OPERATIONAL WRITE UP FOR COAL SAMPLING SYSTEM FOR CSU The Primary Sampler 1 & 2 (rotary scoop belt

top) shall be collected sample from the Belt Conveyor No. either 9A.or 9B during conveyor in operation .This equipment shall be driven through electro-mechanical device in intermittent operation. This operation will be achieved through limit switch, brake & PLC Timer. The setting of time interval needs to be adjusted through PLC Timer according required time interval for primary sample collection. When starts command comes though PLC Cutter of Primary Sampler will start to rotate and hits the limit switch and brake un-energized to stop cutter in parking preposition. After PLC time out the same cycle shall be repeated and cutter will start to rotate. The proximity switch provided in Primary sampler to ensure safe parking zone of cutter, so it may be understood the Primary Sampler are running in safe condition. Primary Sample 1 & 2 shall be feed through interconnecting chute in to Belt Conveyor 1 & 2 respectively. This equipment shall be drive through electro-mechanical device. The Belt sway switch provided in Belt Conveyor to control the belt sway. PLC get running signal of Belt Conveyor through zero speed switch. In forward direction Belt Conveyor 1 & 2 feed the material to Surge Hopper 1 or 2 respectively and in reverse direction Belt Conveyor 1 & 2 feed the material to Surge Hopper 3 or 4. Belt Conveyor 1 and 2 will be operated in forward direction for consecutive 2 cycle of with respective Primary Sampler to discharge Chemical Sample in to Surge Hopper 1 and 2. Belt Conveyor 1 and 2 will operate once in reverse direction to collect sample for size analysis into Surge Hopper 3 and 4 for onward feeding to screen after completion of 2 cycle of Primary increment transferred to Surge Hopper by forward direction. EMV Feeder 1 or 2 feed the material from Surge Hopper 1 or 2 are for feeding to Sample Crusher for chemical testing. The Sample Crusher shall be driven through motor, v-belt. Zero speed switch provided on Sample Crusher to send the running signal to PLC. Sample Crusher crushed the material to desired size and feed the same to the Sample Divider through interconnecting chute. This equipment shall be driven through electro-mechanical device and divide the material in two part (viz. Sample & Rejects). Sample part of the material transferred to the Bottle Sample Collector through interconnecting chute. The final sample collection from Collector is taken manually for Lab testing purpose. On the other side reject part of the material transferred to the Bucket Elevator through interconnecting chute. Bucket Elevator discharges the material to Reject Screw Conveyor. Reject Screw Conveyor discharges the material to either Conveyor No 10A or 10B through selection of motorized Slide Gate. Reject sample material transfer to conveyor no 10A when slide gate is in the open condition and the close condition of slide gate, material transferred to conveyor no. 10B. PLC get running signal of Screw Conveyor through zero speed switch.

1. OUTLINE OF EQUIPMENT a) PRIMARY SAMPLER (ROTARY SCOOP TYPE) No 1 & 2 Scoop type Sampler is intermittent operation. This operation will be achieved through Limit Switch & PLC Timer. Time setting to be adjusted through PLC Timer according to the required time interval of collecting the sample. When start command comes through PLC, the cutter of the Primary Sampler will start to rotate and hits the Rotary Limit Switch. The motor of the Primary Sampler will stop and cutter will be on the parking position. After PLC time out the same cycle shall be repeated and cutter will start to rotate. A proximity switch is provided in this equipment. When cutter starts rotating from its parking position, Proximity Switch will be sense and PLC timer start counting time. After traveling the working zone, the cutter hits the Rotary Limit Switch and PLC timer stop the counting time at travel between Proximity Switch and Rotary Limit Switch. The normal travel time is 800 ms. If cutter dose not hit the Limit Switch within 800ms, it is to be considered that the cutter has been stuck up within the working zone (Ref. Traveling diagram.). In this situation the conveyor shall trip to avoid spillage and damage of belt and cutter. If Proximity switch senses continuously, in that case PLC indicate cutter is beyond the parking zone, in this condition Sampling System should be shut down and brake required adjusting. It consists of 11 kW motor.

b)

BELT CONVEYOR -1 (REVERSIBLE) Belt Conveyor-1 is used for carrying the sample material from one end to other end. In Normal mode, Belt Conveyor-1 will be operated in forward direction for consecutive 2 cycle of with respective Primary Sampler-1 to discharge Chemical Sample in to Surge Hopper 1. Belt Conveyor1 will operate once in reverse direction to collect sample for size analysis into Surge Hopper 3 for onward screen after completion of 2 cycle of Primary increment transferred to Surge Hopper by forward direction. In By Pass mode, Belt Conveyor-1 will run only forward direction. Zero Speed Switch has been provided for this equipment. It consists of 1.5 kW motor.

c) BELT CONVEYOR -2 (REVERSIBLE) Belt Conveyor-2 is used for carrying the sample material from one end to other end. In Normal mode, Belt Conveyor-2 will be operated in forward direction for consecutive 2 cycle of with respective Primary Sampler-2 to discharge Chemical Sample in to Surge Hopper 2. Belt Conveyor1 will operate once in reverse direction to collect sample for size analysis into Surge Hopper 4 for onward screen after completion of 2 cycle of Primary increment transferred to Surge Hopper by forward direction. In By Pass mode, Belt Conveyor-2 will run only forward direction. Zero Speed Switch has been provided for this equipment. It consists of 1.5 kW motor. d) EMV Feeder 1 EMV Feeder-1 is used for discharged the material from Hopper-1 to Crusher and provided rated feed to Crusher as per requirement. It is continuous operation. It consists of 1.5KVA, 240V AC Electro Magnet. e) EMV Feeder 2 EMV Feeder-2 is used for discharged the material from Hopper -2 to Crusher and provided rated feed to Crusher as per requirement. It is continuous operation. It consists of 1.5KVA, 240V AC Electro Magnet. f) EMV Feeder 3 EMV Feeder-3 is used for discharged the material from Hopper -3 to Vibrating Feeder and provided rated feed to Vibrating Feeder as per requirement. It is continuous operation.. It consists of 1.5KVA, 240V AC Electro Magnet. g) EMV Feeder 4 EMV Feeder-4 is used for discharged the material from Hopper -4 to Vibrating Feeder and provided rated feed to Vibrating Feeder as per requirement. It is continuous operation. It consists of 1.5KVA, 240V AC Electro Magnet. h) CRUSHER ( Hammer type ) Crusher is used for crushing the material as per requirement of the system. It is continuous operation. Zero Speed Switch has been provided for this equipment. It consist of 18.5 kW motor, V-belt, V-pulley. i) DIVERTER GATE The operation of Diverter Gate is to divert the sample for moisture testing and re-set to chemical testing. This equipment is to be operated only manual mode. When sample is require for moisture testing, press Gate close PB from PLC panel. When Diverter Gate received close command through P.B, motor starts to move in forward direction until it hits the Forward Limit Switch to stop the motion of motor. After collecting the sample for moisture testing, press open P.B from PLC panel. When received the Gate close command, motor start to move in reversed direction until it hits the Reversed Limit Switch to stop the forward motion. It consists of 0.37 kW motor

j) SAMPLE DIVIDER ( Rotary sector type ) Sample Divider is used for dividing the crushed material (Sample + Reject) as per requirement of the system. The operation of secondary sampler is Continuous. It consists of 1.5 kW motor. k) BOTTLE SAMPLE COLLECTOR Bottle Sample Collector is intermittent operation. This operation will be achieved with the help of Proximity switch. Sample collection container position will change normally by application of Proximity switch, Brake motor, PLC timer. When PLC set time is out (i.e. every 60 min.) the same cycle shall be repeated. It consists of 0.75 kW motor. Cycle :-PLC On Delay Timer time out Motor start Proximity switch sense PLC On Delay Timer energies and Motor stop.

l) BUCKET ELEVATOR Bucket Elevator is used for discharging the reject sample material to Reject Screw Conveyor. It is continuous operation. Zero Speed Switch have been provided for this equipment for getting running signal. It consists of 2.2 kW motor. m) REJECT SCREW CONVEYOR Reject Screw Conveyor is used for discharging the reject sample material to either Conveyor No. 5A or 5B through slide gate. It is continuous operation. Zero Speed Switch have been provided for this equipment. It consists of 2.2 kW motor. n) ELECTRICAL SLIDE GATE When Gate received open command, motor starts to move in reverse direction until it hits the Reverse Limit Switch to stop the motion of motor. After receiving the Gate close command, motor start to move in forward direction until it hits the Forward Limit Switch to stop the forward motion. Operation of Electrical Slide Gate is required as per requirement of the system and selection for open/close of Slide Gate to be interlocked with Conveyor No. 5A & 5B. When conveyor 5B runs, the Slide gate will be in closed condition and conveyor 5A runs the Slide gate will be in open condition. It consists of 0.75 kW motor. o) VIBRATING SCREEN Vibrating Screen is used for discharged the material to Bias Sample Box. It is continuous operation. Zero Speed Switch has been provided for this equipment for getting running signal. It consists of 1.5kW motor.

2. OPERATIONAL SEQUENCE It is to be ensured that all downstream equipments are to be started before starting Primary sampler. So that material once proceed by the sampler, can flow through the successive units without any problem or chocking. The Coal Sampling System shall be operated in two modes Manual mode and Auto mode. Manual operation and Auto operation mode can be selected from CHS PLC panel at CHP main control room with the help of CHS HMI. a) MANUAL OPERATION : Select Auto/Manual Selection in Manual position from CHS HMI. All the units can be started or stopped individually from their respective start/stop Push Bottom mounted on the Local Control Cum PLC Panel near the equipment MCC room with the help of CSU PLC without any system interlock except compulsory interlock. This mode of operation is kept for the testing / maintenance purpose of equipment. b) AUTO OPERATION : In Auto mode there shall be two selections: i) Normal Mode. ii) By Pass Mode. i) Normal Mode: Select Normal Mode from CHS HMI. When start command comes from CSU PLC then all the sampling equipments will start running one by one in a sequential order. Before starting the sequence it shall be ensured that Conveyor No. 9A or 9B and 10A or 10B are in operation. Primary Sampler 1 & 2 shall be interlocked with respective Conveyor 9A & 9B. After every cycle of increment, the Scoop type Sampler will be stopped through DC Brake. The Sampler will start again after a pre-setting time delay, but the other downstream of the system will run continuously except Bottle sample collector and Belt Conveyor. Bottle sample collector will be operated hourly. Belt Conveyor 1 and 2 will be operated in forward direction for consecutive 2 cycle of with respective Primary Sampler to discharge Chemical Sample into Surge Hopper 1 and 2. Belt Conveyor 1 and 2 will operate once in reverse direction to collect sample for size analysis into Surge Hopper 3 and 4 for onward screen after completion of 2 cycle of Primary increment transferred to Surge Hopper by forward direction. Selection for open/close of Slide Gate is to be interlocked with Conveyor No.10A & 10B. When conveyor 10B runs, the Slide gate will be in closed condition and conveyor 10A runs, the Slide gate will be in open condition. System MIMIC is to be provided on the Local Control Cum PLC Panel. Brake over ride proximity switch provided to fix the over ride position of Primary Sampler brakes. In case proximity switch energized continuously more than 400mS the systems will shut down and brake resetting to be done. Sequence: Slide Gate (Open/Close) Screw Conveyor Belt Bucket Elevator

Sample Divider Bottle Sample Collector Sample Crusher

EMV Feeder 1 or 2

Belt Feeder 1 or 2 Primary Sampler 1 or 2.

ii) By Pass Mode: To avoid collection of Screen Sample, By Pass mode provided at remote with following condition. Primary Sampler will have 24 increment each per hour as Chemical Sample. Belt Conveyor 1 or 2 will operate only in forward direction for collection of sample into Surge Hopper 1 and 2 for Chemical Processing bypassing the sequence operation of Belt Conveyor. Select By Pass Mode from CHS HMI. When start command comes from CSU PLC then all the sampling equipments will start running one by one in a sequential order. Before starting the sequence it shall be ensured that Conveyor No. 9A or 9B are in operation. Primary Sampler 1 & 2 shall be interlocked with respective Conveyor 9A & 9B. After every cycle of increment, the Scoop type Sampler will be stopped through DC Brake. The Sampler will start again after a pre-setting time delay, but the other downstream of the system will run continuously. In this mode, Belt Feeder 1 or 2 will be running only forward direction. Sequence: Slide Gate (Open/Close) Screw

Sample Divider Bottle Sample Collector Sample Crusher

Belt EMV Conveyor Feeder 1 or Feeder 1 or 2(Fwd.) 2 Belt Bucket Elevator Primary Sampler 1 or 2.

c) Screen Testing: This will be operating only Manual Mode. First start EMV Feeder 3 or 4 to process Screen Sample from PLC Cum Local Control Panel and then start Screen from PLC Cum Local Control Panel in Manual mode. Sequence: EMV Feeder 3 or 4 Vibrating Screen

MATERIAL FLOW DIAGRAM OF COAL SAMPLING SYSTEM

Conveyor 9A (CON) Conveyor 9B (CON) Rotary scoop type Rotary scoop type Primary sampler no-1 (INT) no-2 (INT) It will be operated alternative. It will be operated Belt Feeder 1 (CON) Belt alternativ 2 (CON) e. It will be operated alternative It will be operated alternative Fwd. Rev. Fwd. Rev. Surge Hopper 4

Primary sampler

Feeder

Surge

Hopper 1 EMV EMV Hammer Vibrati ng Screen (CON) Diverter Gate.

Surge Hopper 3 Surge Hopper 2 Feeder1(CON) EMV Feeder3(CON) Feeder2(CON) EMV Feeder-4(CON) Crusher (CON)

Close Moisture Testing Sample Box.

Sample Box. Open Note: CON -Continuous operation . INT -Intermittent operation