SOP For Coal Unloading and Loading at CHP-1

OPG POWER GENERATION PVT LTD.
, DOC NO:
2X77,1X80 & 1X180MW THERMAL POWER PLANT OPGPG/0/OPN/CHP/01/01
DOC TITLE SOP FOR COAL HANDLING PLANT-I REV 0 DATE 24-JUNE-2012
NO
Objective
The objective of this document is to guide the operation engineer in Operating the Coal handling
plant in safe and sequential manner and to ensure uninterrupted supply of coal to the bunkers
Description
 HTT’s unloads incoming coal from HTT1 and HTT2 and receives in two conveyor stream BC1 &
BC1A respectively. Unloading can also be done through Hopper 1 and Hopper 2.
 Coal from BC1, BC1A and BC 2 streams is fed, through a series of belt conveyors to the CHP-1
coal yard. THE stream has toothed roller crusher 1A and 1 B from screeners 1A and 1B.
 CHP-1 storage yard No. 1 has a storage capacity approx of 25,000 MT.
 Coal being fed from BC1, BC 1A and BC 2 are being feed through the stacker 1 which stores the
coal in bay wise from A to H bay and each bay being spitted into ten section say A1 to A10.
 Reclaimed coal from the storage yard through reclaimer 1 and reclaimer 2 is fed to 1,2&3 unit
bunker through Conveyor series of BC 3, BC 2A BC 4,BC 7A & BC 7B bunkered through BC 7A
or BC 7B tripper cars in Unit-1, 2&3.For Unit-4 bunker coal feed through conveyor series of BC 3 ,
BC 2A BCN 8A,8B,9A,9B,10A&10B with help of 10 A & 10B Tripper cars
 CHP 1 has a capacity of unloading at the rate of 300 TPH.
 Direct bunkering can be performed without stacking through the series BC 1 , BC 1A BC 2, BC 2A,
BC 4 .From BC 4 can feed through either BC 7A or BC 7B IN Unit-123
 Direct bunkering can be performed without stacking through the series BC 1 , BC 1A BC 2, BC 2A

BCN 8A. From BCN 8A can feed through either BCN 9A or BCN 9B and BCN 10 A or BCN 10 B
System Technical Data
BC1 BC1A BC2 BC2A BC3 BC4 RBC

415+/- 415+/- 415+/-
VOLTAGE 415 10% 415 10% 10% 415 415
CURRENT 62.2 33 65 38 38 96 28.5
POWER(KW) 37 18.5 37 22.8 22 55 15
FREQ 50 50 50 50 50 50 50
P.F 0.86 0.86 0.82
SPEED 1470 1470 1470 1470 1470 1460
INSULATION Class F Class F Class F Class F Class F Class F Class F
DUTY S1 S1 S1 S1 S1 S1 S1
CONNECTOIN Delta Delta Delta Delta Delta
EFFICIENCY 91 92.5 91.5 91.5 93 90
TORQUE(Nm)
ENCLOSURE IP55 IP55 IP55 IP55
OPG POWER GENERATION PVT LTD., DOC NO:
NO
Relevant Hazards and Required PPE’s
Hazards:
 Dust
 Smoke
Required PPE’s
 Helmet
 Safety shoes
 Nose Mask
 Goggles
Pre checks lists for CHP Engineers
 Drive condition
o Gear box oil level temp (Physically touching OK/not OK
o Fluid coupling leakage
o Coupling guards
o Vibration (if any)
 Belt condition (Tear,damage etc.)
 Safety guards for
o Fluid Coupling
o Gear Flexible coupling
o Gravity Take-up
o Head-end return
o side guards
 Abnormal vibration at drive end/tail pulley/bend pulleys (if any)
 Belt running with sway
o Under no load
o Under load
 Belt joint defects, if any
 Pulley's lagging condition
 Belt scrapers availability and it's effectiveness.
 External scrapper at discharge pulley
o External scrapper at head-end return side
o Internal scrapper at tail- end
 Abnormality of rollers operation
o Carrying
o Return
o Impact
o others
 Skirt rubber condition
NO
 GTU Condition
 Structure
o Counter-weight box guide
o Coal build-up, if any
o Position of counter-
o weight box
to be checked On idle conveyor
While in service
 Chute punctures, if any
 Walkway damages/obstructions
 Spillages/coal accumulation
 Inspection doors condition
 Receiving chute
 Discharge chute
 Missing roof/side sheets if any
 Chute build-up/caking (if any)
 Scraps and other material in the vicinity to be cleared.
 Coal spillage, presence of scraps & condition of house-keeping
 Defective pull cord & belt sway zero speed switches (if any) and pull cord availability
 Condition of conveyor lighting
 Availability of fire fighting
 Fire hazard, if any, including\ coal dust accumulation on cable tray
 Other points (such as gallery vibration, openings to be closed, missing hand-rails etc.)
 Adherence to safety norms during O&M activities, if being carried out
NO
1. Start up / Shutdown/Isolation Procedure
Sr.
Activity Action By
No
1 Taking in service and Isolation of Hydraulic Tippler (HTT 1 & HTT 2)
A Taking Hydraulic Tippler in service
1 Ensure that all Permit are cleared CHP Opr
2 Ensure that the vehicle to be unloaded is weighed (Gross weight) CHP Opr
3 Ensure that hydraulic circuit is lined up CHP Opr
4 Ensure that hydraulic tank level is OK CHP Opr
5 Ensure the corresponding Vibrating feeder of the bunker to be loaded is ON CHP Opr
6 Ensure the corresponding MRP Gate of the bunker to be loaded is Open CHP Opr
7 Ensure BC 1, BC 1A, BC2 & Stacker I I are running CHP Opr
8 Switch ON 415 V supply to Local control panel from Coal Handling MCC 2 Swgr Opr
9 Switch ON 415 V supply isolator at Local control panel CHP Opr
10 Switch ON hydraulic pump CHP Opr
11 Ensure Cooling fan has started CHP Opr
12 Raise the retractable stopper from the local control panel CHP Opr
13 Allow the vehicle to be unloaded on the tippler platform CHP Opr
Hook the chains to the chassis of the vehicle to be unloaded and adjust the hook
14 CHP Opr
position as needed
15 Ensure that there is nobody in the vehicle CHP Opr
16 Ensure that the rear gate of the vehicle is open CHP Opr
NO
Sr.
Activity Action By
No
16 Slowly raise the hydraulic tippler to an angle of @ 45 deg CHP Opr
17 Ensure that the vehicle is empty CHP Opr
18 Slowly lower the hydraulic tippler to its Normal ground level CHP Opr
19 Unhook the chains CHP Opr
20 Lower the retractable stopper from the local control panel CHP Opr
21 The vehicle can now be sent for weighing its Tare weight CHP Opr
Stop the Hydraulic pump if there are no more trucks to be unloaded from the Hydraulic
22 CHP Opr
Tippler
B Isolation of Hydraulic Tippler (HTT 1 & HTT 2)
1 Ensure that Hydraulic Tippler is in Horizontal position CHP Opr
2 Ensure that retractable stopper is down CHP Opr
3 Stop Hydraulic pump CHP Opr
4 Ensure Cooling fan has stopped CHP Opr
5 Switch OFF 415 V supply to Local control panel CHP Opr
6 Switch OFF 415 V supply to Local control panel from Coal Handling MCC 2
Switch tags on the following isolating points
 415 V supply to Local control panel CHP Opr
 415 V supply breaker to Local control panel Swgr Opr
7 Give clearance to maintenance for commencing their work CHP Opr

NO
Sr.
Activity Action By
No
Taking in service and Isolation of Tippler Unloading Hopper (HOPPER 1 &
HOPPER 2)
A Taking Tippler Unloading Hopper in service
1 Ensure that all Permit are cleared CHP Opr
2 Ensure BC 1, BC 1A, BC2 & Stacker I I are running Swgr Opr
3 Switch ON 415 V supply to Vibrating feeder Swgr Opr
4 Switch ON 415 V supply to MRP Gate Swgr Opr
5 Start Vibrating feeder CHP Opr
6 Open MRP Gate and check it has opened locally CHP Opr
7 Coal can now be unloaded into the hopper CHP Opr
B Isolation of Tippler Unloading Hopper
1 Ensure no trucks are being unloaded into the hopper and that it is empty CHP Opr
2 Stop Vibrating feeder Swgr Opr
3 Close MRP Gate and check it has closed locally CHP Opr
4 Switch OFF 415 V supply to Vibrating feeder Swgr Opr
5 Switch OFF 415 V supply to MRP Gate Swgr Opr

NO
Sr.
Activity Action By
No
6 Switch tags on the following isolating points
 Vibrating feeder Local Push button CHP Opr
 MRP Gate Local Push button CHP Opr
 415 V breakers to Vibrating feeder Swgr Opr
 415 V breakers to MRP Gate Swgr Opr
7 Give clearance to maintenance for commencing their work Shift in charge

NO
Sr.
Activity Action By
No
Taking in service and Isolation of Belt Conveyor 1
A Taking Belt Conveyor 1 in service
1 Ensure Crusher & Vibrating screen, BC 1A, BC 2 & Stacker I I are running CHP Opr
2 Switch ON Belt Conveyor 1 breaker Swgr Opr
3 Ensure that all Pull chords and sway switches are not operated CHP Opr
4 If the Auto program is ON, ensure that BC 1 starts CHP Opr
5 If the Auto program is OFF, start BC 1 locally CHP Opr
6 Ensure BC 1 is running OK CHP Opr
B Isolation of Belt Conveyor 1
1 Ensure no trucks are being unloaded into the hoppers CHP Opr
2 Ensure all Vibrating feeders are OFF CHP Opr
3 If the Auto program is ON, ensure that BC 1 stops CHP Opr
4 If the Auto program is OFF, stop BC 1 locally CHP Opr
5 Switch OFF Belt Conveyor 1 breaker Swgr Opr
6 Switch tags on the following isolating points CHP Opr
 Belt Conveyor 1 breaker CHP Opr
 415 V breakers of all MRP Gates Swgr Opr
 415 V breakers of all Vibrating feeders Swgr Opr

NO
Sr.
Activity Action By
No
Taking in service and Isolation of Crusher & Vibrating screen
A Taking Crusher & Vibrating screen in service
1 Ensure BC 1A, BC 2 & Stacker I I are running CHP Opr
2 Switch ON 415 V supply to Crusher & its Vibrating screen changeover damper Swgr Opr
3 Line up one Crusher & its Vibrating screen CHP Opr
4 Switch ON Crusher & its Vibrating screen, 415 V breaker CHP Opr
5 If the Auto program is ON, ensure that Crusher & its Vibrating screen starts CHP Opr
6 If the Auto program is OFF, start Crusher & its Vibrating screen locally CHP Opr
7 Ensure currents and other parameters are OK Swgr Opr
Isolation of Crusher & Vibrating screen
3 Ensure BC 1 is not running CHP Opr
4 If the Auto program is ON, ensure that Crusher & its Vibrating screen stop CHP Opr
5 If the Auto program is OFF, stop Crusher & its Vibrating screen locally CHP Opr
6 Switch OFF Crusher & its Vibrating screen breakers CHP Opr
7 Switch tags on the following isolating points

NO
 Both Crushers breakers Swgr Opr
 Both Vibrating screens breakers Swgr Opr

NO
Sr.
Activity Action By
No
Taking in service and Isolation of Belt Conveyor 1A
A Taking Belt Conveyor 1A in service
1 Ensure all Permit are cleared CHP Opr
2 Ensure BC 2 & Stacker Is are running CHP Opr
4 Switch ON Belt Conveyor 1A breaker Swgr Opr
5 If the Auto program is ON, ensure that BC 1A starts CHP Opr
6 If the Auto program is OFF, start BC 1A locally CHP Opr
7 Ensure BC 1A is running OK CHP Opr
B Isolation of Belt Conveyor 1A
3 Ensure Belt Conveyor 1 is OFF CHP Opr
4 If the Auto program is ON, ensure that BC 1A stops CHP Opr
5 If the Auto program is OFF, stop BC 1A locally CHP Opr
6 Switch OFF Belt Conveyor 1A breaker Swgr Opr
 Belt Conveyor 1A breaker CHP Opr

NO

NO
Sr.
Activity Action By
No
Taking in service and Isolation of Belt Conveyor 2
A Taking Belt Conveyor 2 in service
2 Ensure Stacker I is running CHP Opr
3 Ensure Belt Conveyor 1 is OFF CHP Opr
3 Ensure Belt Conveyor 1A is OFF CHP Opr

NO

NO
Sr.
Activity Action By
No
Taking in service and Isolation of Stacker I
A Taking Stacker I in service
2 Switch ON Stacker I breaker Swgr Opr
3 Switch ON QF1 to QF10 CHP Opr
4 Ensure QF 11 is OFF CHP Opr
5 Press Fault restoration button on HMI CHP Opr
6 Press Control power PB (illuminated) on panel door CHP Opr
7 Switch ON all motor MPCBs CHP Opr
8 Reset HMI by pressing Fault restoration button CHP Opr
9 Switch ON QF11 CHP Opr
10 Reset HMI by pressing Fault restoration button CHP Opr
11 Select Local from HMI panel CHP Opr
12 Select Manual from HMI panel CHP Opr
13 Start Hydraulic pump CHP Opr
14 Press Up / Down buttons to position the boom to the required level CHP Opr
15 Run the boom conveyer CHP Opr
Move the Stacker I either Left or Right using “Travel left” or “Travel Right “ buttons on
16 CHP Opr
HMI
B Isolation of Stacker I
NO
1 Switch OFF 415 V supply to HMI panel Swgr Opr
Swgr Opr /
2 Switch the permit on staker breaker and staker panel
CHP Opr
NO
Sr.
Activity Action By
No
2 Ensure that Belt Conveyor 4 7A or 7B are in service CHP Opr
1 Ensure that neither the Stacker I nor Reclaimer are in service CHP Opr
2 Ensure that Stacker I breaker is OFF CHP Opr
3 Ensure that Reclaimer breaker is OFF CHP Opr
3 If the Auto program is ON, ensure that BC 2A stops CHP Opr
4 If the Auto program is OFF, stop BC 2A locally CHP Opr
 Reclaimer breaker breaker CHP Opr

NO
 Stacker I breaker CHP Opr

NO
Sr.
Activity Action By
No
Taking in service and Isolation of Reclaimer 1 and Reclaimer 2
A Taking Reclaimer in service
1 Ensure all Permit are cleared CHP opr
2 Ensure BC 2A, BC 4 are running CHP opr
3 Switch ON QF1 to QF10 MCB CHP opr
4 Ensure QF 11 MCB is OFF CHP opr
5 Switch ON Control power PB (illuminated) on panel door CHP opr
6 Switch ON QM1, QM2, QM3, QM5 & QM6 MCBs CHP opr
7 Switch ON QF11 MCB CHP opr
8 Reset HMI by pressing Fault restoration button CHP opr
9 Select Local from HMI panel CHP opr
10 Select Manual from HMI panel CHP opr
Position the scrapper boom to required level by Selecting either “Up quickly” or “Down
11 CHP opr
Quickly” OR selecting either “Up slowly” or “Down slowly”
12 Start Scrapper motor CHP opr
Move the Reclaimer either Left or Right using “Travel left” or “Travel Right “ buttons on
13 CHP opr
HMI
B Isolation of Reclaimer
1 Switch OFF 415 V supply to HMI panel Swgr Opr
Swgr Opr /
2 Switch the permits on Reclaimer breaker and local panel
CHP Opr.
NO
Sr.
Activity Action By
No
Taking in service and Isolation of Belt Conveyer 3
A Taking Belt Conveyer 3 in service
2 Ensure BC 2A, BC 4 are running CHP Opr
1 Ensure Reclaimer or Stacker I is not in service CHP Opr
 Reclaimer 415 V breaker CHP Opr
 Stacker I 415 V breaker CHP Opr

NO
Sr.
Activity Action By
No
Taking in service and Isolation of Belt Conveyer 4
A Taking Belt Conveyer 4 in service
2 Ensure BC 7A or 7B and Trippler Trolley lined up and are running CHP Opr
B Isolation of Belt Conveyer 4
2 Ensure Belt Conveyor 2A is not in service CHP Opr
3 Ensure Belt Conveyor 3 is not in service CHP Opr

NO

NO
Sr.
Activity Action By
No
Taking in service and Isolation of Belt Conveyer 7A
A Taking Belt Conveyer 7A in service
2 Ensure Tripper Trolley IS lined up and is ON CHP Opr
B Isolation of Belt Conveyer 7A
2 Ensure Belt Conveyors 2A, 3 & 4 are not in service CHP Opr

NO
Sr.
Activity Action By
No
Taking in service and Isolation of Tripper Trolley 7A
A Taking Tripper Trolley in service 7A
2 Ensure Tripper Trolley is lined up to one of the bunkers CHP Opr
4 Switch ON Tripper Trolley breaker Swgr Opr
Sr.
Activity Action By
No
Taking in service and Isolation of Belt Conveyer 7B
A Taking Belt Conveyer 7B in service
2 Ensure Trippler Trolley IS lined up and is ON CHP Opr
NO
4 Switch ON Belt Conveyor 7B breaker Swgr Opr
5 If the Auto program is ON, ensure that BC 7B starts CHP Opr
6 If the Auto program is OFF, start BC 7B locally CHP Opr
7 Ensure BC 7B is running OK CHP Opr
B Isolation of Belt Conveyer 7B
2 Ensure Belt Conveyors 2A, 3 & 4 are not in service CHP Opr
5 Switch OFF Belt Conveyor 7B breaker Swgr Opr
 Belt Conveyor 7B breaker CHP Opr
7
Give clearance to maintenance for commencing their work Shift in charge
NO
Sr.
Activity Action By
No
Taking in service and Isolation of Trippler Trolley 7B
A Taking Trippler Trolley in service 7B
2 Ensure Trippler Trolley is lined up to one of the bunkers CHP Opr
4 Switch ON Trippler Trolley breaker Swgr Opr
5 If the Auto program is ON, ensure that BC 7B starts CHP Opr
6 If the Auto program is OFF, start BC 7B locally CHP Opr
7 Ensure BC 7B is running OK CHP Opr
Sr.
Activity Action By
No
2 Ensure that Belt Conveyor 9A or 9B and 10A or 10B are in service CHP Opr
5 Ensure that BC 2A Flap gate feedback are changed in 8A side CHP Opr
5 If the Auto program is ON, ensure that BCN 8A starts CHP Opr
6 If the Auto program is OFF, start BCN 8A locally CHP Opr
7 Ensure BCN 8A is running OK CHP Opr

NO
3 If the Auto program is ON, ensure that BCN 8A stops CHP Opr
4 If the Auto program is OFF, stop BCN 8A locally CHP Opr
 Reclaimer breaker CHP Opr
Sr.
Activity Action By
No
2 Ensure that Belt Conveyor 10A or 10B are in service CHP Opr

NO
Sr.
Activity Action By
No
Taking in service and Isolation of Belt Conveyor 9B
A Taking Belt Conveyor 9B in service
2 Ensure that Belt Conveyor 10A or 10B are in service CHP Opr
5 If the Auto program is ON, ensure that BCN 9B starts CHP Opr
6 If the Auto program is OFF, start BCN 9B locally CHP Opr
7 Ensure BCN 9B is running OK CHP Opr
B Isolation of Belt Conveyor 9B

NO
3 If the Auto program is ON, ensure that BCN 9B stops CHP Opr
4 If the Auto program is OFF, stop BCN 9B locally CHP Opr
Sr.
Activity Action By
No
Taking in service and Isolation of Belt Conveyer 10A
A Taking Belt Conveyer 10A in service
2 Ensure Tripper Trolley is lined up and is ON CHP Opr
B Isolation of Belt Conveyer 10A

NO
2 Ensure Belt Conveyors 2A,3,8A,9A are not in service CHP Opr
7
Sr.
Activity Action By
No
Taking in service and Isolation of Tripper Trolley 10B
A Taking Tripper Trolley in service 10B
NO
Sr.
Activity Action By
No
Taking in service and Isolation of Belt Conveyer 10B
A Taking Belt Conveyer 10B in service
2 Ensure Tripper Trolley is lined up and is ON CHP Opr
B Isolation of Belt Conveyer 10B
2 Ensure Belt Conveyors 2A,3,8A,9B are not in service CHP Opr
3 If the Auto program is ON, ensure that BCN 9B stops CHP Opr
4 If the Auto program is OFF, stop BCN 9B locally CHP Opr

NO
7
Sr.
Activity Action By
No
Taking in service and Isolation of Tripper Trolley 10B
A Taking Tripper Trolley in service 10B

OPGPG/0/OPN/CHP/01/01
2X77&1x80,1X180 MW THERMAL POWER PLANT
DOC TITLE SOP FOR COAL HANDLING PLANT-I 0
R DATE 24-JUNE-2012
E
V
2. Single Line diagram with All equipment/Local isolation/Root valves
N
O
OPGPG/0/OPN/CHP/01/01
2X77&1x80,1X180 MW THERMAL POWER PLANT
DOC TITLE SOP FOR COAL HANDLING PLANT-I 0
R DATE 24-JUNE-2012
E
V
N
O

SOP For Coal Unloading and Loading at CHP-1

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OPG POWER GENERATION PVT LTD.

 Direct bunkering can be performed without stacking through the series BC 1 , BC 1A BC 2, BC 2A

System Technical Data

BC1 BC1A BC2 BC2A BC3 BC4 RBC

Relevant Hazards and Required PPE’s

Pre checks lists for CHP Engineers

1. Start up / Shutdown/Isolation Procedure

1 Taking in service and Isolation of Hydraulic Tippler (HTT 1 & HTT 2)

A Taking Hydraulic Tippler in service

1 Ensure that all Permit are cleared CHP Opr

3 Ensure that hydraulic circuit is lined up CHP Opr

4 Ensure that hydraulic tank level is OK CHP Opr

7 Ensure BC 1, BC 1A, BC2 & Stacker I I are running CHP Opr

9 Switch ON 415 V supply isolator at Local control panel CHP Opr

10 Switch ON hydraulic pump CHP Opr

11 Ensure Cooling fan has started CHP Opr

13 Allow the vehicle to be unloaded on the tippler platform CHP Opr

15 Ensure that there is nobody in the vehicle CHP Opr

16 Slowly raise the hydraulic tippler to an angle of @ 45 deg CHP Opr

17 Ensure that the vehicle is empty CHP Opr

19 Unhook the chains CHP Opr

B Isolation of Hydraulic Tippler (HTT 1 & HTT 2)

1 Ensure that Hydraulic Tippler is in Horizontal position CHP Opr

2 Ensure that retractable stopper is down CHP Opr

3 Stop Hydraulic pump CHP Opr

4 Ensure Cooling fan has stopped CHP Opr

5 Switch OFF 415 V supply to Local control panel CHP Opr

Switch tags on the following isolating points

 415 V supply to Local control panel CHP Opr

 415 V supply breaker to Local control panel Swgr Opr

7 Give clearance to maintenance for commencing their work CHP Opr

A Taking Tippler Unloading Hopper in service

1 Ensure that all Permit are cleared CHP Opr

2 Ensure BC 1, BC 1A, BC2 & Stacker I I are running Swgr Opr

3 Switch ON 415 V supply to Vibrating feeder Swgr Opr

4 Switch ON 415 V supply to MRP Gate Swgr Opr

5 Start Vibrating feeder CHP Opr

7 Coal can now be unloaded into the hopper CHP Opr

B Isolation of Tippler Unloading Hopper

2 Stop Vibrating feeder Swgr Opr

4 Switch OFF 415 V supply to Vibrating feeder Swgr Opr

5 Switch OFF 415 V supply to MRP Gate Swgr Opr

6 Switch tags on the following isolating points

 Vibrating feeder Local Push button CHP Opr

 MRP Gate Local Push button CHP Opr

 415 V breakers to Vibrating feeder Swgr Opr

 415 V breakers to MRP Gate Swgr Opr

7 Give clearance to maintenance for commencing their work Shift in charge

Taking in service and Isolation of Belt Conveyor 1

A Taking Belt Conveyor 1 in service

2 Switch ON Belt Conveyor 1 breaker Swgr Opr

4 If the Auto program is ON, ensure that BC 1 starts CHP Opr

5 If the Auto program is OFF, start BC 1 locally CHP Opr

6 Ensure BC 1 is running OK CHP Opr

B Isolation of Belt Conveyor 1

2 Ensure all Vibrating feeders are OFF CHP Opr

3 If the Auto program is ON, ensure that BC 1 stops CHP Opr

4 If the Auto program is OFF, stop BC 1 locally CHP Opr

5 Switch OFF Belt Conveyor 1 breaker Swgr Opr