------------------
Symbol Description

A Critical BHEL & Customer Customer

B Major BHEL & Customer Customer

C Minor BHEL BHEL

Legend : Customer : Customer or any other agency authorised by customer.

BHEL : Concerned engineers of BHEL – Task Performer.

HOS : HEAD OF SECTION for BHEL

NOTE :

1. Quantum of check shall be 100% for all characteristics unless otherwise

mentioned in reference documents.

2. Customer shall witness A & B category checks. He is also authorised to carry out
Surveillance in any of the C category of checks at his discretion.

3. In case of non-conformity, accepting authority shall ensure dispositioning

before accepting and the dispositioning shall be reflected in log sheets /
protocols. Dispositioning of non-conformities to be authorised by Head/TSX
with intimation to Head/Quality.

4. Instruments with valid calibration to be used for measurements.

WI:QLY:03-F06/R0

FIELD QUALITY PLAN FQP. NO.: QPE:SRG:660:ST:49

FOR
REV. NO.: R01
MISC. PUMPS
N (ERECTION) SHEET 1 / 4 SHEETS
PSER - QLY

STATEMENT OF CHECKS

Unit Capacity : 660 MW

System : Steam Turbine
Sub System : Misc. pumps
Area : Erection

 For checks where log sheets are not called for, suitable records should be
maintained in the form of log book / protocols.

 As an evidence of having carried out the work satisfactorily, a general purpose log
sheet L-00 shall be maintained for all the checks.

 Abbreviations used in the column “Type of check” are :

R : Record Verification

M : Measurement

V : Visual

WI:QLY:03-F07/R0
FIELD QUALITY PLAN FQP. NO.: QPE:SRG:660:ST:49
FOR REV. NO.: R01
MISC. PUMPS
PSER - QLY
(STATEMENT OF CHECKS) PAGE 2 OF 4

SYSTEM : MISC PUMPS SUB-SYSTEM : VERTICAL PUMP AREA : ERECTION

TYPE QUANTUM / FORMAT OF
SL. CLAS REFERENCE DOCUMENT/ REMAR
CHARACTERISTICS / ITEM OF INSTRUMENT FREQUENCY OF RECORD
NO. S ACCETANCE STANDARD KS
CHECK CHECK

1 Check foundation dimensions including floor elevation, M Tape C 100% Drawing Protocol
position of foundation bolt pockets, pit depth, vortex
breaker location etc. as applicable.
2 Chipping / dressing and blue matching of packers with V B
frame.
3 Removal of shop paint from foundation ring. V B
4 Assembly of foundation ring and level of the assembly V/M Spirit level B Drawing
on foundation.
5 Assembly of pump on floor. Record clearances V/M B Drawing Protocol
between sleeve & shaft, sleeve & cut-less rubber
bearing and between wearing rings of casing &
impeller.
6 Lowering of Pump in pit. P B
7 Tightening of foundation bolts and grouting of V/M C Drawing / Grouting Log book
foundation ring. Ensure proper elevation of pump Procedures
discharge centerline.
8 Revision of bearing. V C Log book
9 Check float of Pump shaft and fix Rotor position (as M A As per Drawing L-01
mentioned in drg./instruction manual).
10 Ensure proper contact between motor stool and V Log book
foundation ring. Leveling & centering of motor stool.
WI:QLY:03-F08/R0

??
A
FIELD QUALITY PLAN FQP. NO.: QPE:SRG:660:ST:49
FOR REV. NO.: R01
MISC. PUMPS
PSER - QLY
(STATEMENT OF CHECKS) PAGE 3 OF 4

SYSTEM : MISC PUMPS SUB-SYSTEM : VERTICAL PUMP AREA : ERECTION

TYPE QUANTUM / FORMAT OF
SL. CLAS REFERENCE DOCUMENT/ REMAR
CHARACTERISTICS / ITEM OF INSTRUMENT FREQUENCY OF RECORD
NO. S ACCETANCE STANDARD KS
CHECK CHECK

11 Check distance between coupling halves of Pump & M B Drawing L-01

Motor

12 Alignment between Pump & Motor shafts and their M A Drawing L-01
coupling. NOTE: Coupling to be done after Motor trial
run.

13 Ensure mounting of all instrumentation on pump as V C Drawing Log book

applicable.

14 Filling of Bearing Oil Sump, Check for any leakage. V C

Submit the erection procedure/ manuals and relevant

documents.

WI:QLY:03-F08/R0
FIELD QUALITY PLAN FQP. NO.: QPE:SRG:660:ST:49
FOR REV. NO.: R01
MISC. PUMPS
PSER - QLY
(STATEMENT OF CHECKS) PAGE 4 OF 4

SYSTEM : MISC PUMPS SUB-SYSTEM : HORIZONTAL PUMP AREA : ERECTION

TYPE QUANTUM / FORMAT OF
SL. CLAS REFERENCE DOCUMENT/
CHARACTERISTICS / ITEM OF INSTRUMENT FREQUENCY OF RECORD REMARKS
NO. S ACCETANCE STANDARD
CHECK CHECK

1 Check foundation dimensions including floor elevation, M C 100% Drawing Protocol

position of foundation bolt pockets etc.

2 Chipping / dressing and leveling of foundation (Blue V/M B Log book

matching of packer plates wherever applicable).

3 Grouting of foundation bolts. Ensure elevation and V B Drawing Log book

leveling of suction and discharge flange.

4 Curing of foundation bolt grout and tightening of bolts V C Grouting Procedures Log book

5 Leveling & grouting of frame and curing. V/M B Grouting Procedures Log book

6 Alignment of pump and motor. M Dial gauge / A Protocol

Micrometer
7 Greasing and filling of Bearing Oil Sump, Check for V B Drawing
any leakage

8. Check for mechanical seals (wherever applicable) & V B Drawing Log Book
associated hardware are in place as per drawing.

WI:QLY:03-F08/R0
FIELD QUALITY PLAN FQP. NO.: QPE:SRG:660:ST:49
FOR
REV. NO.: R01
MISC. PUMPS
N (ERECTION) SHEET 1 / 1 SHEET
PSER - QLY

DOCUMENTS REFERRED IN FIELD QUALITY PLAN

SL.NO. Reference Document Issuing Authority

1. Grouting Procedure PSER

WI:QLY:03-F09/R0
RECORD OF QUALITY CHECKS
PSER - QLY

DRAWING /
RESULTS
CHECK DOCUMENT FORMAT OF INSPECTED BY CLEARED BY
ACHIEVED OK REMARKS
NO. REFERENCE RECORD SIGN. & DATE SIGN. & DATE
/ NOT OK
PSER - QLY

Note: Any protocol made is to be numbered & mentioned in “Format of Record” column.

FQP. NO.: QPE:SRG:660:ST:49

SYSTEM SUB-SYSTEM AREA
PROJECT REV. NO. : R01
UNIT NO. LOG SHEET NO. : L- 00
RATING PAGE 1 OF 1
WI:QLY:03-F10/R0
INSTRUMENT REG. NO./TAG NO.

DATE OF INSPECTION

PSER - QLY
DRAWING / DOCUMENT REF.
ALIGNMENT OF PUMP & MOTOR

RADIAL AXIAL

DISTANCE BETWEEN COUPLING HALVES = …………………

TOTAL FLOAT AS PER DRAWING = …………………

TOTAL FLOAT OF PUMP SHAFT (ACTUAL AS MEASURED) = …………………

Submit manual along with FQAP for CEP/CW/ACW

pumps.

Remarks (If any):

NAME SIG./DATE FQP. NO.: QPE:SRG:660:ST:49

PROJECT CHECKED BY REV. NO. R01

UNIT NO. ACCEPTED BY LOG SHEET NO. L-01

RATING CUSTOMER SHEET: 01 OF 01

WI:QLY:03-F11/R0

INSTRUMENT REG.
NO./TAG NO.

DATE OF INSPECTION
PSER - QLY
DRAWING / DOCUMENT
REF.
PROTOCOL

NAME SIGNATURE & DATE FQP. NO.: QPE:SRG:660:ST:49

PROJECT INSPECTED BY REV.NO.: R01
UNIT NO. CLEARED BY PROTOCOL NO.
RATING CUSTOMER PAGE:
WI:QLY:03-F12/R0
FEEDBACK ON
FIELD QUALITY PLAN
PSER - QLY

In the Field Quality Plan, following Checks / Log sheets may be added / rewritten / deleted (cannot
be carried out / not required) due to reasons as mentioned below :

Sheet No. Check No. /

Proposed Change / Reasons / Remarks
of FQP Log Sheet No.

From : To
PROJECT FQP. NO.: QPE:SRG:660:ST:49
1. Head (Quality)
PS-ER
UNIT NO. Kolkata-91
REV NO. R01

RATING SHEET 1 / 1 SHEET

WI:QLY:03-F13/R0
1
Website : www.bevconwayors.com H-11, IDA, Uppal, Hyderabad-500 039, A.P., India COAL HANDLING PLANT
E-mail : info@bevconwayors.com Tele: 040 - 27201956, 27201959, Fax: 040 - 27208279 OPERATION & MAINTENANCE MANUALS
For more details contact us on:

BEVCON WAYORS PVT. LTD.

UNIT-II: Plot No - 139, IDA Phase-III, Cherlapally, Adj. H. P. Gas Co.,
R. R. District – 500 039. Andhra Pradesh, india.

Cherlapally (Unit-I) : +91 40 27261666, 27260025 / 27

Uppal (Unit-I) : +91 40 27201956, 27201959

Cherlapally (Unit-I) : +91 40 2726 1667

Uppal (Unit-I) : +91 40 2720 8279

Cherlapally (Unit-I) : projects@bevconwayors.com

Uppal (Unit-I) : factory@bevconwayors.com

2
Website : www.bevconwayors.com H-11, IDA, Uppal, Hyderabad-500 039, A.P., India COAL HANDLING PLANT
E-mail : info@bevconwayors.com Tele: 040 - 27201956, 27201959, Fax: 040 - 27208279 OPERATION & MAINTENANCE MANUALS
CONFIDENTIAL
This publication contains information of a confidential nature deemed proprietary to the
M/s. BEVCON WAYORS PVT. LTD. Its purpose is to provide technical guidance and / or
information to the client M/s. BHEL ISG, at Site 2X600 MW SURATHGARH
SCTPS,UNIT 7 & 8 . And for BEVCON WAYORS PVT. LTD. Personnel, in the conduct of the
company’s business.

In any case, this publication or information should not be disclosed in whole or in part to any
other person and the text work referred or performed for any other company, in the conduct of
its business any other purpose.

3
Website : www.bevconwayors.com H-11, IDA, Uppal, Hyderabad-500 039, A.P., India COAL HANDLING PLANT
E-mail : info@bevconwayors.com Tele: 040 - 27201956, 27201959, Fax: 040 - 27208279 OPERATION & MAINTENANCE MANUALS
OPERATIONS AND MAINTANANCE VOLUME - I

INDEX
S.NO. DESCRIPTION PAGE NO.

1 BELT CONVEYOR MANUAL 5

4
Website : www.bevconwayors.com H-11, IDA, Uppal, Hyderabad-500 039, A.P., India COAL HANDLING PLANT
E-mail : info@bevconwayors.com Tele: 040 - 27201956, 27201959, Fax: 040 - 27208279 OPERATION & MAINTENANCE MANUALS
5
Website : www.bevconwayors.com H-11, IDA, Uppal, Hyderabad-500 039, A.P., India COAL HANDLING PLANT
E-mail : info@bevconwayors.com Tele: 040 - 27201956, 27201959, Fax: 040 - 27208279 OPERATION & MAINTENANCE MANUALS
BELT CONVEYOR

ACCEPTANCE AND STORAGE

a. It should be ensured that the belt is supplied in crate / spool in properly packed
condition with logo embossed on belt surface.

b. The “DOs” and “DON’Ts” for proper storage are listed below and all attempts should be
made to follow them.

S. No DO’s DON’Ts

To hoist the drum , place bar through Do not drop drum from wagon or truck as
01 the center and protect belt edges dropping will damage packing and
adequately possibly the belting

Jack up the drum clear off the ground

Do not place roll with weight on one side
by placing bar through center of roll.
02 as with constant dead weight the belt edge
An elevated platform is recommended
will get distorted throughout the length
for sorting the drums

Store in a cool, dry, covered and well-

Do not store near heating units or where
03 ventilated place away from direct
oil/grease may come in contact with belt
sunlight

Whenever lengths are cut from the

Do not store, as far as possible, for long
belting roll, the ends should be sealed
periods over, say, 1-1½years, as rubber
04 with conveyor belting solution to
slowly ages and loses its properties with
prevent ingress of moisture into the
time
carcass

Precautions to be taken to prevent

any fires and means should be Do not secure the end of a roll with nails –
05
provided to extinguish it immediately, use binding around the roll
should it occur.

Once in, say, 2/3 months, examine the

06 drums in storage. Spraying the -
packing with DDT power will help

6
Website : www.bevconwayors.com H-11, IDA, Uppal, Hyderabad-500 039, A.P., India COAL HANDLING PLANT
E-mail : info@bevconwayors.com Tele: 040 - 27201956, 27201959, Fax: 040 - 27208279 OPERATION & MAINTENANCE MANUALS
1. COMPONENTS OF BELT CONVEYOR

A. STRINGER
The stringer consists of two channel of ISMC suitably reinforced by ISA for better
strength and rigidity. The whole stringer is divided to suitable individual lengths for
bolting to access easy installation.
B. GALLERIES
The gallery consists of a box type ISMC construction of suitably reinforced by ISA for
better strength and rigidity. The whole gallery is divided to suitable individual lengths
for bolting to access easy installation.
C. TAIL FRAME
The tail frame consists of ISMC reinforced by suitable angle on which take up bearings
are mounted to support the tail pulley. The take-up arrangement is provided to adjust
the necessary belt tension.
D. HEAD FRAME
The head frame consists of ISMC reinforced by suitable angle on which Plummer blocks;
pillow blocks are mounted to support the head pulley, snub pulley. The frame is
extended to accommodate the gearbox and the motor for driving the conveyor.
E. However the belt conveyor consists of carrying idlers, return idlers, pulleys, conveyor
belting, motor, gearbox and take-up. The components are described in detail to acquaint
the operating staff with their functions.
F. CARRYING IDLERS
Carrying idler configuration used is to support the troughed belts. The two outer rollers
are inclined upward, the center roll is horizontal. Idler rolls consist of ERW tube
enclosed at each end and fitted with stationary shaft, anti-friction bearings and seals.
G. RETURN IDLERS
Return idlers are usually are of horizontal rolls, positioned between brackets which
normally are attached to the underside of the support structure on which the carrying
idlers are mounted.
H. PULLEYS
The pulley used is the standard steel drum pulley, which consists of a continuous rim,
and two end discs fitted with compression hubs, made up of mild steel/EN-8. The pulley
is covered with rubber to increase the co-efficient of friction between the belt and the
pulley.
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I. TAKE-UP

All belt-conveyors require the use of some form of take-up device for the following
reasons.
a. To ensure the proper amount of slack side tension at the drive pulley to prevent
belt slippage
.
b. To ensure proper belt tension at loading and other points along the conveyor.

c. To compensate for changes in belt length.

d. To allow belt storage for making replacement splices (without which storage,
small sections of new belt would have to be added, requiring two splices for each
splice repair).

The type of take-up given is manual, which has the advantage of compactness and low
cost. It is located at the tail end of the conveyor mounted on two guides. Adjusting the
screw fitted with nuts can vary the tension of the belt. However a careful observation is
required while adjusting the manual take- up.
Automatic take-up (VGTU) are above provided in long conveyors near the return side at
discharge end. The take-up pulley location is controlled by the counter weight attached
to the sliding pulley on vertical guide channels which move accordingly to the tension
requirements.

J. BELTING

While a belt conveyor is composed of many important than the conveyor belt itself since
its accounts for substantial part of the initial cost in a belt conveyor a system.

2. INSTALLATION INSTRUCTIONS

The installation of the belt conveyor begins with the proper positioning and alignment
of the structural. It is necessary to ensure that the center line of the conveyor is maintained all
through.
The erection of mechanical components like idlers, pulleys, drive units etc. should be
taken up after the structural’s are permanently leveled and aligned. All idlers and pulleys
should be positioned at right angles to the conveyor central line. Install the belt in position
ensuring that the carrying side of the belt should be kept no tighter than the necessary to
prevent slipping on the drive pulley or pulleys under the most extreme loading conditions. This
belt tension must also be sufficient to eliminate any abnormal sagging between the toughing
idlers near the tail end and at all loading points. Excessive belt tension, due to extremely high
return belt tension, may causes unnecessary belt stress, premature slicing failure and extra
load on bearings and shafts. Brakes if provided shell be adjusted so that
Clearance is approx 1 to 1.5 mm between break drum and break shoe when released.

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Automatic take-ups are desirable to provide a convenient method of compensating for
changes in the belt length due to variations in belt tensions which occur during starting,
braking or when the conveyor is partially loaded and operation in a manner that is considered
abnormal.

3. INSTALLATION, JOINING AND INITIAL RUNNING OF BELT

INSTALLATION:
a. The conveyor belt drum should be brought to site with care and mounted at a
Convenient location.
b. Belting to be pulled on to the conveyor, after suitably fastening the end.
c. Belt not to rub or catch on sharp corners of the conveyor when the belt is drawn over
the idlers.
d. When installing the belt make sure that the carrying side, which is generally the
branded side, is right side up.

JOINING:
a. Great care should be taken that the ends are cut square and the joint is not crooked.
b. Method of joining may be hot/cold vulcanization or by the use of metal fasteners.

INITIAL RUNNIG:
a. Trial runs of the empty belt should be made to ensure that the belt sits satisfactorily on
the idlers.
b. Belt should not touch any foreign material, belt should be free run.
c. The belt to run aligned at all points of the conveyor, both on the carrying and return
runs.
d. With minor idler adjustments, the belt may be made to run centrally throughout its
length.
e. Excessive adjustment in any one idler will result in increased back cover wear. Better to
make slight adjustments in several set of idlers
f. If the belt runs true when empty but off-centre with load, the obvious fault lies in the
method of loading.
g. It is preferable to carry out all adjustments on the conveyor before running the belt on a
production basis.

4. REPAIR OF BELT

(i) Repairing of damaged portion of the belt is given top priority to avoid undesired
propagation
(ii) Recommended rubber cover & solutions are to be used as per stated procedure of
belt supplier & trained personals only to be employed for repair.
(iii) Steel hinges may be used for medium tensioned conveyors or to buy time.
(iv) Repair to be circular or oval in shape
(v) Each coat of solution to be allowed to dry completely.
(vi) Curing to be done properly and as prescribed in manufacturer’s catalogues.
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5. INSTRUCTION FOR PULLEYS

A) - Open bearing package only when required for fitting

- Bearings & associated components to be cleaned, inspected, checked for measurements.
- Light coat of lubricant before actual mounting.

3.1 - New bearings need not be cleaned

- Only previously mounted bearings to be washed with white spirit and dried.
- Don’t use kerosene / diesel/ petrol for cleaning

3.2 remove anti rust paint from bearing seating

- If rusted, use fine emery cloth, wash with paraffin and dried.

3.3 bearings to be free from core sand remains

- Painted on all surfaces except the bearing seating.

B) LAGGING
- Only natural rubber shall be used for lagging
- Lagged pulley shall stored by covering with wooden battens on surface tied with wire
- Lagged pulley not to be kept on floor
- Lubrication Schedule to be strictly followed
- Only 60% of empty space inside the bearing to be filled with grease of specified grade
(Grade-3)
6. SEQUENCE OF INSTALLATION OF CONVEYOR

1. Centre line marking & elevation of Stringer / structure fixing.

2. Civil work to be carried out for stringer, short support, drive foundation, take up and tail
foundation.

3. Checking of foundation central line.

4. Checking of foundation levels as per drawing.

5. Erection of short supports and trestles.

6. Alignments of stringer short support and trestles.

7. Half grouting of short support and trestles.

6. Base Frame alignment & grouting.

7. Drive, GB, coupling, brake, pulley alignment and grouting.

8. Take-up, Stringer and galleries Erection and full grouting of pedestals.

9. Idler frame & Idler erection and alignment.

10. Belt laying.

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11. Pull cord switch fixing.

12. Belt Sway switch fixing.

13. Zero speed switch fixing

14. Cable lying & termination.

- +2 mm in vertical plane,+2mm in horizontal plane.

8. Deviation in central line of conveyor – 2mm in one meter length but 15 mm max for total
length.

7. Guidelines for training of belts

It is often noticed that the belt tends to run sideways when operating with a new belt. While
training a belt the first attempt should be made to bring the belt over the middle of the head
and tail pulleys. A slight adjustment of the return idlers or snub pulley will bring the belt on to
the middle of tail pulley. The tail pulley can also be slightly adjusted to achieve this result
whereas on no account should the drive pulley be shifted. To adjust the belt on the carrying
and return side the idlers may be slightly tilted to train the belt. In this regard it should be
noted that the belt tends to move towards the end of the idler which touches the belt first. In
other words if one end of the idler is moved forward in the direction of belt travel the belt
tends to move towards the other end of the idler.
Belt scrappers – scraper rubber should protrude uniformly throughout the width.
Skirt rubber – only a small clearance (1MM max) must exist between skirt rubber and belt.

8. FIRST START UP AND COMMISSIONING

1. Visual Inspection of the system especially the lower belt strand to remove for forgotten
tools and other alien articles – which may be carried along by belt and jammed between
belts and pulleys.

2. Conveyor frame work must be checked for perfect alignment, movement.

3. Counter weight (of TU) must have correct amount of slabs / weight.

4. During actual start up process-

a. Check belt running straight especially on drive & return pulleys for longer
conveyors.
b. Observers standing along the length of conveyor use pull cord switch to stop
whenever the belt runs off the track.
c. Similarly observation is necessary when conveyor runs with material for the first
time

5. Ensue belt should run empty for 5-6 mins before feeding the material for checking the
belt movement & tracking of the belt or any abnormalities. Ensure uniform loading as
far as practicable.

6. Electrical Safety System.

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a. The first switch-on should allow only a run of 10m -50m. The second switch-on should
again be very short.
b. Listen the comments of observers each time regarding belt tracking for rectification.
c. Fabric belt may need a certain time for adjustment under load to specific plant
conditions.

7. a. Belt alignment is possible only during running the belt to see the result of
Corrections undertaken.

b. Belt alignment may be affected by re-alignment of Drive Pulley, or Idler

Stations or Tail Pulley (specially in small conveyors) or return Idler stations.

9. OPERATING INSTRUCTION FOR CONVEYORS

1. Ensure that the transmission machinery like motor, gear box, couplings etc. have been
properly aligned.
2. Ensure that the direction of the motor is correct.
3. Before starting check and remove the lumps of material chips of wood and pieces of
scrap etc., wedged, between the chutes / skirt and belt or between pulley and belt.
4. Belt should start in empty at any point of time to avoid slippages & damages of
Pulleys/Idlers.
5. Check the tension of the belt and if any slippage is noticed adjust the tension with the
help of take-up.
6. Fill up the gear box / geared motor with flushing oil as specified in the lubrication chart,
run for approximately half an hour without load and refill with the recommended grade
of oil up to the correct level.
7. Run the belt continuously for 5-10 mins no load trails.
8. Carry out a thorough check of all fastens and free running of idlers. Check for excessive
heating of bearings, gear box and motor. Possible reasons are misalignment, improper
lubrication or loose bolts. Take preventions incase abnormality noticed.
9. Rectify / repair all the defects found during No-Load test.
10. Now the conveyor is ready for continuous operation on load.
11. Start loading the conveyor gradually to attain the maximum specified capacity.
12. Run the conveyor in this condition, continuously for hours.
13. During the above period, check for proper discharge clogging of chutes, central feeding
on succeeding conveyor.
14. Stop the conveyor after empty the belt and recheck for loosening of fasteners.
15. If everything is okay, the conveyor can be run continuously.
16. At the time of stopping the conveyors belt should be empty always.
17. Take readings of volts, amperes and watts for the empty belt. These readings and length
of conveyor should be recorded for future reference. These will be valuable at a later
date for checking against similar readings to determine whether the belt conveyor is
running normally or not.
The voltmeter and watt readings should be taken by the operator every day. If the readings
are much higher than the normal values for the same conveyor, then the maintenance man
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should immediately check the belt line for jammed idlers, return belt dragging on the
bottom and other factors that would cause the increase load on the motor.

10. MAINTENANCE INSTRUCTIONS

INSPECTION AND EXAMINATION:

Proper belt conveyor maintenance means having a clean conveyor system at all times. The
belt line should be patrolled for every shift.
The operator on the conveyor system should be responsible for making quick belt

examinations each day so that any seriously damaged spot in the belt can be
immediately reported and the belt shut down for emergency repairs. The belt is the most
vulnerable and expensive part of a belt conveyor, so frequent and thorough inspection is
imperative.

A weekly inspection should be made by a foreman. A quarterly inspection of a more

thorough nature would include belting, driving machinery, electrical control, cables and
other related parts of the conveyor.

SAFETY AGAINST FIRE:

The danger of fire caused by the belt conveyor system can be minimized by:

a. Using centrifugal switches, or similar devices, at the head end to remove power from
the motor when the belt speed falls below normal. Slippage or jamming of the belt
causes excessive friction resulting in fire.

b. Using centrifugal or speed responsive switch installed for sequence control of feeder
belts so that material will not pile up on a stopped belt.

c. Using paddle switches, or equivalent, at all transfer points.

d. Providing ample clearance to the conveyor frame and to objects along the belt line.

e. Seeing that electric cables, protective devices and electrical compartments are kept
clean and dry. All possible precautions should be taken to prevent shorts and grounds.

LUBRICATION:
The lubricating components of the conveyor are the outboard bearings, speed reducer and the
transmission chains .The lubrication procedure for each of these components is described as
under.

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RE-LUBRICATION INTERVAL:
The re-lubrication interval for both the head and tail end bearings is about 100 operating
hours, provided the temperature of bearing at the outer race is within 70°C. For every 15°C
rise in temperature, this interval must be halved.

LUBRICATION PROCEDURE:
Wipe lubricating nipples. Clean before fresh grease is injected. If the bearing housing is not
provided with nipples, requisite re-lubrication should be carried out during a planned
stoppage of the machine. The housing cover has to be removed, the used grease taken out and
fresh grease added. Even where nipples are fitted on the housing, the used grease should be
removed and replaced with fresh from time to time. During application, fill the space between
the rollers with grease, which is suitable for operating conditions.

The free space around the bearing should normally be between a third and half filled with
grease.

OIL LUBRICATION:
Check the oil level and replenish if necessary. Ensure that the air-vent of the oil level gauge is
not blocked. When the oil is to be changed, it is drained off and the bearing arrangement rinsed
with fresh, clean oil of same type, before refilling to the same level. With oil bath lubrication, it
is generally sufficient to change the oil once a year, provided the operating temperature does
not exceed +50°C and the oil does not become contaminated. The oil must be changed more
frequently, when operating temperatures are higher.

LUBRICANT:

The lubricant recommended for various temperatures is given in the following table.
Ambient Temperature Recommended
Degree °C Lubricant

-5 to 5 SAE20
6 to 25 SAE30
26 to 45 SAE40
46 to 70 SAE50

12. BEARINGS

STORAGE OF BEARING

Bearings should preferably be kept in a store where the relative humidity does not exceed 60%
and where the temperature is reasonably constant.

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ROUTINE CHECKUP OF BEARINGS DURING OPERATION

a) Listen to any loud noise often irregular and rumbling using a listening rod, screw driver
or similar object.
b) Check the temperature of the bearing arrangement by using a thermometer or often
simply by placing a hand on the bearing.
c) Ensure that lubricant does not escape through defective seals or insufficiently tightened
plugs.
d) Re-lubricate the bearing arrangements according to instructions enclosed.

The housing cap or end cover has to be removed, the used grease taken out and fresh grease
added.

TO BE NOTED THAT TEMPERATURE MAY RISE UNDER CONDITIONS OF EITHER

INSUFFICIENT QUANTITY OR ELSE EXCESS QUANTITY OF GREASE.

INSPECTION OF BEARING DURING NON-OPERATION

This should preferably be done during a planned stoppage of the machine or when the machine
is to be dismantled for some reason, such as inspection or repair.
- Remove the covers & seals.
- Wash the exposed bearing where it is possible to carry out inspection without
dismounting.
- Use a paint brush dipped in white spirit & dry with a clean lint free cloth or
compressed air.
- If the bearing is undamaged it should be re-lubricated.
- Carefully replace the seals and covers.

DISMOUNTING BEARINGS & ITS INSPECTION

- Mark the position of sleeve on the shaft.
- Dis-engage the bent tab of the locking washer from the lock nut slot.
- Unscrew the lock nut a few turns.
- Place a length of tubing against the nut & apply sharp evenly distributed blows until
the bearing become loose.

Clean the dismounted bearing as above & then inspect it for any damage for any signs of
damage.

A bearing which is undamaged may be remounted without risk.

CAUSES OF BEARING DAMAGE

- Faulty Mounting
- Faulty Lubrication
- Foreign matter in bearing
- Water ingress
- Inaccurate Shaft or housing seating
- Vibration

IT IS ADVISABLE TO INVESTIGATE THE REASON & ELIMINATE IT.

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MOUNTING BEARINGS

- Place the sleeve on the shaft at the position marked before it was dismounted.
- Remove the rust – inhibiting compound from the bearing bore only.
- Place the bearing on the sleeve & screw on the lock nut and drive the bearing up the
sleeve by tightening the lock nut.
- Check the reduction in radial internal clearance by rotating the bearing.
- When the lock nut has been correctly tightened, it should still be possible to rotate
the outer ring easily.
- Remove the lock nut after the drive up has been completed & place the locking
washer in position.
- Screw the lock nut again and tighten it.
- Bend down a suitable tab of the locking washer so that it engages in one of the slots
in the lock nut.
- Measure it engages in one of the slots in the lock nut.
- Measure the residual clearance again to see that it is unchanged.

MINIMUM PERMISSIBLE RESIDUAL CLEARENCE.

Bearing Bore Diameter Permissible [mm] Minimum Residual Clearance

50 – 65 0.035
65 – 80 0.040
80 – 100 0.050

13. SAFETY INSTRUCTIONS

A brief listing is presented here simply to illustrate the type of safety considerations generally
applicable to belt conveyor installations and equipment.

1. At no time should the conveyor be used to handle material other than that originally
specified. Capacity and belt speed design ratings should not be exceeded / altered.

2. Any point of time conveyor should be start without any material on the top of the belt
and while stopping the conveyor belt should be empty.

3. Only trained personnel should be allowed to operate the conveyor system. They
should have complete knowledge of conveyor operation, electrical controls, safety and
warning devices, and the capacity and the performance limitations of the system.

4. A program should be established to provide frequent inspections of all equipment.

Guards, safety devices, and warning signs should be maintained in their proper
positions and in good working order. Only competent and properly trained and
authorized persons should adjust or work on safety devices.

5. A “walking inspection” of a belt conveyor system is a good means by which well

trained maintenance personnel can often detect potential problems from any unusual
sounds made by such components as idlers, pulleys, shafts, bearings, drives, belts, and
belt splices.
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6. No person should be allowed to ride on, step on, or cross over a moving conveyor, nor
to walk or climb on conveyor structures, without using the walkways, stairs, ladders.

7. Good lighting with sufficient illumination levels to be maintained on conveyor

Galleries & Walkways.

8. Ensure in monthly checks for transmission equipment like motor, gearbox, and
couplings are within the limits of alignment.

9. Ensure that the direction of rotation of the motor is correct before putting the belts on.

10. Before starting, check and remove the lumps of material, chips of wood, and pieces of
scrap etc wedged between the chutes/skirt and the belt or between the pulley and the
belt.

11. Check the tension of the belt and if any slippage is noticed adjust tension with the help
of the take-up (for a screw take-up arrangements).

12. Fill up the gearbox/geared motor with flushing oil as specified in the lubrication chart,
run for approximately half an hour without load and re fill with the recommended
grade of oil up to the correct level after draining the flushing oil.

13. Run the belt continuously for no load trials observing for proper functioning of
running of the belt, bearing seating etc. This can be observed from the amps drawn by
the motor and visual inspection.

14. Carryout a thorough check of fasteners and free running of idlers. Check for excessive
heating of bearings, gearbox and motor. Possible reasons are misalignment, improper
lubrication or loose belts. Take prevention in case of abnormality noticed.

15. Ensure loading of the conveyor gradually to attain the maximum specified capacity.

16. To stop the Belt in the event of any Hazard / injury to the personnel, pull the wire /
chord in any direction so that the pull chord switch gets operated to stop the
conveyor.

17. Belt sway switches provided on both sides of the Belt at staggered intervals or
opposite to each other for longer conveyors will ensure the belt doesn’t sway / get out
of track beyond a point.

18. The zero speed switches operate with the help of sensor (the sensor counts the pulse /
speed of non drive pulley / tail pulley in most of the cases) with a set point to ensure
stoppage of motor in case of belt snap / cut or under speed.

19. Periodic checking of operation of the above three safety devices should be made for
man & machine safety.

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14. TROUBLE SHOOTING
RELATED TO BELT
With the belts in operation on full load it is to be expected that various types of problems crop
up. It is hence important for the Engineer at site to be able to take all possible measures to
prevent most of such troubles before they show up and in cases where they do occur, to be able
to identify and get to the root of what is causing the trouble.
The symptoms, the causes and the cures of common problems that occur with conveyor
belts in service are listed below for easy reference.

S. No Symptoms Causes Remedies

Rubbing due to any of the

following

a Defective Joint Rectify Joint

Check conveyor alignment and re-

b Misaligned running
align belt

Re-position loading chute to feed

c Off-center loading
load centrally

Belt edges
1 Defective self-aligning
worn or frayed d Rectify or replace faulty idler
idler

Minimum recommended clearance

Inadequate edge
e between belt edge and structure is
clearance
100 mm

Install a laterally more flexible belt

Belt too stiff for Repair or paint edges with conveyor
f
adequate troughing belt solution to prevent ingress of
moisture, grit, etc.

.No Symptoms Causes Remedies

Excessive Specify thicker covers of corrects of

Cover under – specified
2 uniform wear of a correct grade depending on loading
or of Incorrect quality
top cover cycle and material carried
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Install cleaning devices of rubber
disc idlers.
Worn or seized Return
b Check periodically if all idlers rotate
Idler
freely. Replace seized idlers with
new ones

Spilled material under Increase clearance between tail

c tail pulley setting up pulley and floor, fit decking to avoid
abrasion spillage

Prevent spillage along the run of the

Return run of belt
conveyor. Check returns idler
rubbing against spilled
d spacing and belt tension. Ensure all
material along the
spilled material is removed
conveyor
immediately

Load disturbance owing

to uneven conveyor Ensure correct conveyor level and
e
level and incorrect idler recommended idler spacing
spacing

Trouble Cause Corrections

Replace or free the idlers,

Non-rotating idlers
improves maintenance.
Conveyor belt
catches fire Rubbing between frame & belting Re-align frame

poor housekeeping Clean up belt line

Advance the end of idler to

One or more idlers in the trouble spot are
which belt has shifted in
not at right angles to centre-line of belt.
the direction of belt travel

Correct the alignment.

Conveyor frame not aligned properly; idler
Conveyor belt bracket is bent Defect to be rectified by
runs to one side at straightening the bend.
a particular point
on the conveyor. Non – rotating idlers Replace or free the idler s

Structure not level & belt tends to shift to

Level the structure.
low side.

Build up of material on idlers. Clean the idlers.

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Conveyor belt
Make changes in loading
runs to one side
station and loading
for some distance Improper loading of belt.
conditions so that load is
along conveyor
centered properly.
line
May be due to newness. If
so, allow proper break-in-
time. It will shorten the
Belt has erratic
break-in-time if belt is
action following
Belt is too stiff kept loaded. Use forward
no particular
tilted troughing idlers of a
pattern
max. of 2 degrees if
conveyor is non –
reversible.

Head / tail pulley or troughing idlers Check alignment of pulley

Approaching head / tail pulley are not and adjacent troughing
Belt running off at aligned. idlers.
head / tail pulley
Remove material, adjust
Build up of material on return idlers. belt cleaners, and provide
better housekeeping.

Trouble Cause Corrections

Replace or free the idlers,

Non-rotating idlers
improves maintenance.

Conveyor belt
Rubbing between frame & belting Re-align frame
catches fire

poor housekeeping Clean up belt line

Advance the end of idler to

One or more idlers in the trouble spot are
which belt has shifted in
not at right angles to centre-line of belt.
the direction of belt travel.

Correct the alignment.

Conveyor belt Conveyor frame not aligned properly; idler Defect to be rectified by
runs to one side bracket is bent. straightening the bend.
at a particular
point on the Non – rotating idlers Replace or free the idlers
conveyor.

Structure not level & belt tends to shift to

Level the structure.
low side.

Build up of material on idlers. Clean the idlers.

20
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Conveyor belt
Make changes in loading
runs to one side
station and loading
for some distance Improper loading of belt.
conditions so that load is
along conveyor
centered properly.
line

May be due to newness. If

so, allow proper break-in-
Belt has erratic time. It will shorten the
action following break-in-time if belt is kept
Belt is too stiff
no particular loaded. Use forward tilted
pattern troughing idlers of a max.
of 2 degrees if conveyor is
non – reversible.

Head / tail pulley or troughing idlers Check alignment of pulley

Approaching head /tail pulley are not and adjacent troughing
aligned. idlers
Belt running off
at head / tail
pulley Remove material, adjust
Build up of material on return idlers. belt cleaners, and provide
better housekeeping.

Increase tension on belt

Slipping between belt and drive pulley or take – up device.
pulleys. Lag drive pulleys or relag if
Excessive wear lagging is worn out.
on bottom side of
Non – rotating troughing idlers. Replace or free the idlers.
belt.
Check scrappers in front of
Material falls between pulley belt. tail / head pulley on return
belt.
Check belt cleaners at head
and tail end.
Dirty , frozen or miss-aligned return idlers.
Clean, repair & align return
idlers.
Increase belt tension if too
Excessive wear Excessive sag between troughing idlers low.
on carrying side causing load to move & shift on belt as it Reduce idler spacing.
of belt. passes over idlers.

Use rubber skirt material.

Abrasive skirt boards.
Avoid use of old belting.

Poor Loading Check feed chute.

21
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Reduce friction by
replacing frozen or worn
out idlers. Provide better
maintenance. Decease
tension by improving drive:
a) Lagging on drive pulleys

b) Increase angle of contact

tandem drive.
Increase speed, If feasible,
Belt requires too Keeping shift tonnage the
Improper alignment of troughing and return
much tension same.
idlers.
resulting in
excessive stretch Reduce tonnage at same
in belt. speed.

Tighten screw take-up just

enough to keep belt from
slipping. On a gravity take-
up,

Reduce counterweight to
minimum amount
sufficient to keep belt from
slipping.

See description above.

Replace belt with proper
Tension too high.
fasteners that have
Wrong type fasteners or fasteners not tight.
required strength.
Fasteners pullout
Use vulcanised splicing if
of belt. feasible.

Use more accelerating

Improper starting
steps in starting.

22
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NOTE:

CONDITIONS DO EXIST ON ANY CONVEYOR THAT CAN CAUSE INJURY TO THE PERSONNEL.
NO MANUAL CAN COVER ALL THE HAZARDOUS CONDITIONS THAT MIGHT DEVELOP.
THEREFORE PERSONNEL INVOLVED SHOULD BE CONSTANTLY ALERT FOR UNSAFE
CONDITIONS AND USE ALL POSSIBLE CARE, ALONG WITH COMMON SENSE AND STRICT
ADHERENCE TO THE COMMON SAFETY STANDARDS TO ESCAPE SAFETY.

23
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ROTARY BREAKER

INSTALLATION , OPERATION MAINTANANCE,

MANUAL
OF
ROTARY BREAKER
CLIENT:- R.R.V.U.N.L-SURATGARH

ORDER NO : - CO/2447

MACHINE NO : - CR : 1290-91

MANUFACTURER:-

ANAND-SOJITRA ROAD, V.V.NAGAR-ANAND

ROTARY BREAKER

INDEX

SECTION:-I

 TECHNICAL DATA SHEET

 INTRODUCTION
 ERECTION AND MAINTENANCE
 OPERATING INSTRUCTION
 MAINTENANCE INSTRUCTION
 CAUTION
ROTARY BREAKER

SECTION:-II

ACCESSORIES

 BEARING (MOUNTING & DIMOUNTING)

 GEAR BOX
ROTARY BREAKER

SECTION:-I
ROTARY BREAKER

ROTARY BREAKER

ORDER NO : - CO/ 2447

M/C NO. : - CR: 1290-91
CLIENT : - R.R.V.U.N.L-SURATGARH.

G.A. DRG. NO. :- M18321/0

TECHNICAL SPECIFICATION :-

TYPE : DRUM TYPE ROTARY BREAKER

MODEL & QTY : 14” X 28”, QTY - 2 NOS. (BOTH ACW)

CAPACITY : 2000 TPH (RATED) / 3000 TPH (DESIGN)

MATERIAL TO BE HANDLED : ROM COAL, HGI:45 TO 65 CONSIDERED

DENSITY : 0.8 T/M3 FOR VOLUME , 1.6/T/M3 FOR

STRUCTURE

INPUT LUMP SIZE : (-) 400 mm – MAX.

PRODUCT SIZE : (-) 200 mm - 90%,(-1 MM LIMITED TO 10%)

MOISTURE : 20% MAX

MOTOR : 250 KW X 1500 RPM.

SQ. CAGE INDUCTION MOTOR
(BY BHEL) NOT BY ELECON

GEAR BOX : SBN 400, RATIO – 18:1

MAKE- ELECON QTY.2 NOS.
ROTARY BREAKER

FLUID COUPLING : ESC-584,AIR COOLED WITH GEARED

COUPLING.-ELECON QTY. 2 NOS.

SPROCKET FOR DRIVE :

1) NO. OF TEETH : 30, QTY . 1 NO.

2) PITCH : 3” TRIPLEX

CHAIN : TRIPLEX CHAIN 3” PITCH

SPROCKET FOR DRIVEN :

1) NO. OF TEETH : 136 ,QTY . 1 NO

2) PITCH : 3” TRIPLEX

MATERIAL OF CONSTRUCTION :-
CASING : ST- 42 ROLLED STEEL, 5MM THIK

SPIDER : ST- 42 ROLLED STEEL

SCREEN PLATE : Mn. STEEL/LA-55/SALIMA-350/450HI-25MM

.THK

TIRE RIM(SPLIT TYPE) : GS42 CrMo4 /080M40/FORGED ALLOY

STEEL

SUPPORT WHEEL SHAFT : FORGED ALLOY STEEL

LIFTING SHELVES : CAST Mn STEEL,

SUPPORT WHEEL : CAST STEEL, Gr-II, IS: 2707

GUIDE ROLLER : ALLOY STEEL , IS:2004

GUIDE ROLLER BRG. : TAPER ROLLER BEARING

REFUSE PLOUGH : ST – 42 ROLLED STEEL
METHOD OF LUBRICATION : BY GREASE GUN.MANUALLY
DEFLECTOR PLATE : TISCRAL/ SAILHARD/Equi.
ROTARY BREAKER

ROTARY BREAKER

1. INTRODUCTION

The material handling plant of a Thermal Power Station usually includes crushing and
screening units. The crushing unit either primary or secondary type is by a vibrating screening unit.
Rotary Breaker is a unique machine combining breaking and screening units. It comprises of a
huge perforated cylindrical screening shell fitted with tyres and mounted on supporting guide rollers.
Deflector plates are fixed circumferentially inside the shell at feed end. Adjustable lifting shelves are
fixed radically all along the shell. The Shell is enclosed in a casing to avoid dust pollution. At the
discharge end of the shell a refuse plough aids in the discharge of un-crushable material.

Rotary Breaker is chain driven and operates at low frequencies. The machine is charged with
ROM Coal from mines, at the feed end of the shell. Minus size lumps i.e. below the stipulated Screen
opening make their way through the screening shell. Larger lumps , scooped up by the adjustable
lifting shelves , fall in the screening shell due to gravity. The deflector plates at the feeder end force
the feed to flow along the shell. Adjustable lifting shelves control the flow velocity and the number of
impacts of the feed. Hard material like bony sulphur , ore ., slate , rock etc. if present in the feed are
scavenged and discharged through refuse chute.

Rotary breaker is built of components made of selected material to sustain extraordinary

operating conditions. This makes it one of the most reliable rugged full proof and dependable
machine.
ROTARY BREAKER

2. ERECTION AND INSTALLATION

The supports of Rotary breaker are usually built integral with the building. The principal
beams which carry the shell supports are constructed out of reinforce concrete members. These are so
designed as to ensure the rigidity of the machine during operation. An allowance of 2.5 to 3.0 over the
dead weight figures shown in the certified General Arrangement and foundation Drgs. is
recommended in the design of supports to account for line loads. Before erecting the machine check
that The supporting structure foundations are laid in accordance with the foundation drawing.

The bed plates are to be so laid that, they are parallel to one another. The center distance
shown in the G.A.Drg.must be strictly adhered to ensure minimum end clearance or float as shown in
the erection diagram no.1. The center distance between the rollers must be measured in two
directions i.e. parallel and perpendicular to the axis of the shell. The diagonal distance of the rollers
must be measured and they must be equal to ensure correct location, as shown in fig.1.

The both spiders ( end cones ) are mounted vertically held in position by supports and props at
a slightly gather distance than indicated in the G.A.Drg the special beams are then rigidly bolted in
sequence as shown in fig.2 , using fitting bolts and nuts. The end cones are then fitted to the " T "
beam unit with end cones is mounted on supports. The rotation of the supporting assembly is
prevented by use of suitable fixture. The shell screens plates are then bolted bolted to the Skelton
accommodate deflector plates and lifting shelves. Lifting shelves and deflector plates are to be initially
assembled in their mean position as shown in erection diagram no. 1 & 5 the final position of these
are established only after testing under working conditions to suit the feeder rate of material through
effuse chute, after all parts are properly assembled. In this final position the lifting and deflectors must
be securely tightened . Refuse plough is fixed at the discharge end of the machine.

The drive unit of the machine comprising of an electric motor , fluid coupling , gear box
chain with sprockets at drive and non-drive ends are to be assembled the same order on a suitable
base. The roller chain is to be so assembled that the chain tension prevents the movement in return
ROTARY BREAKER

side. Feed and refuse chutes are to be assembled with suitable reinforcements to be enclosed in
chain guard and casing respectively to ensure safety of personnel and to control dust. Before
attempting to start the machine, roller chains, gear box , bearing ,sprockets etc. ,should be properly
lubricated. The machine should run successfully for a minimum of eight hours on no load before it
is fixed permanently to the foundation. The alignment of support roller must be thoroughly
checked during the trial run.

The axes of the drum and the support rollers must be perfectly horizontal, so that the roller
parts do not rub against one another resulting in the wear of the same. For these the axes of rollers
must be parallel not only with one another but also with that of shell screen ( fig-1 ).The machine
should not float towards either end. But during operation the shell slightly floats towards the feed
end when running under light or no load and towards discharge end when running on full load. To
adjust the miss-aligned supports roller and for maintenance purpose sometimes the machine needs
to be floated towards either end. This has to be achieved by equally shifting the roller in pairs, thus
maintaining the parallelism of the axes of support roller with that of the shell Ref .Fig.3. Rollers of
only one end must not be disturbed as this will result in tilting the axis of the shell disturbing the
balance of the machine. Refer Fig.4.The alignment of support rollers must be checked as indicated
in Fig.1 after setting the support roller assembly.

The feed and refuse chute must be free from dust deposits to ensure smooth flow in to and
out of the machine. It is advised to enclose the end cones to protect them from dust. The axial
movement of the shell is prevented by the Guide Roller assemblies on either end of the machines.
The Guide Rollers are always in contact with the faces of the tier ring as shown in Fig.5 .The
instructions to install the guide roller assemblies are as under. Locate the maximum run out point
of the tyre ring on the face which shall have to be facing the guide roller. Keep a gap about 1 MM
between the roller face and max. run out of the tyre ring and locate the guide roller assembly. The
roller and pin location is to be such that the right angles to the centre line of the machine. So that
the adjustment is possible either to increase or decrease the gap between the roller and tyrering
faces at a later date due to wear etc. At this position of the guide roller, weld the roller stand on the
base frame of the rotary breaker.
ROTARY BREAKER

ERECTION DIAGRAMS

DIA.1 Shows the orientation of lifting shelf with respect to screen plate and direction of
rotation of Rotary Breaker.

DIA.2 Shows the position of refuse plough with respect to direction of rotation of Rotary
Breaker.

DIA.3 Shows the play between plain wheel and tyre ring.

OPERATING INSTRUCTION

The feeder to a Rotary Breaker should be as even as it is possible and if the feed chute is steep
so as to cause rushes of the feed material down the length of Rotary Breaker. Some from of
restriction must be used to avoid it. The life of screen plates can be enhanced by ensuring a bed of
material in the shekel, except when the machine is idling. Should there be excessive breakage of
feed material then the angle of the lifting shelves must be increase in order to speed the passage of
the feed through the breaker.

If however , considerable quantity of breakable material is being discharged with rejects, then
the shelves may be set , at a lesser angle ( almost horizontal in extreme cases).Various
arrangements of the material drum details can be used , but it is important to see that
configuration is kept in balance at all times.

The discharge and Refuse chutes should be watched for building up of dust. Clearing of dust
collected in the vicinity of supporting and guide rollers must be carried out at the end of except
each shaft. The dust problem can be minimized by enclosing the end cones as much as possible and
ROTARY BREAKER

by employing suitable dust collection system. The tightness of the bolts holding the screen plates
and other internal parts should be checked At the least one in a week or as found necessary.
Periodic tightening will have to be carried out to Account for loosening of the bolts due to the
continuous shocks of material which fall on the shell plates.

The roller mounted machine should be periodically checked for misalignment wear while dust
the machine is in operation ensures that there are no excessive vibrations. The support rollers and
guide rollers must run free. Refer to the instruction under “CAUTION "before starting the machine.
ROTARY BREAKER

IMPORTANT NOTE

DURING COMMISSIONING / OPERATION OF THE MACHINEAS REGARDS FIXING BOLTS,

FOLLOWING POINTS SHOULD BE TAKEN CARE.

 WHILE FIXING THE BOLTS , USE THREAD SEALING SOLUTION.

 AFTER ERECTION OF MACHINE DURING NO LOAD TRIAL ALL BOLTS

 SHOULD CHECKED AND TIGHTED AFTER 10 TO 15 HOURS OF OPERATION.

 CHECKED AND TIGHT THE BOLTS AFTER EVERY 400 HOURS OF OPERATION.

 DO NOT USE SUB GRADED BOLTS, NUTS AND WASHERS.

ROTARY BREAKER

MAINTEANANCE INSTRUCTION

TYPE OF DEFECTS :-

o EXCESSIVE VIBRATION

o FACE OUT

o RUBBING OF TYRE RING AGAINST THE SURFACE OF ROLLER.

o UNEVEN WEAR

o SEERING OF ROLLERS AND TYRE RINGS.

REMIDIES :-

(B) EXCESSIVE VIBRATION.

THIS MAY BE DUE TO.

o IMPROPER BALANCING

o UNEVEN WEAR

o WEAR AND IMPROPER FOUNDATION.

B.1 IMPROPER BALANCING OF SCREEN PLATES:

Let rotor to be run for some time (without load ) and put off the switch so that rotor will come to
half. Make a chalk mark on the lowest position of the tyre ring. Again put of the machine and bring
it to half observe the position of the chalk mark previously made .If that mark is not at the lowest
position but in different position, again make a new chalk mark at the new lowest position of the
riding ring.

Respect to this several times , if each times the position of the mark changes then it is an
indication that the balancing is correct. If on the contrary it is found that the mark first made always
ROTARY BREAKER

comes to the lowest position then it is an indication of improper balancing and suitable weights
should be added to the side of shell opposite to the mark. By repeating this procedure for a no. of
times the rotor should be balanced , so that it comes to rest at any position along the
circumference of the tyre ring and not a specific point.

B.2 . UNEVEN WEAR OF ROTATING PARTS

If after balancing the rotor vibrations still persist then check the tyre ring and roller for any uneven
wear. If there is any ovality either in the tyre ring or in the rollers these may also cause vibrations.
These defects have to be removed by machining the part .In doing so special care must be taken to
ensure that all the rollers and tyre ring among themselves are finished to their respective common
diameters.

B.3 . WEAR & IMPROPER FOUNDATION.

If after eliminating then above two defects vibrations still persists then they may be done to a poor
foundation this defects has to be tackled by the Civil Engineering Dept.
C. THE FACE RUN OUT OF ROTOR MAY BE DUE TO THESE REASONS

(a) Axial displacement of shell.

(b) Facial displacement of shell.
(c) Rubbing of tyre ring against faces of roller.
The axial run out and facial run out are shown in the sketch A&B respectively.

C.1 AXIAL DISPLACEMENT OF SHELL

In this case the faces of rollers may be parallel ( sketch – A ) and true but the distance must be x
only. It should not vary like X1, X2, X3 & X4.This variation would cause a skew to the rotor and
would tends to float on either direction causing shear and rubbing against the roller flanges .To
correct this defects the bearing closures fitted on shaft ends are to be removed and measuring aids
are to be introduced in the shaft centre and the distance X is to be set correctly from rotor line
maintaining the parallelism of the roller flanges.

C.2 FACIAL DISPLACEMENT OF SHELL

ROTARY BREAKER

If the roller flanges are out as shown in Sketch- B this also would tends to knock the rotor causing
end float to rotor. This defect can be corrected by the help of plane wire tied perpendicular to rotor
axis. The installation procedure can be referred in the connection.The face run out due to
machining fault or assembly fault is an in born defect. If it is a small Amount within 2 to 3 mm. This
may be left as it is. If it is excessive this may corrected by remachining or reassembly as the case
may be.

C.3 RUBBING OF TYRE RING AGAINST FORCES OF ROLLER

Rubbing of tyre ring against faces of rollers. This occurs due to two reasons.

1. Face run out of rotor and rollers as discussed earlier.

2. Due to un-balance shift of rollers.

For this there should be equal distance between the rollers centre line at the feed end as well
as discharge end.

D. Uneven wear:

Uneven wear on Rollers and Tyre ring may take place on account of 3 Reasons.

D.1. Improper relative motion of rollers and tyre ring due to bearing jam.

D.2. Difference in hardness of individual rollers.

D.3. Improper support of tyre ring on rollers or improper bearing of rollers against tyre ring.

 The rollers mounted on defective bearing will have staggered relative motion and have an
irregular wear.

 The same may be transferred to tyre ring.

 If the hardness of the four rollers are not maintained equally the wear rate will differ.

E. Scoring and Furrowing of Rollers and Tyre rings :

Scoring may be due to face run out of either of the tyre rings or the rollers or both
together. This run out causes the rotor to travel axially to and fro. This rotation of the heavy mass
combined with this to and from action results in screw motion between the rollers and the tyre
ROTARY BREAKER

rings causing damage to both of them. Another cause may be the improper relative motions of
rotor & rollers due to bearing jam.

The score marks should be carefully examined. If the score is due to axial run out the mark may
be slightly inclined. If there is a bearing jam a small amount of flatness may be corrected by feeling
the bearing or by replacing the bearings. The react due to skew of the rotor and its correction was
deal under the heading face run out .The burring and budge out of material on the side of tyre ring
as well as on roller may occur due to uneven hardness of the material. Softer the material higher
the rate of burring. So higher the hardness of the material to be used.
ROTARY BREAKER

CAUTIONS
 Do not run the Rotary Breaker without proper lubrication.

 Do not operate Rotary Breaker if excessive vibration is developed during operation.

 Do not start Rotary Breaker with load, machine should be clear or rushing material before
starting feeding.

 Check periodically loosening of the Plummer block holding down bolts and alignment of the

coupling. Loose bolts and misaligned Coupling may result in excessive vibration.

 Check the bearing clearance before commissioning the Rotary Breaker. Excessive bearing
clearance may cause excessive vibration.

 Feed to the Rotary Breaker should be uniform to avoid uneven wear. Excessive vibration may
developed during operation if the bearing of the components are not uniform.

 If the feed material contains more moisture than specified it will result in reduction of capacity
and increase of power consumption.

 DO not modify or disconnect any Mechanical /Electrical System without consulting" ELECON”

 Check oil level in chain casing , Fluid coupling and Gear box.

 Check the alignment of,

a. Motor and Gear box

b. Tyre ring and Wheel

 Check the direction of adjustable lifting shelves with the direction of rotation of Cylinder. Refer
Erection diagram no.1

 Check the location of tyre ring on the wheel as per erection diagram no.3

 Check the tightness and slackness of the chain.

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