1 3814 GY SE 901003 IS03 Technical Especification

Document Identification Code
TECHNICAL SPECIFICATION
COAL HANDLING SYSTEM
3814-GY-SE-901003
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Client: CDEEE - Corporacin Dominicana de Empresas Elctricas

Estatales
Plant: 2x360 MW Coal-Fired Power Plant
Location: Punta Catalina, Ban Repblica Dominicana
OWNER DOCUMENT CLASSIFICATION CODE

IN INTERNAL ISSUANCE
FI FOR INFORMATION ONLY
FA FOR OWNERS REVIEW AND APPROVAL
FC FOR CONSTRUCTION OR FOR PURCHASE

FR FOR RECORDS
R. Ramella Pezza
S. Gaiani
S. Gaiani
15 JUN 2014 FINAL ISSUE
R. Ramella Pezza
S. Gaiani
S. Gaiani
30.APR.2014 PRELIMINARY ISSUE
R. Ramella Pezza
S. Gaiani
S. Gaiani
03
08 JAN 2015 ISSUE FOR ORDER
02
01
Issue
Date
Reason for Issue Revision Description
Prepared
Checked
This document is CDEEEs property, and cannot be used by others for any purpose, without prior written consent
Approved
03
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CONTENTS
1
FOREWORD .................................................................................................................................. 4
1.1
1.2
1.3
COAL HANDLING DESIGN BASIS ............................................................................................... 5

2.1
2.2
OPERATING CONDITIONS..................................................................................................... 9
MAIN DESIGN CHARACTERISTICS ....................................................................................... 9
BELT CONVEYORS .............................................................................................................. 10
PIPE CONVEYOR ................................................................................................................. 14
TRIPPERS ............................................................................................................................. 14
SKIRT BOARDS .................................................................................................................... 14
FEEDER ENCLOSURES ....................................................................................................... 15
CHUTES AND HOPPERS...................................................................................................... 15
BELT ENCLOSURES HOODS............................................................................................... 18
MAGNETIC SEPARATORS AND METAL DETECTORS ....................................................... 18
ELECTRIC DRIVEN FLOP DIVERSION VALVES .................................................................. 19
FEEDERS .............................................................................................................................. 20
COAL CRUSHERS ................................................................................................................ 20
DUST CONTAINEMENT ........................................................................................................ 21
DUST SUPPRESSION SYSTEM: WATER SPRAY TYPE ...................................................... 24
COAL SAMPLING SYSTEMS ................................................................................................ 25
WEIGHING SCALES ............................................................................................................. 26
BELT CONVEYOR STRUCTURES AND AUXILIARY SYSTEMS ............................................... 26

5.1
5.2
5.3
5.4
EXTENT OF PREFABRICATION AND STATUS OF EQUIPMENT AT SHIPMENT........................................ 8
MINIMUM REQUIREMENT FOR EQUIPMENT ............................................................................. 9

4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
COAL CONVEYING FROM SHIP UNLOADING TO BULK WAREHOUSE .................................................. 5

COAL CONVEYING FROM BULK WAREHOUSE TO BOILER SILOS ....................................................... 6
SCOPE OF SUPPLY AND BATTERY LIMITS............................................................................... 7

3.1
GENERAL INFORMATION ...................................................................................................... 4

MATERIAL TO BE HANDLED .................................................................................................. 4
AREA CLASSIFICATION ......................................................................................................... 4
TRANSFER TOWERS AND GALLERIES .............................................................................. 26

MAINTENANCE EQUIPMENT ............................................................................................... 29
PIPING NET INSIDE GALLERIES AND TOWERS ................................................................. 30
FIRE FIGHTING..................................................................................................................... 31
INSTRUMENTATION EQUIPMENT ............................................................................................. 33

6.1
INSTRUMENTATION FOR BELT CONVEYOR CONTROL.................................................... 33
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6.2
7
ELECTRICAL EQUIPMENT ........................................................................................................ 34

7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
INSTRUMENTATION CABLES AND JUNCTION BOX........................................................... 33

ELECTRICAL DESIGN CRITERIA ......................................................................................... 34
ELECTRICAL MOTORS ........................................................................................................ 34
LIGHTING AND SOCKET ...................................................................................................... 34
MCC AND ADDITIONAL ELECTRICAL EQUIPMENT ............................................................ 35
GROUNDING SYSTEM ......................................................................................................... 35
LIGHTNING PROTECTION SYSTEM .................................................................................... 35
EQUIPOTENTIAL BONDING ................................................................................................. 35
MODES OF CONTROL .......................................................................................................... 36
PLANT 3D VIEWS ....................................................................................................................... 37
ATTACHMENTS:
Attachment 1 Preliminary arrangement top of bunker area
Attachment 2 Preliminary arrangement pipe conveyor on jetty
Attachment 3 Preliminary arrangement conveyor & hopper on pier
Attachment 4 Typical section of belt conveyors installed in galleries
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FOREWORD
This specification summarizes the design and engineering prescriptions for the supply of the Coal
Handling System installed on Coal Power Plant located in the Dominican Republic.
The purposes of coal handling are the followings:
Transfer the Coal from ship to the coal bulk warehouse and boiler bunkers at the same time
Transfer the Coal from the coal bulk warehouse to the boiler bunkers
To optimize the spare parts Vendor shall consider as much as possible the standardization of all
equipment, particularly for motors, reducers, pulleys, coupling, idlers, belt cleaners, etc. also if this
approach can cause the over sizing in the design parameters of some components.
The selection of components has also to be carried taking into consideration reliability, safety and easy
maintenance of the system.
1.1
GENERAL INFORMATION
The coal for the new boiler plant at Santo Domingo power plant will be delivered by self discharging
ships 80000 tons displacement. HandyMax and le Supra Max that download the coal into hoppers
located on dedicated jetty. Unloading facilities have to be designed to accept ships equipped with
unloading boom.
Under the hoppers troughed belt conveyors extract the coal and deliver it to conveyors that provide the
connection with the coal bulk warehouse or directly to the coal bunkers located over the mills.
1.2
MATERIAL TO BE HANDLED
The material to be handled is Thermal coal having characteristics as per specification 3814-YZ-SG000001 Design basis and site conditions.
1.3
AREA CLASSIFICATION
All items included in the supply will be located in areas classified by NEC as per area classification
drawings attached to the Material Requisition.
All electrical equipment included in the scope of supply will be:
Class II, Division 1, Group F / T3B
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COAL HANDLING DESIGN BASIS
2.1
Coal conveying from ship unloading to bulk warehouse
The coal, transported from boom equipped self unloading ships, is transferred from the jetty to the
power plant by means of belt conveyor chain composed by the following items:
Movable hoppers 00EAA10BR001;

belt conveyors 00EAC10AF001;
pipe conveyors 00EAC11AF001;
belt conveyors 00EAD10AF001 equipped with movable tripper 00EAD10AF002;
The motorized hopper 00EAA10BR001 located on the jetty can be moved along the belt conveyor
00EAC10AF001 match the position of ship unloading boom and allow a correct coal discharge.
In the middle of the hopper will be installed a net necessary to avoid the passage of big lumps.
The size of holes will be determined during the detail engineering. The main purpose of this net is the
protection of the pipe conveyor. In any case max allowed hole dimensions are 200 x 200 mm.
The conveyors 00EAC10AF001 will be equipped with the weighing scale 00EAT10CW001 in order to
verify the real quantity of coal discharged from the ships.
The coal sent to the tripper conveyor 00EAD10AF001, through the pipe conveyors 00EAC11AF001,
reaches the tripper 00EAD10AF002 that provides the coal stacking in the coal bulk warehouse.
The closed coal bulk storage is sized considering the recovery of 30 days of two boilers operation at
rated capacity.
To allow the refilling of boiler bunkers directly with the coal discharged from ships the following items
are installed:
Splitter valve 00EAC12AA101 at the discharge of pipe conveyor 00EAC11AF001;
Diverter valve 00EAC12AA102 downstream the splitter valve 00EAC12AA101;
Weighing scales 00ECT11CW001 & ECT21CW001 installed on belt conveyors
00ECD010AF001 & 00ECD20AF001;
The splitter valve (pneumatic actuators are recommended) 00EAC12AA101, (type will be defined by
vendor and will be subjected to Contractor approval during detailed engineering) will split the coal flow
as per the following:
Delivery of 3000 t/h to the coal yard when its not requested coal in the bunkers
Delivery of up to 1500 t/h to the bunkers (flow rate will be taken within a range that will absorb
the flow rate fluctuations without continuous adjustment of the splitter valve) measured by
weighing scales 00ECT11CW001 & ECT21CW001. Coal exceeding the settled flow rate will be
sent to coal storage
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2.2
Coal conveying from bulk warehouse to boiler silos
The coal reclaimed from bulk warehouse by means of portal reclaimers 00EAF10AE001 &
00EAF20AE001 will be delivered to the boiler bunkers through a belt conveyor chains composed by the
following items:
Portal reclaimers 00EAF10AE001 & 00EAF20AE001;

Belt conveyors 00ECB10AF001 & 00ECB20AF001;
Belt conveyors 00ECD10AF001 & 00ECD20AF001;
Intermediate hopper 00ECF01 BB001;
Extractor feeders 00ECF10AF001 & 00ECF20AF001;
Coal crushers 00ECF10AJ001 & 00ECF20AJ001;
Belt conveyors 00ECG10AF001 & 00ECG20AF001;
Belt conveyor 00ECH10AF001 equipped with travelling
20ECH10AF001;
Belt conveyor 00ECH20AF001 equipped with travelling
20ECH20AF001.
trippers
10ECH10AF001
&
trippers
10ECH20AF001
&
The coal stored in the bulk warehouse will be recovered by the portal reclaimers 00EAF10AE001 &
00EAF20AE001 that discharges it in the belt conveyor 00ECB10AF001 & 00ECB20AF001.
Each conveyor is connected and dedicated to a portal reclaimer. Each portal reclaimer shall be able to
work for all warehouse length. Both reclaimed coal conveyors will be located on the same side of the
warehouse.
In the belt conveyors 00ECB10AF001 & 00ECB20AF001 are installed the weighing scales
00ECT10CW001 & 00ECT20CW001 that provide a feedback to the reclaimer in order to regulate the
reclaiming flow rate of the machine. Weighing accuracy shall be enough to guarantee a correct
reclaiming flow rate from the portal reclaimers.
On conveyors 00ECD10AF001 & 00ECD20AF001 will be installed the devices to clean the coal from
magnetic and non magnetic metal debris.
The buffer hopper 00ECF01BB001, installed downstream conveyors 00ECD10AF001 &
00ECD20AF001 is used as intermediate capacity during the positioning of the bunkers trippers to avoid
the start and stop of the reclaimer.
At the outlet of the hopper will be installed the belt feeders 00ECF10AF001 & 00ECF20AF001 and the
crushers 00ECF10AJ001 & 00ECF20AJ001 used to destroy all possible residual lumps (lumps breaker
will be installed also on the reclaimer chutes) and to reduce the coal size.
On the conveyors 00ECG10AF001 & 00ECG20AF001 are installed the coal sampling system 00ECU10
used to analyze the coal recovered from coal storage. The sampling system shall be located on the
tower 00UEF50.
Belts conveyors 00ECH10AF001 & 00ECH20AF001, located above the boiler bunkers, are equipped
with travelling trippers 10/20ECH10AF001 and 10/20ECH20AF001.
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The diverter valves 00ECG10AA101 & 00ECG20AA101, installed in the chute of the belt conveyors
00ECG10AF001 & 00ECG20AF001, are used for the deviation of the coal flow in one of the
downstream tripper conveyors.
Dedusting systems will be provided where necessary to confine the powder inside chutes and to keep
clean the bunker area.
The centralized dry type dedusting systems indicated on the PFD 3814-GZ-DP-901005 are mandatory.
For local dedusting on conveyor chutes Vendor can propose the most appropriate technical solution
based on his experience.
SCOPE OF SUPPLY AND BATTERY LIMITS
The supply of coal handling system includes, but is not limited to, the main equipment that are indicated
in the Process Flow Diagram 3814-GZ-DP-901005.
The portal reclaimers 00EAF10AE001 & 00EAF20AE001 are part of the system but they are not
considered in this specification. They are described on the specification 3814-GY-SE-901004
Technical specification for portal reclaimers.
Equipment & machines shall be supplied adopting the package philosophy. Each component / unit shall
be supplied prefabricated and preassembled as far as permitted by the transport limitations and shall
be complete at least with all equipment and materials listed here below.
All items necessary for a good and safety operation of the system shall be included in the supply also if
not directly listed or mentioned in the specification or in the other specifications attached to the Material
Requisition. Vendor is responsible for the design of the whole system.
The equipment shall be sized for the following flow rates:
From ship unloading to bulk warehouse:

From bulk warehouse to boiler:
3000 t/h
1500 t/h
Here below a summary table of the conveyors with main characteristics:

Item
Type
Flow rate (t/h)
Length (m)
00EAC10AF001
Troughed conveyor
3000
275
00EAC11AF001
Pipe conveyor
3000
2105
00EAD10AF001
Troughed conveyor
3000
500
00ECB10/20AF001
Troughed conveyor
1500
535 / 540
00ECD10/20AF001
Troughed conveyor
1500
80
00ECG10/20AF001
Troughed conveyor
1500
270
00ECH10/20AF001
Troughed conveyor
1500
160
00ECF10/20AF001
Extractor belts
1500
8
Elevation (m)
5
38
8
3
20
50
15
Horizontal
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Item
00UEF10
00UEF20
00UEF30
00UEF40
00UEF50
00EAC10AF001
00EAC11AF001
00ECD10/20AF001
00ECG10/20AF001
00ECH10/20AF001
Type
Tower
Tower
Penthouse
Tower
Tower
Gallery
Open bridge with walkways
Closed gallery
Common Gallery
Common Gallery
Common gallery
Width (m)
10
10
10
10
10
4.5
3 (*)
5
7
7
9 (**)
Length (m)
8
10
8
10
12
36
126 (*)
50
50
220
50 + 44 (**)
Height (m)
8
45
8
20
54
2.9
2.7 (*)
3.5
2.8
2.8
4 (**)
(*)
The portion of pipe conveyor located on jetty will be installed directly on concrete foundations.
Jetty is studied considering lateral concrete walkways for all the conveyor length. The portion of
elevated conveyor from ground to tower 00UEF20 is required complete with support structure,
lateral walkways and trestles. The transition portions of pipe conveyors shall be installed inside
closed gallery.
(**)
The gallery is not complete for all the conveyors length but is limited to the portion of conveyors
from tower 00UEF50 to the boiler and the portion between boilers. The gallery shall be designed
taking into account the need to contain and support also the tail of the trippers when they are
positioned to refill the first silo of each unit.
3.1
Extent of prefabrication and status of equipment at shipment
a)
Equipment machinery
Equipment (main machines and conveyor heads) shall be completely prefabricated, pre assembled up
to the transportation limit with electric motors, instrumentation, tubing and wiring up to junction box. To
optimize the transportation volume, the intermediate portion of conveyors (structures & components)
will be delivered loose to be assembled on site.
Vendor can avoid the pre installation of tubing, wiring and instrumentation when is evident a possible
damage during the transportation and erection
Cable and tubing partially installed shall be marked on the not connected side to allow an easy
assembly at site.
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b)
Structure
Steel structure shall be supplied prefabricated, loose, clearly marked and ready for the erection at site.
They will be transported inside containers as much as possible. All parts to be assembled on site shall
be bolted. Field welding are not allowed.
c)
Cables
Both electric and instrument cables not installed will be supplied loose in coils
d)
Bulk materials and minor items
Shall be supplied loose with clearly identification codes and tags for erection.
MINIMUM REQUIREMENT FOR EQUIPMENT
4.1
OPERATING CONDITIONS
The Coal Handling System, including equipment involved in the ship unloading operations, shall be
designed for service defined as heavy duty and continuous operation 365 days/year.
In particular the elongation of the various services is summarized here below:
4.2
Stacking
Reclaiming
Expected Equipment Life
24
24
30
h/d (during the presence of ships)

h/d
years
MAIN DESIGN CHARACTERISTICS
Vendor shall design the belt conveyors taking into account the prescriptions here below and the belt
conveyors characteristics:
The width of Conveyor Belts will be expressed in millimeters.

Belt width will be selected choosing between the values standardized by ISO.
Standard Edge Distance of Troughed Belt will be according to ISO Standard.
Filling factor of Troughed belt conveyors will be 85%.
Troughed Belt Conveyors speed will be 3.2 m/sec.
The Troughed Belt Conveyor slope will be 14.
Pipe conveyor speed: as per Vendor suggestion (to be agreed with TCM)
Pipe conveyor filling factor: 75%
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Slopes angle of the discharge chutes will be at minimum 65 degrees from horizontal.
Bearings: L-10 life, approx. 90000 hours (Note: bearing of conveyor rollers are not included in
this category but are as per specification CEMA)
Service factor: gear reducers and drives: 1.5 minimum based on calculated motor horse power.
The Coal Handling System will be designed on the basis of Main Dimension and Technical Parameter
indicated by TCM. Any deviation proposed by the Vendor has to be justified with technical explanation
and approved by CDEEE or CNO.
4.3
BELT CONVEYORS
Belt conveyors shall be designed in accordance with CEMA Belt conveyors for bulk Materials and
considering the prescriptions of following paragraphs
4.3.1 Rubber Belts:

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

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

Carcass: conventional ply construction
Edges bonded and protected to resist edge abrasion
Elongation: not exceeding 2 % during belt life
Design for start with belt conveyor fully loaded
Splices: Hot vulcanized field splices
Note: ONT, according to previous referenced application, consider the rubber belt K quality as per
DIN22102 to take into consideration the need to privilege the antistatic and auto extinguish
properties instead to fulfill the request to have wear resistant belt.
Coal can be considered Non abrasive material
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4.3.2 Belt conveyor splicing kits

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

Designed for 150% maximum running load or maximum acceleration load whichever is greater.
Construction: welded steel, heavy duty, self aligning, anti friction roller bearings with grease seals.
Tapered or curved ends are acceptable
Provide bearing brackets with screw adjustment and locking device for aligning on both sides of
each bearing bracket.
Shaft key for drive and head pulley in accordance to ANSI B17.1
Lagging as per conveyor belt recommendation.
Pulley total indicated run-out tolerances:
12 and under diameter: 0.063;
over 12: 0.125

Pulley manufacture and information about pulley & shaft design shall be provided
4.3.4 Drives:

Type: Electric motor driven gear reducer directly coupled to head pulley shaft
Gear reducer
Totally enclosed oil bath type with helical or equal gears and antifriction bearings.
Gears and bearings mounted in oil and dust tight split steel or split cast iron housing; split seals
Drive motor: Direct connected to drive pulley by means a fluid coupling. Electric motor, fluid
coupling and gear reducer shall be shop mounted and aligned on a common steel base plate
Fluid coupling: Adequate to service intended to provide soft start
Provide removable coupling guards
Provide 2 jacking bolts at each of 4 corners of motors
Provide 2 jacking bolts at each of 4 corners of gear reducer.
4.3.5 Belt cleaners provided for each belt conveyor. Locate for easy maintenance access

Head pulley access doors: Sizes as required to service new pre-cleaner and secondary cleaner.
Head pulley pre-cleaner and mounting hardware:
Blade material: Polyurethane.
Slide-in/slide-out blades.
Head pulley secondary cleaner and mounting hardware:
Arms: Polyurethane, slide-in/slide-out multi arms.
Blades: Stainless steel snap-in/snap-out swivel blades.

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Tail pulley V-plow:
Torsion arm system.
Blades: Urethane blades.
4.3.6 Back stop:

To prevent backward movement of inclined conveyors.

Minimum size: 1.5 times drive motor horsepower.
Provide additional equipment, if required, to prevent coal pile-ups due to coasting of belt after
tripping off downstream conveyor, when operating at fully loaded condition.
4.3.7 Belt take-ups

Type: Vertical automatic gravity take-up whenever feasible.

Provide tail pulley screwed take-ups with hydraulic assist only when gravity take-up is not feasible.
Design for belt tension to control belt sag between idlers to 2% maximum.
Location: As recommended for belt tensions, maintenance, and available space.
Provide necessary pulleys, counterweights, guides, cables, and other equipment required for
complete installation.
Take-up travel: Conform to minimum CEMA requirements plus 2 and as recommended by belt
manufacturer.
Provide means to confine counterweight in event of belt failure; provide means of resisting impact
loads due to free fall of take-up.
Counterweight steel boxes shall have capacity of at least 130% of required weight. Boxes shall
have bolted removable cover and drain holes in bottom.
Counterweights for vertical take-up assemblies shall be located as close as possible to grade or
elevated platform, as applicable.
Extend lubrication points to access platforms.
4.3.8 Idlers

Carrying idlers:
Type: 3 equal-length rolls with 35 side roller angle; reduce angle at approaches to terminal
pulleys.
Size: 5 diameter rollers minimum, CEMA Series D minimum.

Return idlers:
Type: full length single roller. Two roll Vee return idler to be used to facilitate maintenance for
belt having width greater than 1200 mm.
Size: Diameter and CEMA series to match carrying idlers.
Use steel return idlers between head pulley and take-up pulley.
Impact idlers: Support each loading point with at least 6 special impact type carriers.
Idler spacing:
Carrying:
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o Not more than 4-0. (1200 mm)

o Under skirt boards: Not more than 2-0. (600 mm)
Return: Not more than 10-0. (3000 mm)
Impact: Not more than 1-0. (300 mm)

Rollers:
Seamless steel tubing with rounded ends.
Antifriction roller bearings enclosed in dust tight and moisture tight housings with grease seals.
Self-aligning training idlers:
Same type as carrying and return idlers, with pivot mounted side guide rollers.
Install maximum 15 belt-widths from each terminal or closer as recommended by belt

manufacturer and at spaces not exceeding 100-0 on both carrying and return runs.
Installation: Laser align idlers to following tolerances.
No more than 1/16 misalignment in any direction between adjacent idlers.
No more than 1/8 misalignment between any idlers over entire length of conveyor.
4.3.9 Lubrication:

External means for lubricating bearings.

Gear trains, etc., arranged for enclosed oil bath lubrication; oil sight gage and train valve with plug
on enclosure.
Grease fittings:
Location: Extend to allow servicing from access platforms or walkways; plastic extension piping
is not acceptable; install for all fittings including training idler rollers.
Hollow shaft idlers with one fitting serving all bearings are acceptable.
4.3.10 Deck plate:

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

Galvanized chain link fence, framed for mounting.

Install at following locations:
Tail pulley enclosure.
Gravity take-up bend pulleys along walkways.
Along all conveyor length
Other locations as determined by Contractors design engineer.

Design to prevent coal build-up.
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4.3.12 Vertical curves of belt conveyors

Radius of Concave Vertical Curves of troughed belt conveyors will be determined according to CEMA
in order to allow the belt to assume a natural path on the troughing idlers under all conditions.
Radius of Convex Vertical Curves (when the center of curvature lies below the belt) will be determined
according to CEMA recommendations, in order to avoid over stress of belt edges or buckling in the belt.
In accordance with CEMA Belt conveyors for bulk materials
4.4
PIPE CONVEYOR
For the design of the pipe conveyor the following will be considered:
4.5

The motors of the pipe conveyor will be located at elevation 100.000 to simplify the
maintenance ant to reduce the amount of the heavy equipment installed in elevated position.
The motors will be suitable for unclassified area
To limit the quantity of structures at elevated quote is accepted the entrance of pipe conveyor in
the tower 00UEF20 with inclination angle less than 14 degrees.
TRIPPERS
Location: Above boiler silos and above coal pile inside bulk warehouse.
Type: Movable. Design for belt capacity. Provide direct drive gear reducer electric motor drive
system to move tripper.
Provide discharge chute arranged to allow diversion of coal into silos below.
Chutes: Not lighter than 1/4 thick ASTM A36 steel with ceramic lining.
Pulleys: As specified in paragraph 4.3.3.
Grease fittings: High pressure. Extend to allow servicing from tripper floor. Plastic extension piping
is not acceptable.
Festoon cable or cable reel system with cable for power and control circuits suitable for use in
areas classified by NEC as Class II, Division 1, Group F T3B. as per indicated in the area
classification drawing
Steel wheels and track.
Enclose tripper chute for dust control.
Tripper speed for translation: 0.16 m/sec corresponding to 10 m/min
4.6

SKIRT BOARDS
Provide as required for proper operation of material handling equipment.
Arrangement: To be determined by Vendor on the basis of the configuration shown on Drawings.
Design requirements:
Construct of not less than 1/4 ASTM A36 steel plate or better.
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4.7
FEEDER ENCLOSURES

4.8

Skirt boards, adjustable seal strips, dust curtains, shaft seals, gaskets, calking, packing, and
other accessories required for maximum dust tightness; include dust tight inspection doors
where shown and recommended.
Locate skirt boards to allow for vertical offset of impact idlers, due to uneven loading.
Loading point: Self-adjusting one piece ribbed dual skirt board sealing system for use on belts
with 35 idlers.
o One-piece seal.
o Material: Nitrile Rubber, 60 Durometer.
o Free belt area: 2.5 on both sides of exterior chute wall.
o Service temperature range: -20 to 160F.
o Length: 12 minimum.
Loading point skirt board liners:
o Configuration: Straight.
o Material: Type 304 stainless steel.
o Mounting holes: 24 intervals.
Cover plate:
o Material: 10 gage (3 mm) galvanized steel.
o Use spring clip closures at 1 spacing.
o Calk joints with clear silicone calking.
Feed chute, stationary skirt, and discharge chute with flexible seals to feeder.
Dust tight inspection doors located where recommended and indicated.
Regulating gate in feed chute to control material to feeder. Construct of minimum 1/4 abrasion
resistant plate.
Other accessories as required for maximum dust tightness.
Provide connections on all feeder enclosures and on all conveyor discharge and loading
enclosures
CHUTES AND HOPPERS

Arrangement: As determined by Contractor.
Size chutes for specified capacity.
Design for most direct connection from point to point.
Provide U shaped chutes when drop distance greater than 12.
Avoid dog legs and fast tapers.
Materials:
Chutes and hopper shells: 1/4 minimum thickness ASTM A312 Type 304 stainless steel.
Liners:
o Hoppers at sloping surfaces subject to wear: 5/8 minimum thickness ASTM A312 Type 304
stainless steel.
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Abrasion-resistant ceramic wear tile liner for all chutes, except portion under belt cleaners:
Hardness: 400-450 Brinell, minimum.
Chemical composition for corrosion resistance: Minimum 90% alumina ceramic.
Material thickness: 1/2 minimum.
o UHMW polyethylene lining for use under belt cleaners:
Density (Test Method ASTM D792): 0.96 g/cc.
IZOD impact, ft-lb/inch notch at 23C (Test Method ASTM D256A): 28 to 30.
Tensile strength (Test Method ASTM D638):
Yield: Minimum 3,200 psi.
Ultimate: Minimum 5,600 psi.
o Coefficient of friction (Test Method ASTM D1894): Maximum 0.11.
o Material thickness: 1/2.
o Mounting: Stainless steel welding washers spaced at 12 maximum any direction and at 12
center to center 2 from edge of sheet with UHMW polyethylene plugs to provide smooth
lining surface.
Wear plates:
o Average Brinell hardness: 400-450 minimum.
o Chemical composition for corrosion resistance.
o Butt joints: Continuously welded; side joints tack welded.
o Use: Impact areas.
o Material thickness: 1/2 minimum.
Provide head chutes with liners as specified above up to centerline of discharge pulley on front
and sides or 6 higher than material impact point, whichever is greater.
Provide exterior stiffeners and bracing to prevent excessive vibration and deflection during
operation and when plugged.
Access doors:
Complete with gasket, dust tight.
Size: Minimum 24 x 24 inside dimensions.
Quick-opening type with hinges and latches.
Type: Handle style lift and turn latch.
Latch to apply compression to pull enclosure tight against frame.
Install deflector angles to protect door seals.
Provide access doors as shown and as required for access to all moving parts, critical wear
Areas, belt cleaners, and equipment inside chutes and hoppers.
Provide adjustable baffle plate at discharge from each conveyor head pulley designed for
material
Impingement, with adjusting bar operable from outside of discharge chute. Construct of
minimum
1/4 wear liner plate. See Wear Plates above.
Provide access doors approximately 4 above skirt board in loading chute and at 15 intervals.
Chute at diversion/flop gates:
Symmetrical about centerline.
Design to eliminate material pocket below shaft.

o

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Design to recess top of gate in chute when gate is in operating position.

Minimum valley angle: 60 to horizontal.
Loading chutes: Arrange to enable belts to carry maximum load, avoid spillage, and reduce
abrasion. Arrange loading chutes with V-shaped or rounded bottoms designed to deposit fines on
belt before larger lumps.
Provide chutes in welded segments. Limit segment length for easy removal during maintenance.
Bolt segments together and use gaskets to provide connections dust tight.
Hopper and chute side walls shall be as nearly vertical as possible.
Liners welded in place shall have welds accessible for cutting and re-welding for maintenance
purposes. Liner sections shall not exceed 150 lb to allow easy replacement.
Incorporate means for collection of dribble from belt cleaners with delivery to conveyor discharge
hoppers.
Tramp iron chute:
From magnetic separator to 3-0 above ground floor.
Construct of not less than 1/4 stainless steel plate.

Provide stainless steel silo chute inlet grate 5/8 minimum thickness.
Note:
The hopper 00ECF0BB001 installed in the crusher building will be equipped with manually operated
hammers to be used in case of material bridge creation or clogging.
4.8.1 Ship unloading hopper 00EAA10BR001
The ship unloading hopper will be realized with a half cylindrical roof divided into two parts. One portion
is fixed and the other is movable to allow the boom positioning during unloading.
When the unloading system is not used the roof is complexly closed to protect the conveyor from rain.
The movement of the roof will be motorized with push buttons located on board of the hopper.
The hopper will be equipped with inspection / maintenance walkways and stairs. Arrangement will be
developed during the detail engineering.
Rail and bumpers, as well as retaining devices are included in the scope of supply.
The hopper will be designed taking into account the following wind speeds as per FEM regulation:
Normal operation:
Under operator responsibility:
Retaining:
< 20 m/sec
from 20 to 25 m/sec
> 25 m/sec (mandatory!)
The part of hopper in contact with coal will be realized in Carbon steel.
The chute between hopper and conveyor will be made in SS AISI 304
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4.8.2 Crusher hopper 00ECF01 BB001

The hopper is used to guarantee a constant feeding to the crushers
The part of hopper in contact with coal will be realized in Carbon Steel.
The chute between hopper and extractors will be lined with SS AISI 304
The hopper shall be equipped with explosion venting panel in accordance to the prescriptions of
NFPA68 complete with sensor for broken panel.
4.9
BELT ENCLOSURES HOODS
Belt conveyors installed on pier have to be supplied complete with weather protection that consists in
movable metallic covers. The movement of the covers is controlled by the movable hopper that is
equipped with driving beams that provide the opening and take care the closing of the panels without
need of manual operations
Belt conveyors installed in the galleries will be covered with protection panel to confine any powder.
The preliminary configuration of the protections is shown on Attachment 4.
4.10 MAGNETIC SEPARATORS AND METAL DETECTORS

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

The diverter, installed in conveyor chutes and in bunker tripper chutes, shall be driven by electric motor,
pneumatic actuator is not allowed, except for by-pass diverter gate 00EAC11AA101 preferred
pneumatic actuated.
Diverter valves shall be provided with:
Manual wheel operator, chain wheel operator if they are positioned more than 6 (1.8 m) from floor
or platform.
Position indicator / switch
AISI 304 wearing plates minimum thickness 5 mm
Suitable access panel/s for maintenance
Every moving part (bearings, shafts) dust sealed
The slopes shall be minimum 65 degrees from the horizontal

Construction:
Electric operator: Motor operator or electric cylinder operator, complete chain wheel operator if
they are positioned more than 6 (1.8 m) from floor or platform.
Design to withstand stall torque of motor.
Provide local position indicator.
Gate Material: 1/4 Type 304 stainless steel minimum with 3/8 minimum wear plate as specified
for chutes.
Position adjustment capability: 2-position.

Gate slope in operating position: 65 to horizontal minimum.
Design components to withstand material impingement in all gate positions and permit changing
position while material is flowing.
Access panels: Bolted and complete with gasket, as required for access to moving parts and other
equipment inside chutes and hoppers.
Bearings:
Pillow block, ball, or roller type; self-aligning.
Dust-sealed.
Support from chute plate with stiffeners to prevent buckling or warping of plates or misalignment
of bearings when operated.
Equipped with lubricating fittings as specified for belt conveyors.

Shafts: Dust-sealed where passing through material chute plate.
Wear plates: As specified above.
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4.12 FEEDERS
Feeders shall be installed under hoppers to dose the product to the conveyors
Positive displacement rotating spool feeder:
Feeder output shall be proportional to speed of rotation and material shall be fed at a constant
rate.
Drive system: Variable speed drive and electric motor for a continuously controllable feed rate.
Materials of construction: Housing shall be of ASTM A36 or better, creating stationary support
for rotating elements and drive system.
Belt: Feeder.
Furnish complete with motors, drives, and other accessories necessary for proper installation
and operation.
Service: Continuous duty at initial and future capacity.
Capable of accepting dry, wet or frozen material.
Controls:
o Variable speed control utilizing a variable frequency drive.
o Suitable for manual or automatic adjustment, remote electric operated feed rate control.
o Include 4-20 mA DC signals for remote feed rate indication (remote indication by others).
Submit complete feedback signal information.
Design for support on concrete base.
Furnish with lubrication fittings external to housings and frames.
Equipped with adjustable gate for manual control of material flow.
4.13 COAL CRUSHERS

The coal crushers 00EBC10AJ001 & 00EBC20AJ001 are used to destroy all possible residual lumps
and to reduce the coal size from 50 to approximately 35 40 mm.

Type: double roll mill.

Crusher speed: approx 200 rpm
Construction:
Frame and housing: Commercially dust tight, welded, heavy-gage, rolled steel plate. Frame
liners of carbon manganese steel in areas subject to wear.
Provide bypass chute of 1 piece steel fabrication with stiffeners and AR400 steel liners. Chute is
bolted to frame in lieu of front access panel.
Adjustable breaker plate assembly to compensate for wear, adjustable from outside of crusher
housing. Provide grease fittings for pivot shaft bearings.
o Breaker plate support:
Fabricated steel.
Adjustment by synchronized worm gear jacks outside of frame.
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Shims not allowed.

Breaker blocks:
Removable; AR400 or equivalent steel, minimum.
2 beads of tungsten carbide hard facing at peak of each block.
o Breaker plates: Renewable AR400 or equivalent steel.
Rotor: Balanced statically and dynamically.

o Shaft: Forged alloy steel, sealed dust tight at frame opening.
o Rotor breaker plates: Renewable AR400 or equivalent steel
Bearings:
o Anti-friction, self-aligning, dustproof, grease-lubricated.
o Equip each bearing with 3-wire RTD detectors rated 100 ohm at 0 C. Wire and terminate
RTD leads on terminal blocks in externally mounted junction box. Route bearing RTD
signals back to motor protection relay. Terminate signals on protective relay on PRT
Terminals No. 9 and 10.
o Provide provisions in motor and crusher rotor bearings for future installation of vibration
monitoring system; 2 axis each bearing.
Access door: Hinged frame, sized and arranged to expose entire rotor assembly, breaker
plates, and liners; dust tight.
Drive: Motor-driven through gear-type flexible coupling.
Provide suitable coupling guard.
Provide support attachments for crushers and motors on concrete foundation.
Seal crusher outlet to discharge chute work in accordance with manufacturers instructions.
o

4.14 DUST CONTAINEMENT

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

Dust particle size: 2 to 5 microns

Dust bulk density: 80 lb/cu ft. (1280 kg/m3)
Dust temperature: ambient
Air to cloth ratio: 5 cfm/sq ft maximum (1.5 m3/min/m2)
Maximum outlet loading: 0.01 gr/dscf (23 mg/m3)
Service: continuous, uninterrupted.
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4.14.2 Dust collectors system: bag filter type

Coal crushers building and trippers installed over boiler silos shall be equipped with centralized bags
dust collector systems Self-cleaning, low-pressure, high-volume, pulse-jet fabric filter dust
collectors with exhaust fans.

Maximum fabric filter operating pressure drop: 5 w.g. (127 mm w.g.)

Filter housing:
Construction: All-welded, round.
Material: 12-gage (2.5 mm) steel, minimum, panel construction designed to withstand up to 20
(500 mm) minimum w.g. negative pressure.
Explosion venting in accordance with NFPA 68 for collectors for coal handling equipment.
Top bag removal with walk-in plenum.
Safety handrails, platforms, and ladders for units with walk-in plenums. Coordinate with location
and general arrangements.
Hoppers:
Construction: All-welded, round conical shape.
Material: 12-gage (2.5 mm) steel minimum, panel construction designed to withstand up to 20
(500 mm) minimum w.g. negative pressure.
60 slope minimum.
Provide with manufacturers standard size hinged access doors, minimum 18 square.
Bags:
Material: fine denier polyester.
Weight: Minimum 16 oz/sq yard. (540 gr/m2)
Provide grounding in accordance with NFPA 77.
Length: 12 (4 m) maximum.
Bag cleaning: Compressed air pulse jet.
Same length and diameter bags for all collectors.

Rotary locks:
Quantity: 1 for each dust collector hopper outlet.
Type: Deep pocket drop-through; capable of discharging collected dust while maintaining
negative pressure within collector and storage hopper during operation.
Size: Minimum 12
Heavy-duty gear motor.
Valve rotor: Replaceable vanes.
Maximum speed: 22 rpm

Controls:
Locate unit-mounted electronic controls for easy access.
Control system shall provide options to initiate cleaning cycle based on high differential pressure
and adjustable timer and allow for continuous cleaning.
Solid-state electronic timer with duration and interval adjustments.
Differential pressure indicating switch:

o Provide 1 differential indicating transmitter per dust collector for local indication, high
differential pressure control, and high-high differential pressure alarm to monitoring system.
o Provide additional solenoid and connect solenoid output line to each impulse line to be used
to keep impulse lines free of any dust particulate build-up. Additional solenoid shall pulse
line clean during bag house pulsing.
Provide broken bag detector.

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Electrical and instrumentation enclosures: In accordance with NEC requirements for installed
location.
Shop finishing paint:
Interior of dust collector shall be painted at workshop.
Collector shall arrive at jobsite finish-painted.
Field touchup of all surface areas damaged during shipment and installation.
Accessories:
Access platform:
o Provide access to controls and access doors for inspection and maintenance.
o Conform to OSHA requirements.
o Size for convenient removal and replacement of bags and cages.
Diaphragm valves, pulse pipes, solenoid pilot valves, and compressed air header.
Instrument Air line filter: Provide regulator and flow control valve for plant air.
For walk-in plenum, provide upper access door in clean air plenum.
o Size: Minimum 24 wide by 60 high; hinged.
o Arrange to allow maintenance and change out of bags.
External caged ladder and catwalk shall be provided complete with grating, kick plates, and
handrails.
Support legs for hopper bottom units.
4.14.3 Exhaust fan

Design air flow as necessary per system design.

Size: Air flow rating shall match dust collector air flow at 13 (325 mm) w. g.
Construction:
Housing: Welded steel; flanged inlet and outlet connections
Wheel and shaft: Dynamically balanced to comply with median value of Quality Grade G6.3 of
ISO 1940 (ANSI S2.19)
Provide quick-opening access doors
Manual outlet damper
Provide casing drain and plug

Drive: direct drive
Guards:
Conform to OSHA requirements.
Belt guard:
o Material: Wire mesh.
o Size: Minimum 10-gage (3 mm)
o Frame: Angle iron.
Shaft guard.
Bearings: Grease-lubricated, ball or roller.
4.14.4 Ductwork

Ductwork fabrication and installation shall be in accordance with latest edition of SMACNA Round
Industrial Duct Construction Standards and NFPA 91 standards.
Minimum duct air velocity: 3,500 fpm (17.78 m/s).
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Ductwork arrangements shall provide adequate clearances for maintenance.

Materials: Galvanized steel conforming to ASTM 526.
Fabrication:
Ductwork: 16-gage (1.5 mm) steel minimum thickness in 15 (5 m) sections (maximum) using
welded construction with gasket and flanged connections.
Elbows: 12-gage (2.5 mm) steel minimum thickness with centerline radius of 2 times duct
diameter.
Branch entries: 12-gage (2.5 mm) steel minimum thickness.
Hoods: 10-gage steel minimum thickness. Included angle shall be 90 and face area minimum
of 2 times duct area. Hoods may be either bolted or welded in place.
Clean out doors: 12-gage (2.5 mm) steel minimum thickness; locate on top or sides of ductwork.
Doors hinged and held with snap locks or clamps. Space in accordance with NFPA 91.
Blast gates: 12-gage (2.5 mm) steel minimum thickness; locate in accordance with NFPA 91.
Slides shall be locked, or drilled and bolted in place after final adjustment.
F.
Permanent test fittings may be installed in ductwork. Cover test holes drilled in ductwork with
welded patches.
4.15 DUST SUPPRESSION SYSTEM: WATER SPRAY TYPE

Each conveyor chute shall be equipped with a water spray abatement system suitable to restrain coal
dust emission using available raw water as per specification 3814-YZ-SG-000001 Design Basis & site
conditions.
The water is pumped to the spray systems thanks to a pumping stations mounted on enclosed skid,
shipped preassembled and installed at the base of the towers complete as minimum with:

running pumps + spare (N+1)

water filter
water tank
Instrumentation wired to enclosed skid Junction Box.
Raw water piping battery limit is at the inlet of the skid pumping station. All piping from pumping skid to
spray systems has to be considered included in vendor scope of supply.
The dust suppression system shall be equipped with a local control panel to control locally each dust
suppression system item in manual mode during start-up / commissioning phase and during
maintenance; Logics will be implemented in the main coal handling system PLC.
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4.16 COAL SAMPLING SYSTEMS

The Coal Sampling System 00UEC10 shall be installed along the conveyors 00ECG10AF001 &
00ECG20AF001 downstream the reclaimer to provide the sampling of coal recovered from the coal
yard. The equipment composing the system will be located inside tower 00UEF50.
The Sampling system will be designed in accordance to:
ASTM D-2013 Standard Practice for Preparing Coal Samples for Analysis
ASTM D-2234/D-2234M Standard Practice for Collection of a Gross Sample of Coal.
The system will take automatically samples of coal, reduce them to the required size in two steps and
prepare aluminum 20 liters containers ready to be sent to the test laboratory.
Sampling process data:
Lot size:
Sample taker slot width:
Weight of primary increment:
Final sample per lot:
300 t (sublot)
125 mm (mind.)
14.9 kg
appr. 10-30 kg
The Coal Sampling Systems shall be composed of the following items:

00ECU10/20AE001
00ECU01AF001
00ECU01AJ001
00ECU01AF002
00ECU01AE002
00ECU01BB001
00ECU01AF003
00ECU01AA101
Local control panel.
Primary Sampler, cross cut type

Primary Belt Feeder.
Sample Crusher
Secondary Belt Feeder
Secondary Sampler (Vezin Type)
Sample container storage
Bucket Elevator
Diverter valve return elevator
Sampling system shall be equipped with a local control panel to control locally each sampling item in
manual mode during start-up / commissioning phase and during maintenance; Logics will be
implemented in the main coal handling system PLC.
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4.17 WEIGHING SCALES

Weighing scales are installed along conveyors at least as per indicated on the PFD 3814-GZ-DP901005.
They shall be complete with weighbridge and speed sensor in order to give a rate output visual
available locally and at PLC Human Machine Interface in the control room.
Multi-idler system is requested in order to reach an accuracy of 0.5 % as minimum.
Wiring to local panel is included in vendor scope of supply.
BELT CONVEYOR STRUCTURES AND AUXILIARY SYSTEMS
The supply of coal handling includes all the steel structure necessary for the support and maintenance
of the belt conveyors and other equipment, moreover includes the auxiliary systems described in the
next paragraphs.
Calculation of all structures shall be subjected to the approval of Seismic Revisor.
The main conveyor structures, auxiliary systems and accessories are:

5.1
Transfer Towers & penthouse

Crusher building
Conveyor galleries
Lateral walkways for elevated portions of pipe conveyors
Alarm and Firefighting System to protect the Transfer Towers, belt conveyors etc.
Water distribution net
Plant air distribution net
Gallery and towers illumination
TRANSFER TOWERS AND GALLERIES
All troughed belt conveyors not installed in closed buildings (warehouse, top of bunkers, etc.) shall be
located inside closed galleries.
The belt conveyors will be equipped with inspection walkways to ensure a correct maintenance along
all the length.
Pipe conveyor located on jetty and shore will be placed on concrete foundations. Lateral walkways will
be in concrete. The portions of pipe conveyors raising to the top of tower 00UEF20 shall be complete
with lateral steel walkways for inspection and maintenance and closed gallery in the transition points at
the start and at the end of pipe conveyors.
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The troughed conveyors installed on the pier will be equipped with movable weather protections and
closed gallery or open conveyor bridge with fixed weather protection for the portion of conveyors raising
to the tower 00UEF10
Tripper conveyors installed on the top of warehouse shall be complete with rails. Support beams and
inspection / maintenance walkways will be supplied by bulk warehouse supplier. Battery limit is
represented by the lower side of the rails and by the lower face of the conveyor legs baseplate.
The preliminary layout of all coal handling system is attached to the Material Requisition (See drawing
3814-XX-DG-000001, 3814-XX-DG-000002 and other equipment layouts).
5.1.1 Belt conveyor structure and galleries
The driving units, the tail ends, and all the interconnecting chutes will be installed in dedicated transfer
towers. Preferably the belt tensioning units have to be located inside transfer towers to reduce the total
amount of structures, simplifying the erection of the system.
All structural parts and relevant foundations shall be designed considering the local regulations, the
ambient conditions and the following prescriptions for the overloads on walkways and platforms:

(*)
Buildings floor
Walkways
Platforms
Gallery walkways
1000 Kg/m2
300 Kg/m2
500 Kg/m2
300 Kg/m2 (*)
The design of local walkways supporting beams is done considering 300 kg/m2 but for the
calculation of the complete gallery or truss a distribute load of 100 kg/m2.
This is valid for galleries of conveyors, including the portion of pipe conveyor from ground to
tower 00UEF20 and the walkways of tripper conveyor inside coal storage.
In the design of the belt conveyors and relevant structures, the Vendor shall considering the following:

Self-supporting preassembled structures shall be provided for driving units, tail ends and snubs for
belt tensioning units
Galleries and supporting structure for belt conveyors
Self standing structure with lateral walkways for pipe conveyor
Maintenance platforms and stairs for all points not served from floors
5.1.2 Transfer towers

The Transfer Towers will be realized by prefabricated steel structures. They shall be supplied complete
with the following:
Main steel framework including supports for lateral walls and roof.
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Secondary steel frameworks suitable for driving unit, tail ends and tensioning units supports.
Floors made by chequered plates.
Side cladding and roofs of Galvanized corrugated sheet.
Supports for Transfer hoppers and chutes.
Stairs and platforms complete with handrails from top up to ground.
Stairways, platforms and emergency ladders if requested by local regulation.
Monorail for Maintenance Bridge cranes or hoists used for maintenance and equipment repair and
will not be in continuous daily use.
Under the monorail opening doors suitable for spare parts and equipment passage shall be
provided. Power cable trays up to hoists installation position have to be provided.
Access doors and opening for natural lighting and ventilation.
Lightning system
The towers shall be designed considering natural ventilation to reduce the heating generated by the
motors installed inside.
Vendor in the design of the towers shall take into consideration:
Confining of dust pollution avoiding dispersion to the ambient
Minimizing of the noise released to the ambient to respect the prescriptions of the specification
3814-SZ-SG-000005 Noise General Specification

5.1.3 Troughed belts Galleries

The galleries for the belt conveyors shall be realized in prefabricated steel structure. They shall be
supplied complete at least with the following:

Main steel framework complete with support for side cladding and roof.
Side cladding and roofs of Galvanized corrugated sheet.
Belt conveyor supports beams
Walkways with steel grating (ant slipping for inclined walkways)
Metal sheet under conveyors (full length) to limit coal dispersion in the ambient
Opening for natural lighting and ventilation.
Intermediate stairways, platforms and emergency ladders if request by local regulation.
Intermediate support trestle complete with hinged support to be fixed on concrete foundation.
NOTE: The floor of tripper room located over boilers silos will be realized in concrete and is part of
boiler building.
The concrete floor is the battery limit. Beams and / or steel structures necessary for trippers
and belts installations inside tripper room are in vendor scope of supply.
Galleries from tower 00UEF50 to first boiler room and between the two boiler rooms are
included in vendor scope of supply. They shall be designed considered the prescription of this
paragraph and taking into consideration the presence of tripper during the refilling of the first
silo of each group.
The boiler structure will be equipped with cantilevers for the support of the galleries. These
cantilevers represent the supply battery limit. All beams necessary to support the galleries and
to reach the floor level has to be considered included in the scope of supply.
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5.1.4 Pipe conveyor structures

The portion of pipe conveyor installed on the jetty shall have a structure suitable for the installation of
cable racks and as support for road illumination as per shown on Attachment 2.
A belt crossing bridge every 100 m with, configuration as per Attachment 2, has to be included in the
scope of supply.
The horizontal portion of pipe conveyor from jetty to the tower 00UEF20 will be located on ground, on
dedicated concrete floor that is designed with lateral walkways for inspection and maintenance.
The inclined portion of pipe conveyor, from ground to the top of tower 00UEF20, will be equipped with
lateral walkways made by steel grating.
5.2
MAINTENANCE EQUIPMENT
5.2.1 Maintenance hoists

Each tower shall be equipped with monorail/s for the installation of maintenance hoist/s.
They are used for maintenance and equipment repair and will not be considered in continuous daily
use. The monorails shall be sized on the basis of the heaviest piece to be lifted.
Service conditions will correspond to Hoist Manufacturer's Institute (HMI) hoist Class H2 or approved
equivalent. All hoist parts will be designed with a minimum safety factor of 1.25, and the equipment will
be factory tested to a 125% overload.
All parts will be readily accessible for inspection, adjustment, and repair. One or more electrical
maintenance winch(s) shall be provided, located in order to lift all the required spare parts at the
highest level where those spare parts are required. The winch shall be suitable to lift the heaviest spare
part. In particular the large and heavy equipment shall be provided with dedicated winch installed on
the relevant monorail.
The expected configuration will be:
Installation point
Tower 00UEF10
Tower 00UEF20
Penthouse 00UEF30
Tower 00UEF40
Tower 00UEF50
Boiler area
Coal warehouse
Pipe conveyor motor
installed on ground (**)
Capacity (ton)
2
5
2
5
2
2
Out of scope
2
Lifting height (m)

5
40
5
10
20
50
Out of scope
30
Type of hoist
Manual
Electrical (*)
Manual
Electrical (*)
Manual
Electrical (*)
Out of scope
Electrical (*)
Electrical
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(*)
(**)
considering the heavy weight the electrical motors will be foreseen both for lifting and translation
The installation of this hoist will be evaluated during the detail engineering. Vendor is considering
as basic solution the complete removal of the pipe conveyor driving group box.
5.2.2 Compressed air generation system

Inside tower 00UEF10 Vendor shall provide a compressed air generation system composed by:
Air compressor reciprocating type complete with inlet air filter (capacity & discharge pressure by
Vendor)
Water demister with automatic condensate removal
Air accumulation vessel, at least 1 m3 capacity
Pressure switch
Electrical devices for the automatic compressor start / stop
Safety valve
Local panel / junction boxes
All the equipment will be supplied assembled on skid to minimize the erection operations.
The purpose of this system is to provide the compressed air necessary for the maintenance and
cleaning of the equipment.
5.2.3 Splicing machine/s
Splicing machine/s necessary to provide the complete vulcanizing of the belt conveyors have to be
added in the scope of supply as special tools.
Vendor shall quote them as option (separate price) but, in parallel have to inform if it is possible to have
these equipment for limited time with a renting contract.
5.3
PIPING NET INSIDE GALLERIES AND TOWERS
Vendor shall provide detailed engineering and materials for all piping that have to be installed inside the
towers and galleries.
Piping Battery Limits shall be at the base of the tower or at the base of trestles.
Vendor with offer shall submit general arrangement drawing indicating also, if possible, preliminary
position of Battery Limits.
The main plants to be engineered and supplied will be:

Filtered water for the feeding of the water spray located on the belt discharge hoppers and feeding
chutes
Raw water for the plant cleaning
Compressed air (instrument air) net where necessary (i.e. for filter bag cleaning)
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Compressed air (plant air) for belt conveyor maintenance
Piping shall be selected taking into consideration the prescriptions of piping classes.
5.4
FIRE FIGHTING
5.4.1 Coal belt conveyor facilities fire protection systems.

Reference standard for coal belt conveyor facilities is NFPA 850 Recommended Practice for Fire
Protection for Electric Generating Plants and High Voltage Direct Current Converter Stations.
5.4.2 General safety aspects
Coal conveying and handling structures and supports should be of non combustible construction.
The accumulation of coal dust in enclosed buildings can be reduced by designing structural members
such that their shape or method of installation, minimizing the surface area where dust can settle.
Access should be provided to facilitate cleaning of all areas.
Provisions should be made for de-energizing both lighting and electrical power circuits without requiring
personnel to enter dust-producing sections of the plant during emergencies.
Static electricity hazards should be minimized by the permanent bonding and grounding of all
conductive equipment, including duct work, pulleys, take-up reels, motor drives, dust collection
equipment, and vacuum cleaning equipment.
5.4.3 Fire fighting systems
Reference 3814-SS-SE-901 Work requisition Coal Belt Conveyor Facilities Fire fighting Systems
5.4.4 Safety signs
A complete set of safety sign in Spanish language shall be provided for firefighting equipment and
escape emergency ways.
Safety sign shall be in compliance with local regulations
5.4.5 Fire detection and alarm systems
Fire detection and alarm system for belt conveyor facilities will be connected to Plant Fire detection and
alarm system (by Other); interfaces and battery limits to be defined.
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All Linear heat detection cable and JB shall be suitable for hazardous area classification and complete
with all necessary supports and accessories for proper installation.
Belt coal conveyor enclosed area will be divided in fire zones; extension of fire zone will be 30 m linear.
Preliminarily belt conveyor fire zones to be considered are 16.
5.4.6 Linear heat detection cables
Linear heat detection cable loops will be provided for each fire zone to detect fire condition. Three (3)
linear heat detection loops will be provided for each belt conveyor fire zone.
NOTE: Picture here below has to be used for reference only the measure indicated are not
valid
For updated drawing see specification 3814-SS-SE-000901

5.4.7 Hot spot detectors
System to detect Hot spot will be installed on the belts 00ECD10AF001 & 00ECD20AF001 at the tail
end just after the loading chute. If the hot spot is detected the belt is stopped, and the material will be
removed manually by the operator. Signal are connected to the main handling system PLC
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INSTRUMENTATION EQUIPMENT
The design of equipment and components to be installed in the system shall be carried having in mind
reliability, safety and easy maintenance.
Refer also to instrumentation specifications.
6.1
INSTRUMENTATION FOR BELT CONVEYOR CONTROL
The following instruments will be installed on Belt Conveyors:
Zero speed switch

Inductive sensor connected to a non-driven pulley, to indicate belt or drive failure.
Belt misalignment heavy-duty switches, operated by the deflection of a side roller,
mounted on the switch lever.
6.2
Pre-alarm signal at angle by Vendor to be defined during detail engineering.

Shutdown at angle by Vendor to be defined during detail engineering.
Installation points: on both sides of conveyor close the driving drum and tail pulleys.
Along conveyor, self-aligning idlers shall be installed every 30 m.
Emergency stop switches
Manually reset emergency stop switches, operable from heavy duty, nylon jacketed, steel cable,
running the length of the conveyor on both sides.
Installation distance 50 m with cable supports every 3m.
Distance of the ropes from the structures 80100 mm.
Emergency stop mushroom push button.
Manually reset emergency stop.
Installation point near conveyor heads and wherever necessary.
Chute plug-up switch
Sensing device, "tilt switch" type.
Installation point outside the normal flow of material.
Start-up alarm:
o Electric siren system, along the belt conveyor every 200 m.
o Sound for 15 sec. before the actual start of the conveyor.
Limit switches for gravity tensioning unit to detect the reaching of stroke limits.
Limit switches for screw type and spring tensioning unit to detect the reaching of stroke limits.
Switches and encoder for correct positioning of trippers
INSTRUMENTATION CABLES AND JUNCTION BOX
Instrument cables along the belt conveyors from the electrical (switches, encoders, etc) until the
connection borders JB are included in vendor scope. Instrumentation JB also included in vendor scope
as well as cable glands and plugs.
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Cable trays, conduits along the belt conveyors and inside the transfer towers are in vendor scope of
supply. Power cable trays and instrumentation cable trays shall be separate.
Vendor with offer shall submit general arrangement drawing indicating also, if possible, preliminary
position of Junction Boxes.
ELECTRICAL EQUIPMENT
7.1
ELECTRICAL DESIGN CRITERIA
Electrical equipment installed in classified areas have to be selected according to NEMA standard and
with mechanical protection suitable for the installation zone.
7.2
ELECTRICAL MOTORS
All electrical motors shall be manufactured for continuous duty and start-up under full load.
Design characteristics are summarized on specifications:
3814-NN-SG-000023 MV Electrical motors.
3814-NN-SG-000024 LV Electrical motors.
Terminal box installed on each electric motor shall be delivered holed to allow the installation of the
cable. Dimension of the holes will be communicated by TCM during the follow up. Plugs for holes have
to be included in vendor scope of supply.
Vendor with offer shall submit general arrangement drawing indicating also, if possible preliminary
position of Terminal Boxes
7.3
LIGHTING AND SOCKET
The lighting of galleries, towers and closed ambient shall be included in the scope of supply.
Lighting shall be provided for all materials handling activity areas, machinery platforms, walkways and
stairs, enclosed rooms and cabs and along the belt conveyor lateral walkways in vendor scope of
supply.
Emergency lighting shall be provided to permit the operator to leave the machine safely in the event
that the main circuit breaker trips after dark.
All lighting, as well as sockets, shall be wired till JB.
Sockets along galleries shall be installed every 30 meters, in the towers at each floor as minimum.
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7.4
MCC AND ADDITIONAL ELECTRICAL EQUIPMENT
The supply battery limits for electrical parts is shown on scheme 3814-NN-SG-000103. Electrical
Particular Requirements - Conveyors
All installation materials (trays, conduits, supports, etc.) indicated in the above scheme has to be
considered as integral part of the supply and have to be quoted by Vendor.
All cable trays will be routed inside galleries and tower or stiffened to the pipe conveyor structures.
Underground installations are not admitted.
Variable speed electric motors shall be supplied complete with VFD and special cables for connections.
VFD & electric motor should be of the same brand. Motor and VFD from different brands have to be
supplied complete with certificate.
7.5
GROUNDING SYSTEM
Secondary grounding system shall be in Vendor scope of supply. Primary grounding system will be
realized by Contractor. Further details on specifications:
3814-NN-SE-000025 Primary Grounding system materials and accessories
3814-NN-SE-000026 Secondary Grounding system materials and accessories
7.6
LIGHTNING PROTECTION SYSTEM
Lightning Protection shall be as per NFPA 780 Standard for the Installation of Lightning Protection
Systems
The protection level shall be defined in accordance with the classification of the volume to be protected.
Exposed metal structures and equipment shall be grounded in the same way as prescribed for standard
down-conductors.
The down-conductors shall have cross-section larger than the value specified by standards, and shall be
so installed as to provide the shortest, most direct path to ground.
7.7
EQUIPOTENTIAL BONDING
Metal installations inside the structure (size cable 1/0 AWG) shall be made equipotential at ground
level, by bonding to one or several interconnected bonding bars, connected to the ground termination
system.
Equipotential bonding shall be carried out also in the points where the distance between the metal
installation and the external protection system is lower than the safety distance defined by the
standards.
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7.8
MODES OF CONTROL
Vendor has to consider the following:

The Coal Handling System will be equipped with a dedicated PLC able to operate the plant in the
following modes of control:
a)
b)
c)
Local
Remote Manual
Remote Automatic
The PLC will be installed in the material handling control room located inside the Building 52.
For control system characteristics and architecture refer to Automation documentation.
7.8.1 Local mode
This operation mode is foreseen only for maintenance and tests procedures.
In this mode, all drives can be controlled locally in the field.
The drives are switches to "local" through PLC and thereby completely de-interlocked from the rest of
the process.
Safety interlocks and equipment protection trips shall not be by-passed.
7.8.2 Remote Manual mode
In the manual mode the operator shall have full control of the machine.
All interlocking protections shall be operational in this mode.
All events and status shall be monitored and visualized by PLC.
7.8.3 Remote Automatic mode
Vendor shall provide the complete engineering of the fully automatic remote operation (complete with
the control of the interfaced systems about the functional sequences start/stop, permissive, alarms/trips
status etc.)
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PLANT 3D VIEWS
Handling system overview
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Tripper conveyors for the boiler feeding
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Warehouse front view with crusher tower
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Attachment 1 Preliminary arrangement top of bunker area
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Attachment 2 Preliminary arrangement pipe conveyor on jetty
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Attachment 3 Preliminary arrangement conveyor & hopper on pier
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Attachment 4 Typical section of belt conveyors installed in galleries
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1 3814 GY SE 901003 IS03 Technical Especification

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1 3814 GY SE 901003 IS03 Technical Especification

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Document Identification Code

Client: CDEEE - Corporacin Dominicana de Empresas Elctricas

OWNER DOCUMENT CLASSIFICATION CODE

FC FOR CONSTRUCTION OR FOR PURCHASE

15 JUN 2014 FINAL ISSUE

30.APR.2014 PRELIMINARY ISSUE

08 JAN 2015 ISSUE FOR ORDER

Reason for Issue Revision Description

Document Identification Code

Client: CDEEE - Corporacin Dominicana de Empresas Elctricas

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

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

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

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

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

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

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

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

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

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

Document Identification Code

Client: CDEEE - Corporacin Dominicana de Empresas Elctricas

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

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

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

Document Identification Code

Client: CDEEE - Corporacin Dominicana de Empresas Elctricas

Document Identification Code

Client: CDEEE - Corporacin Dominicana de Empresas Elctricas

COAL HANDLING DESIGN BASIS

Coal conveying from ship unloading to bulk warehouse

Movable hoppers 00EAA10BR001;

Document Identification Code

Client: CDEEE - Corporacin Dominicana de Empresas Elctricas

Coal conveying from bulk warehouse to boiler silos

Portal reclaimers 00EAF10AE001 & 00EAF20AE001;

Document Identification Code

Client: CDEEE - Corporacin Dominicana de Empresas Elctricas

SCOPE OF SUPPLY AND BATTERY LIMITS

From ship unloading to bulk warehouse:

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

Document Identification Code

Client: CDEEE - Corporacin Dominicana de Empresas Elctricas

Extent of prefabrication and status of equipment at shipment

Document Identification Code

Client: CDEEE - Corporacin Dominicana de Empresas Elctricas

Bulk materials and minor items

MINIMUM REQUIREMENT FOR EQUIPMENT

h/d (during the presence of ships)

MAIN DESIGN CHARACTERISTICS

The width of Conveyor Belts will be expressed in millimeters.

Document Identification Code

Client: CDEEE - Corporacin Dominicana de Empresas Elctricas

Belt and pulleys in accordance with CEMA standard for:

Grade 2 belting or better

Top cover: abrasion, cut and gouge resistant

DIN abrasive rating 90 or better

Over temperature range: 40 to 200 F

Minimum tensile rating: as per K quality

Hardness: 60 Durometer Shore A

Chemical resistant (sulfur)

Top cover minimum thickness: 3/16

Bottom cover minimum thickness: 1/16

Cover ratio to resist cupping