1 - Lmi CHP

NTPC Limited LMI KORBA
TITLE
Manual on Supply, Sampling & Analysis,
Handling and Storage of Coal
REF NO. LMI 01/FM/COS-ISO-00-OGN/OPS/PERF/009
Manual on Supply, Sampling & Analysis, Handling and Storage of Coal
1 INTRODUCTION
At present various activities related with coal, viz., supply, handling, sampling &
analysis, storage, accounting of diverted rakes etc are being dealt with different
departments at stations. These departments have their respective approved
manuals/ guidelines based upon guiding documents sent from Corporate Office
for carrying out the assigned activities.
In Dec.’2011 during the discussions on coal issues Audit Committee of Board

desired that a Comprehensive manual be prepared consisting of various
activities related to coal, viz., handling, sampling & analysis, storage of coal etc.
and to be followed in all the stations uniformly.
Various existing manuals/guidelines (some as OGN/OIN) related to coal have

been reviewed and a consolidated manual on handling, sampling & analysis,
storage of coal has been prepared.
2 DOCUMENTS
2.1 Reference Document: Manual on Supply, Sampling & Analysis, Handling and
Storage of Coal: OGN-OPS-SYST-026 dated 15 Nov 2012.
2.2 Superseded Documents
a) Care in Operation & Maintenance of Coal Handling plant: LMI-02-R5/

CHP/OGN-OPS-SYST-013 dated Oct 2010.
b) Coal as-Fired sampling procedure: LMI 01-R2/CHEM/OGN- OPS- CHEM-

014 dated May 2012.
c) Sample Preparation of Coal: LMI 04-R 4/CHEM/OGN-OPS-CHEM-006

dated Feb 2012.
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3 MAIN DOCUMENT
Section I (A) Guidelines on Supply of Domestic Coal:
At the time of conception of a plant, Long Term Linkage or approval for issue of Letter
of Assurance (LOA) by the Coal Company is accorded by Standing Linkage
Committee (Long Term SLC). This is a pre-requisite for investment approval of NTPC
plants. This Long Term Linkage or LOA subsequently gets converted into Fuel Supply
Agreement (FSA) between NTPC station and Coal Company.
As on date, FSAs are in place for NTPC stations/ units commissioned till 31.03.2009
for Annual Contracted Quantity (ACQ) of 124.9 MMTPA (CIL-114.7 MMTPA and
SCCL-10.2 MMTPA) for the installed capacity of 23,895 MW. This ACQ corresponds
to around 85% Plant Load factor (PLF).
For units commissioned after 31.03.2009, FSAs are being formulated. As a stop gap
arrangement, Memorandum of Understanding (MoU) is signed between NTPC station
and the Coal Company on year to year basis. Coal allocation is done by CEA during
financial year 2012-13 for around 60-70% of LOA quantity.
The FSAs may be referred which have explicit provisions of Quantity/weighment,

Quality/sampling, and Price/Incentive/Penalty etc.
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Section I (B) Guidelines on supply of Imported Coal
INDEX
Sl. No. Contents Page No.
1.0 Quantity Determination 04
2.0 Quality Inspection 05
3.0 Adjustment on Quality Variation 08
4.0 Reconciliation / Adjustment 14
5.0 Payment Terms 14
6.0 Taxes and Duties 19
Annexure A1 Pricing methodology (For high GCV Coal) 22
Annexure A2 Pricing methodology (For low GCV Coal) 27
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Manual on Supply of Imported Coal

(Quantity, Quality and payment terms under Contract)
NTPC is procuring imported coal to mitigate the shortage in supply of domestic
coal at its power stations. The coal is imported for various stations of NTPC on
‘FOR Destination’ basis through international competitive bidding (ICB).
NTPC imports coal of high GCV (6300 Kcal/ Kg ADB) which is used after blending
it with the domestic coal. In the subsequent sections, various aspects on quantity
determination, quality and payment terms of these imported coals have been
described.
1.0 Quantity Determination:
(i) Net Adjusted Quantity of coal received at NTPC power stations, i.e.
quantity worked out after carrying out adjustments due to quality
variations with respect to the base parameters, remains final for the
purpose of assessment of executed quantity and payment.
(ii) Quantity determination of imported coal is done at NTPC power

stations, subject to adjustment due to variations over the base quality
parameters if any, and payments thereof is based on such
determination at NTPC power stations. Base parameters for price
basis for high GCV coal is as under:
Gross Calorific Value (ADB) :

6300 Kcal/Kg
Total Moisture (ARB) :
16 %
Ash (ADB) :
10 %
Sulphur (ADB) :
0.80 %
Size (less than 2.36 mm) not exceeding :
25 % of quantity received
at power plant
For low GCV coal the base parameters for price basis is different and is as
given as below:
Gross Calorific Value (ARB) : 5000 Kcal/Kg

Total Moisture (ARB) : 30 %
Ash (ARB) : 8%
Sulphur (ARB) : 0.60 %
Size (less than 2.36 mm) not exceeding : 25 % of quantity received
at power plant
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(iii) The Coal delivered is weighed at NTPC power stations. The weight
recorded by Weighment System of NTPC having an electronic print-
out facility is taken as final after consideration of empty rake weight. In
case NTPC power stations’ Weigh Bridge is out of order, weight as
determined by Railways Weigh Bridge at nearby station is considered
final for determining the weight at NTPC power station. If rake weight
cannot be determined by the above two processes, actual RR weight
is considered as final for determination of quantity at Power Stations.
(iv) The coal is measured/ weighed rake-wise/ wagon-wise for the
determination of quantity. In case of partial weighment of rake, the
weight of un-weighed wagons is considered as per the nearest railway
weighbridge/ RR weight as described above. The quantity determined
is also subjected to adjustment due to quality variations.
(v) It is the responsibility of the supplier to inform the rake arrival time at
power stations in advance.
(vi) It is the responsibility of the supplier to dispatch rakes under clear
identification tags and distinct identification should appear in all
documents so that the rake at the destination can be identified. No
claim on NTPC can be made or be admissible if there is any error in
determination of quality parameters due to erroneous or non-
identification of rakes at power station.
(vii) The supplier ensures that imported coal rakes are delivered to the
consigned station only. In case the rakes are diverted by Railways for
any reason(s), beyond the control of the supplier, he shall furnish
advance intimation and RR and other necessary details to the
concerned station immediately on diversion of rake.
(viii) The supplier ensures that there is no under loading of wagons.
However, in case of under loading, the charge on proportionate basis
is recovered from the supplier’s dues. All other charges like
Demurrage/ Dispatch, Wharfage, Overloading/ Under-loading charges
etc. as applicable for Ports and Railways should be to the account of
supplier. Any delay/ detention charges of Rakes at NTPC Power
station is to the account of NTPC.
2.0 Quality Inspection:

Quality determination of imported coal is done at Load port, Discharge
port and at NTPC power station. However, Quality of coal is final based
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on the inspection results of the samples taken at NTPC power station

and payments thereof are based on such determination at Power
station.
The supplier ensures the appointment of NABL (National Accreditation
Board for Testing and Calibration Laboratories) accredited Independent
Inspection Agency (ies) (IIA)(not more than three agencies during the
currency of the Agreement) with intimation to NTPC for draft survey,
sampling and quality analysis at Load Port, Discharge Port and NTPC
Power Station before the commencement of first consignment. The costs
of inspection including coal-sampling analysis at various points i.e. Load
Port, Discharge Port and NTPC power station including the fee for
Inspection Agency is borne by the supplier.
NTPC at its discretion and cost can also appoint an Independent
Inspection Agency to carry out Sampling and Quality analysis at Load
Port/ Discharge Port. NTPC at its discretion and cost can also nominate
their representative to witness sampling and analysis at Load Port/
Discharge port.
Sampling and Testing of coal samples drawn at Load Port/
Discharge Port:
Coal samples at Load Port and Discharge Port is drawn, prepared and
analyzed by IIA in accordance with relevant ASTM Standards.
Sampling and Testing of coal samples drawn at NTPC's Power
Station end:
Coal samples at NTPC's power station end, is drawn from each rake
and prepared for analysis by IIA in the presence of NTPC
representative in accordance with the relevant ASTM Standards
The sample so drawn and prepared in presence of NTPC
representative is divided into four (4) parts within one (1) day of its
collection and is distributed as follows:
(a) One part of the sample is taken by NTPC for analysis at their end.
(b) Second part of the sample is taken by IIA for analysis at their end.
(c) The third part of the sample is retained as Referee Sample. Such
Referee Sample is kept under joint lock and joint custody of IIA and
NTPC, to be used for future reference and/or testing.
(d) The fourth part of the sample is taken for joint analysis by NTPC
and IIA for determination of total moisture and size.
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IIA analyzes its portion of the coal sample for the parameters, drawn at
NTPC's Power Station end, at the laboratory (ies) as may be identified
by them.
NTPC analyzes its portion of the coal sample for the same parameters
drawn at NTPC's Power Station end. IIA may also witness, with consent
of NTPC, the test carried out by NTPC at its lab.
For determining the Total Moisture and Size, NTPC and the supplier
undertake joint analysis at NTPC power station laboratory immediately
on receipt of imported coal. In case the analysis for total moisture and
size is not carried out immediately, such sample(s) is kept under joint
lock and joint custody of IIA and NTPC till determination of total
moisture & size. For correction of GCV for landed price, Ash for quantity
and Sulfur for penalty, test results of NTPC is considered and in case of
any dispute, test results of referee sample, if admissible, is considered.
NTPC submits its report to the representative of the supplier at site. In

case of any dispute, due to variance in test results of IIA and NTPC
beyond the limits permissible under the relevant ASTM (except for Total
Moisture and Size), and subsequent claim by the supplier for testing of
referee sample, the report of IIA should be provided to NTPC within
5(five) working days after receipt of NTPC report by the supplier or
10(ten) working days after distribution of sample whichever is later. In
such an event, Referee Sample is forwarded by NTPC to the Third party
laboratories having the facilities for coal analysis as per ASTM methods
and are under Council of Scientific and Industrial Research (CSIR) or
Government owned/ Government approved or has the accreditation of
National Accreditation Board for Testing and Calibration Laboratories
(NABL), Department of Science and Technology, India, for analysis.
If no dispute is raised by the supplier within five (5) working days after
receipt of NTPC report by the Successful Bidder or ten (10) working
days after distribution of sample whichever is later, no request for
consideration of referee sample is accepted subsequently. In such
cases, analysis report of NTPC is binding.
It is specifically agreed that the analysis results of such Referee Sample

by the above stated third party laboratories is binding on all parties and
the cost of testing of the Referee Sample at laboratory is borne by the
supplier.
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3.0 Adjustment on Quality Variations:
3.1 For of High GCV coal:
In the event of variations over the quality parameters from base

parameters, adjustments are carried out as per the formula provided
hereinafter:
a) Total Moisture {As Received Basis (ARB)}
If the actual total moisture as per sampling/analysis through joint

analysis process at NTPC power stations is more than the base
parameters of total moisture of coal, the reduction in weight is done as
per following formula:
Weight of Coal to be reduced

(For 16<B<=20)=Ax1.10x(B-(Cx(100-B)/(100-C))) /100
Weight of Coal to be reduced

(For B>20) = A x1.20x (B-(Cx(100-B)/(100-C))) / 100
(where A is coal received weight, B is percentage value of Total

Moisture of coal received, C is the base parameter value of Total
Moisture)
No correction shall be applied in case of decrease in Total Moisture

below the base parameter value.
b) Gross Calorific Value {Air Dried Basis (ADB)}

For correction of contracted landed price, NTPC’s test results at power
station is considered and in case of any dispute, if admissible as per
S.No. 2.0, test results of third party lab, is considered.
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Corrections are done as follows:

Corrected landed price (for 6300>GCV >= 5800)
(Contracted landed price at NTPC station per Metric Tonne) x
(GCV (ADB) at NTPC Power Station)
(Contracted base GCV (ADB))
Corrected landed price (for GCV < 5800)

0.8x(Contracted landed price at NTPC station Per Metric
Tonne)x(GCV(ADB) at NTPC Power Station)
(Contracted base GCV (ADB))
For above calculation, contracted landed price of coal implies the
landed price of coal arrived at based on the Pricing Methodology at
Annexure – A1 and is excluding Custom Duty, Sales tax/VAT and Entry
tax.
c) Ash Content (ADB)
For correction of quantity due to Ash, NTPC’s test results at power
S.No.2.0, test results of third party lab is considered.
If Ash content is above the base parameter value of Ash, weight to be
reduced is as per the following formula:
Weight of coal to be reduced = Ax1.05x(B–(Cx(100– B)/(100–
C)))/100
No correction is applied in case of decrease in Ash content below the
base parameter value.
d) Sulfur (ADB)
For Sulphur, NTPC’s test result at power station is considered and in
case of any dispute, if admissible as per S.No.2.0, test results of third
party lab are considered.
If Sulfur content is above the base parameter value of Sulfur, a penalty

at the rate of Rs.10.00 per Metric Ton for every increase of 0.1 % in
Sulfur or part thereof is levied.
Sulfur content below the base parameter value of Sulfur is ignored.
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e) Size (ADB)
If the size as per sampling/analysis through joint analysis process at

NTPC Power Stations as determined by ASTM-D4749-87 (re approved
2002) or its latest version in air-dried sample for 0-2.36 mm size
particles exceeds 25% of the sample coal by weight received at power
station, then the weight of coal is reduced as per following formula:
Weight of Coal to be reduced = (A*B/100)*0.1
(Where A is quantity of coal received at power station, B is increase of

the fines particles above 25% in percentage value)
(Example- If fines particles is 30%, then B =(30-25) = 5)
f) After adjusting the received quantity at Power Station for quality

parameters as above, if it is found that the net adjusted quantity is
higher than the net Bill of Lading quantity (i.e. quantity worked out after
carrying out adjustments due to quality variations at Load Port with
respect to the base parameters), the payment shall be restricted to net
Bill of Lading quantity. In case the net adjusted quantity at power
stations is lower than the net Bill of Lading quantity, the net adjusted
quantity at power stations shall prevail for the purpose of payment.
g) For the purposes of adjustment of coal quality the samples is taken

from each rake and analyzed for each rake. The weighted average
results of such analysis of rakes received in fifteen days i.e. rakes
received between 1st to 15th and rakes received between 16th to 30th /
31st of the month at power station shall be applied for carrying the
necessary adjustment.
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3.2 For ‘Low GCV’ coal:
In the event of variations over the quality parameters from base

parameters, adjustments are carried out as per the formula provided
hereinafter:
a) Total Moisture {As Received Basis (ARB)}

If the actual total moisture as per sampling/analysis through joint
analysis process at NTPC power stations is more than the base
parameters of total moisture of coal, the reduction in weight is done as
per following formula:
Weight of Coal to be reduced(For 30<B<=35)=Ax0.13x(B-(Cx(100-
B)/(100-C))) /100
Weight of Coal to be reduced (For B>35) = A x2x0.13x(B-(Cx(100-

B)/(100-C))) / 100
(where A is coal received weight, B is percentage value of Total

Moisture of coal received, C is the base parameter value of Total
Moisture)
No correction shall be applied in case of decrease in Total Moisture

below the base parameter value.
b) Gross Calorific Value {As Received Basis (ARB)}
In the case of low GCV coal, Gross Calorific Value {As Received Basis
(ARB)} is considered.
For correction of contracted landed price, NTPC’s test results at power

S.No.2.0, test results of third party lab, is considered.
A correction is done as follows:
Corrected landed price (for5000>GCV >= 4500)
(Contracted landed Price at NTPC station Per Metric Tonne)x (GCV

(ARB) at NTPC Power Station)
(Contracted base GCV (ARB))
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Corrected landed price (for GCV < 4500)
0.8x(Contracted landed Price at NTPC station Per Metric

Tonne)x(GCV(ARB) at NTPC Power Station)
Contracted base GCV (ARB))
Corrected FOB price (for GCV >5000)
If GCV (ARB) at power station end is found to be more than 5000

kcal/kg, the FOB price is adjusted for payment as below:
Corrected FOB price = (Contracted FOB price Per Metric Tonne) x

(GCV (ARB) at NTPC Power Station)
(Contracted base GCV (ARB))
However, for supply of coal having GCV (ARB) more than 5500 kcal/kg,
adjustment in FOB price is limited to GCV (ARB) 5500 kcal/kg only.
For above calculation, Contracted landed price of coal implies the

landed price of coal arrived at based on the Pricing Methodology at
Annexure-A2 and shall be excluding Custom Duty, Sales tax/VAT and
Entry tax.
c) Ash Content (ARB)
Ash measurement in case of Low GCV coal is ARB and in case of Ash
content above the base parameter value, weight to be reduced is as per
the following formula:
Weight of Coal to be reduced = Ax1.05x(B-(Cx(100-B)/(100-

C)))/100
(Where A is coal received weight, B is percentage value of Ash in coal

received; C is the base parameter value of Ash)
No correction is applied in case of decrease in Ash content below the

base parameter value.
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d) Sulfur (ARB)
For Sulfur, NTPC’s test result at power station is considered and in case
of any dispute, if admissible as per S.No.2.0, test results of third party
lab are considered.
If Sulfur content is above the base parameter value of Sulfur, a penalty

at the rate of Rs.10.00 per Metric Ton for every increase of 0.1 % in
Sulfur or part thereof is levied.
Sulfur content below the base parameter value of Sulfur is ignored.
e) Size
If the size as per sampling/analysis through joint analysis process at

NTPC Power Stations as determined by ASTM-D4749-87 (re approved
2002) or its latest version in air-dried sample for 0-2.36 mm size
particles exceeds 25% of the sample coal by weight received at power
station, then the weight of coal is reduced as per following formula:
Weight of Coal to be reduced = (A*B/100)*0.1
(Where A is quantity of coal received at power station, B is increase of

the fines particles above 25% in percentage value)
(Example- If fines particles is 30%, then B = (30-25) = 5)
f) After adjusting the received quantity at Power Station for quality

parameters as above, if it is found that the net adjusted quantity is
higher than the net Bill of Lading quantity (i.e. quantity worked out after
carrying out adjustments due to quality variations at Load Port with
respect to the base parameters), the payment shall be restricted to net
Bill of Lading quantity. In case the net adjusted quantity at power
stations is lower than the net Bill of Lading quantity, the net adjusted
quantity at power stations shall prevail for the purpose of payment.
g) For the purposes of adjustment of coal quality the samples is taken

from each rake and analyzed for each rake. The weighted average
results of such analysis of rakes received in fifteen days i.e. rakes
received between 1st to 15th and rakes received between 16th to
30th/31st of the month at power station shall be applied for carrying the
necessary adjustment.
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4.0 Reconciliation/Adjustments:
Supplier and NTPC jointly reconcile all payments made for the monthly
coal supplies shipment-wise during each month within fifteen (15)
working days after end of each month. The parties forthwith give
credit/debit notes for the amounts falling due, if any, assessed during
such reconciliation and payments shall be made within five (5) working
days thereafter. The monthly reconciliation statement is jointly signed
by the authorized representative of supplier and NTPC, which is binding
on both the parties.
5.0 Payment Terms:
The payment is to be released to the account of the supplier in three

stages, i.e., initial payment, interim payment and the balance payment.
In case of payments to the domestic bidder and/or the partner (in case
of JV) who is also in the category of domestic supplier, amounts
denominated in USD is to be released to the account in equivalent
Indian Rupees.
The payment terms are as under:
5.1 Initial Payment (Interest Bearing)
85% of C&F coal price of consignment is released (as advance to be

adjusted subsequently at the time of interim payment) upon shipment of
vessel from load port based on the quantity and quality parameters of
coal as specified at load port, on fulfillment of the following conditions:
i) Submission of proforma invoice in quadruplicate along with related

coal price indices (Exchange rate, if applicable, for coal price is
based on Reference Exchange Rate as on the date of Bill of
Lading)
ii) Submission of Hypothecation Deed (as per specified format) for
having hypothecated the coal under the subject invoice to NTPC.
iii) Submission of an unconditional Bank Guarantee (as per specified
format) covering 85% of C&F coal price of the shipment, i.e.,
equivalent of initial payment claimed.
iv) Fax/photocopy of shipping documents which shall include (1) Bill
of Lading; (2) Certificate of Country of Origin; (3) Insurance
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certificate for the cargo; (4) Load Port Analysis certificate of IIA (5)
Certificate of quantity.
v) Submission of unconditional Bank Guarantee towards Contract
Performance Security (as per specified format). Subsequent to
submission of the same initially, the copies of the BG shall be
submitted along with subsequent invoices.
vi) Supporting document for exchange rate conversion, from USD to
Indian Rupee, if applicable.
The Bank Guarantee, towards interest bearing initial payment, should

be furnished and should be initially kept valid for 90 (ninety) days from
the date of bill of lading. However, in case of delay in supply of coal to
the respective power plant beyond 90 days, validity of the BG should be
extended corresponding to such quantity of coal not delivered (to be
certified by site Engineer-in-Charge) by period of such expected delay
or 30 days, whichever is higher.
Initial payment is interest free for the first 30 days period from the date
of release of the initial payment for delivered quantity of coal beyond
which interest is levied. Interest is levied for the quantity of coal
received beyond the 30 day period, separately for each consignment
received at the power plant and is reckoned from 31st day of the date of
release of the initial payment for the corresponding shipment till the
date of receipt of such entire consignment at the power plant and
interest is recovered from the corresponding bill.
Intial payment corresponding to the undelivered quantity of coal at

power plant after supply of the last consignment of the corresponding
shipment is deducted along with interest thereon from the subsequent
payments. It is clarified that interest period for such undelivered
quantity of coal is reckoned from the date of release of initial payment
till the actual date of adjustment of initial payment corresponding to the
undelivered quantity. Once the whole of initial payment along with the
applicable interest, if any, against a shipment of vessel is fully adjusted,
the corresponding BG is discharged.
Any event of Force Majeure conditions or otherwise, of whatsoever

nature, does not entitle the supplier to claim any exemption or rebate in
payment of interest beyond the 30 days exemption period as stated
hereinabove. The applicable rate of interest is @ 14.5 % per annum for
payment made in Indian Rupees and/or 6% per annum for payment
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made in USD.
If the amount payable under any interim bill is not sufficient to cover the
due deduction, the deductions for the balance outstanding interest
amount and other deductibles there from, is recovered from the next
payment immediately becoming due.
In case the supplier is not opting for initial payment and/or does not
provide BG, initial payment is released upon receipt of coal at the power
plant end for the quantity of coal received, along with interim payment
hereinafter.
5.2 Interim Payment
5 % of C&F coal price, 100 % of customs duty, including CVD with cess
and surcharge, if any, 100% of Marine Insurance charges, 100% of
sales tax/VAT and entry tax and 90% of port & inland handling charges
including service tax and 90% of Railways Freight & trip charges, if any
(the port & inland handling charges comprise, inter-alia, port charges,
stevedoring, handling, clearing and forwarding charges & insurance
charges, as detailed in price schedule) is released after adjusting any
outstanding dues including interest on initial payment on receipt of
consignment by NTPC at power plant and on fulfillment of the following
conditions:
i) Submission of Regularizing Invoice in quadruplicate based on the

actual quantity of coal measured at NTPC Power Plant, after making
adjustments for C&F payment already made by NTPC, as per the
standard given format of NTPC. The consignment at Plant end
implies the Rake quantity.
(Exchange rate, if applicable, for CIF Coal Price, for the purpose of
payment, shall be based on Reference Exchange Rate as on the
date of receipt of such consignment by NTPC at Power Plant).
In case actual date of receipt of consignment(s) by NTPC at Power
Plant is beyond the Delivery Schedule for the entire quantity, the
Reference Exchange rate as applicable on the last day of Delivery
Schedule for the entire quantity or the Reference Exchange rate
as applicable on the actual date of receipt of consignment(s),
whichever is lower, is applicable for the purpose of payment.
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Initial Payment made to the supplier is considered as advance and

is adjusted while releasing Interim Payment.
ii) Submission of documentary evidence for exchange rate conversion
from US$ to Indian Rupee, if applicable
iii) Submission of documentary evidence and original certificate for
payment of Customs duty, CVD, Cess & Surcharge, if any, paid
along-with calculation thereof and Submission of documentary
evidence for payment of Railway freight
iv) Submission of original documents/certificate of (1) Original Bill of
Lading, (2) Certificate of Country of Origin (3) Insurance certificate
for the cargo (4) Load Port Coal Quality Analysis certificates of IIA
(5) Certificate of quantity.
Original documents and one certified true copy should be submitted
by supplier. The original documents will be returned by NTPC after
due verification.
5.3 Balance Payment
Balance payment i.e. 10% of C&F Coal Price, 10% of Port & Inland handling,
10% of Railways Freight & Trip Charges, if any is released after receipt of Coal
quality results at NTPC Power Plant and carrying out necessary adjustment in
quantity due to quality variations on fulfillment of the following conditions:
i) Submission of Final Invoice in quadruplicate for Final balance payment
after carrying out the adjustment for quality results.
(Exchange rate, if applicable, for CIF Coal Price, for the purpose of
payment, shall be based on Reference Exchange Rate as on the date of
receipt of such consignment by NTPC at Power Plant)
In case actual date of receipt of consignment(s) by NTPC at Power
Plant is beyond the Delivery Schedule for the entire quantity (Referred in
Volume III), the Reference Exchange rate as applicable on the last day of
Delivery Schedule for the entire quantity or the Reference Exchange rate
as applicable on the actual date of receipt of consignment(s), whichever is
lower, shall be applicable for the purpose of payment.
ii) Submission of documentary evidence for exchange rate conversion from
US$ to Indian Rupee, if applicable.
Submission of original report of NTPC and in case of dispute, report of the
third party lab for Coal Quality at NTPC Power Plant, as described in Vol.
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III and submission of original Discharge Port Coal Quality Analysis

Certificates of IIA.
For adjustment of quantity due to coal quality variations, samples shall be
taken from each rake and analyzed for each rake for payment purpose as
described in Vol. III. The consignment at Plant end implies the Rake
quantity.
Reconciliation of monthly supplies and payments carried out as described
in S.No.4.0.
All elements of Price including C&F Coal price, Customs Duty, CVD, Cess
& surcharge, if any, Port & handling charges, Sales tax/Vat etc. is based on
received and adjusted Net Quantity at NTPC Power Plant. The payments
made is reconciled and settled during the joint monthly reconciliation.
5.4 Reference Exchange Rate: for a day means the RBI Reference Rate in
Indian Rupees for US Dollars ($), as published by Reserve Bank of India or if
such rate is not published on such day, the Reference Exchange Rate shall be
the comparable rate applicable on the last day before such Day for which such
published rate is available.
Any balance adjustment because of quality and quantity shall be settled
through debit/credit notes and payment thereof is made within 5 working days
from the receipt of such debit/credit notes. If the settlements do not take place
in the given time frame, NTPC reserves the right to adjust the same in the next
available payment.
5.5 Railway Tariff Payment: The supplier is free to import coal through any of the
discharge ports in India. Railway freight and trip charges, if any, is payable as
per actual, limited to the quoted charges. Besides, variation in railway freight
tariff, if any, shall be dealt for the purpose of payment/adjustments as under:
The supplier’s quote is based on the Railway Freight prevailing as on 7 days
prior to Bid submission date. For the purpose of calculating the variation in RF
on account of Tariff variation by Railways, the distance for the respective plant
is worked out based on the quoted RF and existing RF tariff, issued by Ministry
of Railways. The revised tariff of Railways is then applied for such distance
worked out and the difference between the quoted RF and such revised freight
is worked out.
The term “Railway Freight” shall imply Base Railway freight plus any
surcharge(s) as levied by Railways.
90% of Railways Freight & Trip Charges, if any, is released with interim
payment as detailed in S.No.5.2. Balance 10% of Railway Freight & Trip
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Charges is released after receipt of coal quality results at NTPC power plant
and carrying out necessary adjustment in quantity due to quality variations on
fulfillment of the conditions outlined in S.No.5.3.
Submission of documentary evidence and original certificate for payment of
Railway freight is mandatory.
6.0 Taxes and duties:
6.1 For the purpose of the Contract, it is agreed that the Contract Price should be
based on taxes and duties prevailing at the date seven days prior to the last
date of bid submission. Except for CST/VAT & Entry Tax, all other statutory
taxes, duties & levies like Basic Customs Duty, Stamp duty, Service Tax, are to
be included by the bidder/supplier in their “Price Schedule – Annexure U”.
While quoting, the bidder/supplier is to take into account all the rules,
regulations & notifications of Government of India, currently in vogue, relating
to applicability and rates of Basic Customs Duty as applicable on Imported
Coal. In case of Bidder availing concessional rate of Customs duty, as
applicable for supplies from ASEAN countries, the Bidder shall quote the
Custom Duty accordingly.
Basic Customs Duty quoted, as above, by the supplier in the “Price Schedule-
Annexure U” of the bid document is considered for the purpose of evaluation.
Further, Counter Veiling Duty (CVD) with various Cess shall is considered for
the purpose of evaluation, as detailed in the Price Schedule- Annexure U of
the bid document.
The bidder/supplier should please note that CST/VAT & Entry Tax are not
required to be quoted by the bidder. However, CST/ VAT & Entry Tax is
considered by the Owner for the purpose of evaluation, at rates indicated at
Annexure- U1 to Volume IV of Bidding Documents
The bidder should clearly indicate, if they enjoy any specific exemption(s) from
taxes and duties, the quantum of such exemption(s) and the period for which
such exemption is available.
6.2 Basic Customs Duty, is payable at the rates as quoted by the bidder in their
Price Schedule - Annexure U” or at actuals, whichever is lower. CVD, Cess &
Surcharge, if any, is then worked out for the purpose of payment, based on the
Basic Customs duty payable.
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6.8 Any refunds received by Contractor on any of these accounts from concerned
authorities is passed on by supplier to owner within five (5) working days of
receipt of such refunds.
6.9 The owner issues the requisite Sales Tax declaration form(s) in order to get
the benefit of any concession in the rate of Sales Tax.
6.10 Income Tax
As per Indian Income Tax Act & Rules, Owner is required to deduct Income
Tax at source from all the payments to be made to non-resident/Foreign
supplier. For this purpose, the contractor is required to either furnish (i) the
certificate from Indian Tax Authority or (ii) Ruling from "the Authority for
Advance Ruling (AAR)" determining the applicable rate of Income Tax in India
before release of first payment.
The Contractor is required to submit the PAN details to the Owner before the
submission of the first bill.
The Owner is authorized to deduct applicable tax at source from the supplier’s
payment becoming due.
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Annexure – A1
Pricing Methodology
(For high GCV Coal)
1.0 Base C&F price quoted is subject to variations for payment purposes, as
detailed below:
1.1 Proposed Methodology of Base Price and its variation and/or Indexation
for supply and payment of imported coal to NTPC.
C&F Price of the Coal is arrived at based on the concept, detailed hereunder,
for supply of imported coal to NTPC.
1.1.1 FOB Coal Price
FOB price is arrived by linking the Base FOB prices with respect to indices as
per following methodologies, as detailed at S.No.3.0 below:
a) As per CERC Methodology; and
b) Index for coal published for the Country of Origin of Coal, applicable for
base parameter with respect to Gross Calorific Value of Coal
specifications.
1.1.2 Ocean Freight
Ocean freight is arrived at as per CERC Methodology linking the Base Ocean
freight prices with respect to Indices as detailed at S.N. 4.0 below:
1.1.3 Total C&F Coal Price
Total C&F Price for the purpose of payment is the Sum of FOB price and Ocean
Freight worked out based on the methodologies described herein.
The indices as furnished by the supplier are verifiable by the respective NTPC
power station.
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2.0 Concept for the purpose of fixation of Base Price:
Base Date for the purpose of fixation of Base Price:
Proceeding Friday with respect to the Techno-Commercial Bid opening date.
Total Coal Price = A+ B
Where,
A = FOB Coal Price
B = Ocean Freight
3.0 FOB Coal Price
3.1 As per CERC Methodology

The above component A of the price is subject to variation for payment as per
date of Bill of Lading, based on the weekly index calculated based on the
weekly indices for the Richard Bay API4, Newcastle Export Index (NEX) and
Global Coal New Castle (GCNEW C), with the weightage 50:25:25 for GCV
of 6000:6700:6700 respectively in line with the methodology adopted by
CERC.
For this purpose, the above indices published for the week preceding to the
date of Bill of Lading is considered. The week for the above purpose is a
period of 7 days starting from Saturday to Friday. In respect of Newcastle
Export Index (NEX), the week starting from Friday to Thursday is considered.
Formulae:
A1 : Index derived on preceding Friday with respect to the Techno-

Commercial Bid opening date. A1 is calculated based on the weekly
indices for the Richard Bay API4, Newcastle Export Index (NEX) and
Global Coal New Castle (GCNEX C) with weightage 50:25:25 for GCV
of 6000:6700:6700 respectively I line with the methodology adopted by
CERC and to remain constant for the entire duration of contract.
A2 : Index for Richard Bay API4, Newcastle Export Index (NEX) and Global
Coal New Castle, with weightage 50:25:25 for GCV of 6000:6700:6700
respectively in line with the methodology adopted by CERC published
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for the week starting from Saturday to Friday preceding to the week of
the date of Bill of Lading of the vessels.
A3 : FOB component of the quoted price of the supplier and the same
remains constant for the entire duration of the contract.
Hence, considering the above the FOB price will be calculated as under:
FOB Coal Price A = ((A2/ A1) X A3)
3.2 As per Country of Origin Indices
The FOB price is subject to variation for payment as per date of Bill of Lading
based on the weekly/ daily index published for the Country of Origin of coal,
applicable for base parameter with respect to Gross Calorific Value of Coal
specifications.
Formulae:
A1 : Latest Index available as on preceding Friday with respect to the

Techno-Commercial Bid opening date. A1 remains constant for the
entire duration of Contract.
A2 : Latest Index available as on preceding Friday with respect to the date

of Bill of Lading of the vessels.
A3 : FOB component of the quoted price of successful bidder and the same
remains constant for the entire duration of contract. Hence,
considering the above, the FOB price for payment purpose is
calculated as under:
FOB Coal Price A= ((A2/ A1) X A3)
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3.3 For the purpose of payment, the lower of the prices worked out based on the
above two methodologies is considered.
The following indices are considered for determination of prices on country

specific index:
S.No. Country of Index Publication

Origin of Coal
1 South Africa API 4 (6000 NAR) Argus/McClosky’s
Coal Price Index
Report
2 Australia Average of
1. Barlow Jonker (now known as Energy Publishing
NEX) (6700 GAD) (Coalfax)
2. GC NEWC (6700 GAD) Global Coal
3 Indonesia ICI 6500 GAR Indonesia Coal
Index by Argus
and Coalindo
The above indices have been notified for the purpose of standardization of
determination of prices, by obviating the chances of using multiple indexes
for single country, during execution of contract and for making payment.
In case the country of origin is other than those listed above, the supplier
indicates relevant index, in the format given in bid document, and publication
preferably published by a government agency in which the index is
published. However, NTPC reserves the right to accept such index and/or
publications.
In the event of such index and/or publication not being acceptable to NTPC for
any reason whatsoever, the index representing the coal closest to the coal
specification offered by bidder shall be considered.
4.0 Ocean Freight

The component B, which indicates the Ocean Freight of Imported Coal varies
for payment as per actual date of Bill of Lading, based on the Singapore 380
CST Bunker Fuel Price (Also referred to as IFO 380) ex Singapore Wharf, as
per Clarkson Research (publication as mentioned in CERC Methodology)
published corresponding to the week preceding the week of date of Bill of
Lading.
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B1 Index as per Singapore 380 CST Bunker Fuel Price (Also referred to
as IFO 380) ex Singapore Wharf, as per Clarkson Research
(Publication as mentioned in CERC Methodology) as on preceding
Friday with respect to the Techno-Commercial Bid opening date and
remains constant during the entire duration of the contract.
(Publication as mentioned in CERC Methodology) published
corresponding to the week preceding the week of date of Bill of
Lading.
B3 Ocean Freight component of quoted price of the Successful Bidder

and the same remains constant for the entire duration of contract.
Considering the above, Ocean Freight for payment purpose will be calculated
as under:
OCEAN FREIGHT B = ((B2/ B1) X B3)
5.0 Total C&F Coal Price
Total C&F Price for the purpose of payment is the Sum of FOB price worked
out as per S.N. 3; and Ocean Freight, worked out as per S.N. 4 above.
6.0 NTPC will intimate through its website indices to be considered i.e. indices as
on preceding Friday with respect to the Techno-Commercial Bid opening date.
7.0 Cap/Ceiling of C&F Coal Prices
In case actual date of receipt of coal by NTPC at Power Plant is beyond the
‘Delivery Schedule for the entire quantity’, due to reasons attributable to
successful bidder, the lower of the ‘C&F prices as applicable for the date of Bill
of Lading’ and ‘C&F prices as applicable on last day of Delivery Schedule’
shall be the ceiling price applicable for the receipts of coal beyond the
Delivery Schedule.
In case C&F price applicable on actual date of receipt of coal at station is
lower than the ceiling price, the lower price is payable.
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Annexure – A2
Pricing Methodology
(For low GCV Coal)
1.0 Base C&F price quoted is subject to variations for payment purposes, as
detailed below:
1.1 Proposed Methodology of Base Price and its variation and/or Indexation
for supply and payment of imported coal to NTPC.
C&F Price of the Coal is arrived at based on the concept, detailed hereunder,
for supply of imported coal to NTPC.
1.1.1 FOB Coal Price
FOB price is arrived by linking the Base FOB prices with respect to:
a) Indices as per Indonesian Coal Index (ICI 3) 5000 GAR as detailed at

S.No.3.0; and
b) Index for coal published for the Country of Origin of Coal, applicable for
base parameter with respect to Gross Calorific Value of Coal
specifications.
Lower of the above two is considered.
1.1.2 Ocean Freight
Ocean freight is arrived at as per CERC Methodology linking the Base Ocean
freight prices with respect to Indices as detailed at S.N. 4.0 below:
1.1.3 Total C&F Coal Price
Total C&F Price for the purpose of payment is the Sum of FOB price and Ocean
Freight worked out based on the methodologies described herein.
The indices as furnished by the supplier are verifiable by the respective NTPC
power station.
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2.0 Concept for the purpose of fixation of Base Price:
Base Date for the purpose of fixation of Base Price:
Preceding Friday with respect to the Techno-Commercial Bid opening date.
Total Coal Price = A+ B

Where,
A = FOB Coal Price
B = Ocean Freight
3.0 FOB Coal Price
3.1 As per ICI Methodology

The above component A of the price is subjected to variation for payment as
per date of Bill of Lading, based on the weekly index calculated based on the
weekly indices for the Indonesian Coal Index (ICI 3). For this purpose, the
ICI 3 index published for the week preceding to the date of Bill of Lading is
considered. The week for the above purpose is a period of 7 days starting
from Saturday to Friday.
Formulae:
A1 : Index ICI 3 for 5000 kcal/kg GAR published on preceding Friday with
respect to the Techno-Commercial Bid opening date.
A2 : ICI 3 Index for 5000 kcal/kg published for the week starting from
Saturday to Friday preceding to the week of the date of Bill of Lading
of the vessels.
A3 : FOB component of the quoted price of the supplier and the same
remains constant for the entire duration of the contract.
Hence, considering the above the FOB price will be calculated as under:
FOB Coal Price A = ((A2/ A1) X A3)
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3.2 As per Country of Origin Indices
The FOB price is subject to variation for payment as per date of Bill of Lading
based on the weekly/ daily index published for the Country of Origin of coal,
applicable for base parameter with respect to Gross Calorific Value of Coal
specifications.
Formulae:
A1 : Latest Index available as on preceding Friday with respect to the

Techno-Commercial Bid opening date. A1 remains constant for the
entire duration of Contract.
A2 : Latest Index available as on preceding Friday with respect to the date
of Bill of Lading of the vessels.
A3 : FOB component of the quoted price of successful bidder and the same
remains constant for the entire duration of contract. Hence,
considering the above, the FOB price for payment purpose is
calculated as under:
FOB Coal Price A= ((A2/ A1) X A3)
3.3 For the purpose of payment, the lower of the prices worked out based on the
above two methodologies is considered.
In case the country of origin is other than Indonesia, the supplier indicates
relevant index, in the format given in bid document, and publication
preferably published by a government agency in which the index is
published. However, NTPC reserves the right to accept such index and/or
publications.
In the event of such index and/or publication not being acceptable to NTPC for
any reason whatsoever, the index representing the coal closest to the coal
specification offered by bidder shall be considered.
4.0 Ocean Freight

The component B, which indicates the Ocean Freight of Imported Coal varies
for payment as per actual date of Bill of Lading, based on the Singapore 380
CST Bunker Fuel Price (Also referred to as IFO 380) ex Singapore Wharf, as
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per Clarkson Research (publication as mentioned in CERC Methodology)

published corresponding to the week preceding the week of date of Bill of
Lading.
(Publication as mentioned in CERC Methodology) as on preceding
Friday with respect to the Techno-Commercial Bid opening date and
remains constant during the entire duration of the contract.
(Publication as mentioned in CERC Methodology) published
corresponding to the week preceding the week of date of Bill of
Lading.
B3 Ocean Freight component of quoted price of the Successful Bidder
and the same remains constant for the entire duration of contract.
Considering the above, Ocean Freight for payment purpose will be calculated
as under:
OCEAN FREIGHT B = ((B2/ B1) X B3)
5.0 Total C&F Coal Price
Total C&F Price for the purpose of payment is the Sum of FOB price worked
out as per S.No. 3; and Ocean Freight, worked out as per S.No. 4 above.
6.0 NTPC will intimate through its website indices to be considered i.e. indices as
on preceding Friday with respect to the Techno-Commercial Bid opening date.
7.0 Cap/Ceiling of C&F Coal Prices
In case actual date of receipt of coal by NTPC at Power Plant is beyond the
‘Delivery Schedule for the entire quantity’, due to reasons attributable to
successful bidder, the lower of the ‘C&F prices as applicable for the date of Bill
of Lading’ and ‘C&F prices as applicable on last day of Delivery Schedule’
shall be the ceiling price applicable for the receipts of coal beyond the
Delivery Schedule.
In case C&F price applicable on actual date of receipt of coal at station is

lower than the ceiling price, the lower price is payable.
Diversion of imported coal from outside NTPC shall not be treated and
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accounted in reference to the said agreement and thereby these guidelines do

not apply to such diversions.
• Contractor shall furnish advance intimation along with following

information to both the stations concerned i.e. designated and
the diverted-in station immediately on the diversion of rake:
- RR No of diverted rake
- Designated Station
- Vessel Name
- Wagon details
• On receipt of the diverted-in rake, non-designated station will
verify the actual rake details with the above details already
provided. Weighment of the rake will be as per weighbridge of
the receiving station. If the weighbridge is not functional,
quantity is to be considered in terms of the agreement.
• Sample analysis and other quality checks will be carried out at
receiving station.
• Purchase order will be created in SAP at a provisional rate at the
receiving station in favour of supplying agency for each vessel
for the diverted quantity. Separate purchase orders will be
created for separate vessels. The quantity considered for PO at
receiving station for the respective vessel should be deducted
from the PO created for the same vessel at the designated
station so as to ensure that the total quantity considered in all
POs created for that vessel matches with the B/L quantity of that
vessel.
• Similarly Vessel master will be created in SAP for each vessel to
account for all the rakes diverted-in from such vessel.
• Goods Receipt will be done by receiving station in reference to
the purchase order and relevant Vessel code. Inventory will be
accounted for at provisional value and following accounting entry
will be generated:
Imported Coal Stock A/c …………..Dr
GR / IR Clearing A/c ………………Cr
• The station with the diverted-in rake will collect the Invoice
breakup of the said rake from the designated station i.e. the
station to which the diverted rake was actually consigned. On
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receipt of the Invoice breakup, the same are to be entered

against respective vessel code in SAP so as to carry out Invoice
verification. Following accounting entry will be generated at
Invoice verification:
GR/IR Clearing A/c………………..Dr
Imported coal Stock A/c …….…….Dr/Cr
Imported coal Consumption A/c…...Dr/Cr
Vendor Liability A/c……………….Cr
(Imported coal Consumption account will be debited or credited based
on the availability of the invoiced quantity).
Imported coal Stock A/c will be debited or credited based on the
difference between provisional GR value and actual Invoice value.
• Thereafter, receiving station will carry out Invoice verification and
liability will be created for the gross amount at the receiving
station. The liability so created in favour of Contractor along with
quality parameters will be transferred to the designated station.
Inter unit entries will be passed in SAP.
• The designated station on receiving liability from the receiving
station will adjust appropriate advance amount, make retention
for quality adjustments and make net liability for the balance
amount for payment. The payment of net liability will be made by
designated station only.
• In case of recovery arrived at the designated station which is
directly attributable to the diverted-in rake, the same will be done
at designated station and credit will be passed on to the
receiving station which will adjust the same from import coal
Inventory account for import coal consumption account as the
case may be,
Adjustment of Railway Freight of the diverted rakes shall be as per
prevailing Import coal agreements
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Section II Coal Sampling and Analysis procedure
Sl. No. Contents Page Nos.
1.0 Introduction 34
2.0 Scope 34
3.0 Coal Sampling Procedure 35
3.1 Coal as fired sampling 35
3.2 Joint coal sampling 38
3.3 Imported coal quality determination 47
3.4 Sample collection from wagons 50
3.5 Sample collection from conveyor 51
3.6 Sample collection from stock pile 51
4.0 GCV based grading system 52
5.0 Coal analysis procedure - Proximate Analysis 52
5.1 Moisture 53
5.2 Volatile Matter 59
5.3 Ash 63
5.4 Calorific Value of Coal 65
5.5 Reporting of Results 79
5.6 Criteria for Rejection of Test Results 81
6.0 Ultimate Analysis 83
6.1 Determination of Carbon and Nitrogen 83
6.2 Determination of Sulfur 88
6.3 Determination of Nitrogen 92
6.4 Determination of Total Chlorine 95
6.5 Determination of Mineral Matter in Coal 97
7.0 Determination of Hardgrove Grindability Index of Coal 100
8.0 Terminology 103
9.0 References 106
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COAL SAMPLING AND ANALYSIS PROCEDURE
1.0 INTRODUCTION
In coal fired power stations, coal is the most important input for
commercial use, also for management of proper combustion and
operational efficiency of the boiler. A good sampling system is one that
collects a representative sample and from whole quantity of the coal in
consideration. For which minimum specified number of increments of
specified weight, at specified interval shall be collected. Correct quality
evaluation of coal depends on its representative sampling, preparation
and analysis. Accurate analysis and reporting of results is essential to
evaluate the original coal quality and the purpose for which it is
intended.
1.1 SUPERSEDED DOCUMENTS
a. LMI: Sample Preparation and Analysis of Coal: LMI 04-R
4/CHEM/OGN-OPS-CHEM-006 Issue Feb 2012
b. LMI: Coal as fired Sampling Procedure: LMI 01-R2 / CHEM/OGN-
OPS-CHEM-014 issue May 2012
2.0 SCOPE
This Guidance Note provides guidelines for coal as fired sampling, Joint
coal sampling and coal sampling from other systems and also provides
methods of laboratory analysis for
a) Proximate Analysis
b) Gross Calorific Value (GCV)
c) Reporting of Results
d) Ultimate Analysis
e) Hard Grove Index (HGI) of Coal
g) Mineral Matter of Coal
2.1 DISCLAIMER
In case of conflict the provisions of BIS/ FSA will prevail over this procedure.
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3.0 COAL SAMPLING PROCEDURES :
3.1 COAL AS FIRED SAMPLING:
Coal received in power station is crushed and fed to bunkers, coal

sample collected before bunkering / firing is termed as coal as fired
sample
SAMPLING LOCATION FOR COAL AS FIRED:
In order to take representative coal sample of coal as fired the sampling

point should be safe, easily accessible and convenient for collecting the
sample. Total coal sample quantity shall not be less than 450 kgs/day,
considering coal used per day is more than 3000 MT. The following
alternatives can be considered depending on site condition.
3.1.1 COLLECTION OF SAMPLES FROM AUTO COAL SAMPLER
Wherever Auto Coal Samplers are installed in the main conveyor belt
going to coal bunkers, Coal as fired sample ( for both Moisture and
laboratory sample) should be collected with installed automatic coal
sampler. This represents the most representative coal-as-fired sample
for a given day.
No of increments ,weight per increment shall be adjusted as per Indian
standard IS:436 requirement. i.e 45 increments per day of approx
10kg weight at equal interval.
Moisture sample should be stored separately without any further
reduction in size and the same should be used for moisture
determination. Rest sample is processed for preparation of coal as fired
laboratory sample.
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3.1.2 COLLECTION OF SAMPLES FROM CONVEYOR BELT
a) In case of supply by conveyer belt sample shall be collected in

increments of full cross section and thickness of the stream in
one operation in a regular interval of time.
b) Before collecting the increments, the speed of the conveyer and
quantum of material passing a certain point in a given time shall
be ascertained so that an appropriate spacing of time between
increments may be identified for whole day.
c) If it is possible to stop the belt periodically for collecting the
sample , increments may be collected from the whole cross
section of the stream by sweeping the whole of the coal lying
across the belt across its full width.
d) Interval for collection of samples , No of increments , weight per
increment shall be adjusted as per IS 436 requirements. i.e. 45
increments per day of approx 10kg weight at equal interval
e) Samples collected in all three shifts of a day shall be used for
preparation of final sample .
3.1.3 COLLECTION OF SAMPLES FROM OTHER PLACES :

a) Coal as fired Sample can be collected manually from sampling
ports at the gravimetric /volumetric feeder, from the bunker to
individual mills at equal interval in all three shifts.
b) Sample so collected in a day shall be used for preparation of
final sample.
c) Quantity of sample per increment should be adjusted to IS 436
requirements.
3.1.4 PREPARATION OF SAMPLE
a) Quantity of Sample:
In order to have better representation, the sample should be
collected in each shift. The un-used sample after preparation and
analysis can be sent back to coal handling system for re-cycling.
The quantities of sample for different lot size of coal being burnt
per day are as follows:-
b) Reduction of Gross Sample:-
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The gross sample of the day shall be mixed and crushed to (-)
12.5 mm by a jaw crusher and finally to 3.35 mm by a Palmac
type of reduction mill. The crushed materials shall be reduced by
using a coal sample refiller till 2 kg sample is obtained. The same
may be schematically represented as follows:-
ORIGINAL COAL (-5cm)
-12.5mm (BY JAW CRUSHER)
-3.35mm
BY PALMAC TYPE OF MILL
BY SAMPLE REFILLER
2Kg
Manual handling of coal for reduction purposes shall be avoided in

order to get representative sample. In case facilities for mechanical
reduction of coal sample is not available than coning and quartering
process should be adopted.
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c) Laboratory Sample:- Finally, the above 2 kg sample for analysis

purpose should be fully grinded in such a manner that the grinded coal
should have the following approximate particle size distribution:
i) Passing 212 microns I.S. Sieve and retained on 125 micron IS

Sieve 35%.
ii) Passing 125 micron IS Sieve and retained on 63 micron IS Sieve

30-35%.
iii) Passing 63 micron IS Sieve remainder.
Excessive grinding of coal sample is harmful
At some places, the above reduction process is carried out manually. In

this, there is always a chance of spillage of fine coal particles during
crushing, thereby making the sample un-representative. Hence, manual
reduction of gross sample should be avoided. This 2 kg sample should
not be excessively grinded while preparing the sample to pass through
212 micron sieve. It has been observed that excessive grinding is
harmful.
3.2 JOINT COAL SAMPLING PROCEDURE:
• This joint coal sampling procedures have been jointly agreed

between NTPC and coal supplier and form part of Fuel supply
agreement. These procedures are based on FSA / BIS standards.
• These procedures are to be followed for coal sample preparation
and analysis, for determination of coal quality for payment purpose.
• This procedure may change at time of review in Fuel Supply
Agreement.
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3.2.1 Modalities for collection, handling, storage and preparation of joint

samples:
General
a) Sample shall be collected source wise, grade wise and Power

station wise.
b) Samples shall be collected, packed and transported in such a

manner so as to make these tamper proof to the satisfaction of
Seller and Purchaser for which detailed procedure may be
worked out at sampling sites jointly by representatives of Seller
and Purchaser
c) Name the colliery / siding / Power Station, date of collection and

other identification details (eg. Rake no. in case of rail supply)
shall be maintained in a register and a proper code number shall
be assigned for each sample for identification and reconciliation
of results.
d) Laboratory samples prepared shall be in the size of 12.5mm for

Total Moisture and for Proximate Analysis 212 micron IS Seive.
Precaution shall be taken so that before analysis, in test
laboratory, further sieving or pulverizing is not required.
e) Proper analysis records shall be maintained at the laboratories

where the samples are analyzed.
f) Samples collected at the loading end shall be analyzed as per

BIS Standards (IS:1350 Part I – 1984) for determination of ash,
moisture content and volatile matter.
g) Monthly statements containing the details of each and every

analysis result finalized during a month based on joint/ referee
analysis, as the case may be, shall be prepared indicating inter-
alia the quantity of Coal covered by the respective analysis
results. Such monthly statements shall be duly authenticated
jointly, as applicable and respective analysis results shall be
applied to the corresponding quality of Coal for billing/
commercial purpose
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middle of the wagon and in the third wagon at the other end and
this sampling procedure will be repeated for subsequent wagons.
f) Before collecting the samples, the spot will be leveled and at
least 25 cm of Coal surface shall be removed/scrapped from the
top and the place will be leveled for an area of 50 cm by 50 cm.
g) About 50 kg of sample shall be collected from each selected
wagon in the rake of a source by drawing 10 increments of
approx. 5 kg each with the help of shovel/scoop.
h) Any stone/shale of size more than that indicated in Schedule-II
shall be removed/discarded, however all stones/ shale of size in
terms of Schedule II shall form part of the sample collected.
i) Source wise, grade wise and Power Station wise Samples
collected from all the selected wagons in a rake shall be mixed
(grade wise/source wise/Power Station wise) separately to form
Gross Sample accordingly.
j) Item (d) to (g) above shall be applicable for Coal supplied in box
wagons as well as BOBR wagons where there is no live
overhead traction line.
k) In case of having live overhead traction line, the parties shall
ensure that the power supply in the over head traction is
switched off to facilitate collection of joint samples from BOX /
BOBR wagons pursuant to points (d) to (g) above.
3.2.3 COLLECTION OF SAMPLES OF COAL DESPATCHES BY ROAD
a) Sample shall be collected colliery wise / grade wise on daily

basis during a day i.e. 6.00 Hr to18.00 Hr
b) The first truck for joint sampling on a day shall be selected
randomly from the first eight trucks placed for loading by the
Purchaser. Every eighth (8th) truck there after shall be subjected
to joint sampling.
c) The spot at the top of the truck, will be leveled and at least 25 cm
of Coal surface shall be removed/scrapped from the top and the
place will be leveled for an area of 50 cm by 50 cm for collection
of sample.
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d) About 30 kg of sample shall be collected from each truck by

drawing 6 increments of approx. 5 kg each with the help of
shovel/scoop.
e) All the samples collected from every eighth truck shall be mixed
together grade wise to form a Gross Sample.
f) Any stone/shale of size more than that indicated in Schedule-II
shall be removed/discarded, however all stone / shale of size as
mentioned in Schedule II shall form the part of the sample
collected.
3.2.4 COLLECTION OF SAMPLES FROM CONVEYOR BELT
a) In case of supply by conveyer belt sample shall be collected in

increments of full cross section and thickness of the stream in
one operation in a regular interval of time as mutually decided by
both Seller and Purchaser and lot shall consist of samples so
collected during a day i.e. 0.00 Hr to 0.00 Hr. of the following day.
b) Before collecting the increments, the speed of the conveyer and
quantum of material passing a certain point in a given time shall
be ascertained so that an appropriate spacing of time between
increments may be arranged over the whole of the lot.
c) If it is practicable to stop the belt periodically, increment may be
collected from the whole cross section of the stream by sweeping
the whole of the Coal lying between the sides of a suitable frame
placed across the belt. The frame should be inserted in the Coal
until it is in contact with the belt across its full width.
d) Minimum 150 kgs of samples to be collected for daily Gross
Sample.
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3.2.5 COLLECTION OF SAMPLES FROM STOCKPILE

a) For the purpose of sampling, the quantity of Coal in the stock pile
shall be divided into a suitable manner of sub-lots as specified in
the following table:
Weight of the lot (MT) No. of Sub-lots
Up to 500 2
501 to 1000 3
1001 to 2000 4
2001 to 3000 5
Over 3000 6
b) The surface of each sub-lot shall be leveled and one point for
approximately every 250 MT of material in the sub-lots shall be
chosen at random for taking gross sample as per the following
procedure:
1. In case height of the stock pile is not more than 1.5 meter, the
material shall be collected at every selected point by taking the
whole section of Coal from top to bottom over the area of a circle
of 30 cm diameter.
2. In case the height of the stock pile is more than 1.5 meter, the
sample shall be collected at every selected point by taking the
material over an area of a circle of 30 cm diameter and up to a
depth of 1.5 meter.
3.2.6 PREPARATION OF MANUALLY COLLECTED SAMPLES:
A) The Gross Sample collected will be divided into two portions.

One portion (one fourth of the Gross Sample) called Part-1 will
be used for analysis of Total Moisture and the other portion
(three fourth of the Gross Sample) called Part-2 for Proximate
Analysis and determination of GCV on Equilibrated basis .
.
The Part-2 Sample shall be jointly reduced into laboratory sample
on the date immediately following the date of collection. The final
laboratory samples will be divided into two parts viz. Set – I and
Set – II
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• Set – I shall be used for joint proximate analysis at loading end

as per BIS standard (IS 1350 Part 1-1984)
• Set – II shall be kept under joint seal as referee sample in the
safe custody for a period of fourteen days or until the analysis
results of Set – I are accepted without dispute, whichever is
earlier.
a) The Gross Samples for each Delivery Point shall be separately

crushed to (-) 5 cm by mechanical means, mixed thoroughly, coned
and quartered.
b) Two opposite quarters shall be retained and the rest rejected.
c) The retained material shall be further mixed, halved and one half
retained.
d) Material so obtained shall be crushed to 12.5 mm by a Jaw Crusher
and then to 3.3 mm by a palmac type of reduction mill/ or jaw
crusher.
e) The crushed material shall be reduced either by coning and
quartering or by ruffling to 2 kgs.
f) The sample so reduced shall be finally ground to pass through 212
micron IS sieve using a Raymond mini mill.
g) From the final sample passing through 212 micron IS sieve, 1.5 Kg
shall be taken, which shall constitute the laboratory sample.
h) Such laboratory sample shall be divided into two equal i.e. Set-I and
Set-II as mentioned at 1.4.2. The sample shall be kept in glass or
polythene container.
All tools and tackles, plastic bags, sealing compound and other items required
for collection, preparation, storage and analysis of the sample shall be
provided by the Seller.
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GROSS SAMPLE
CRUSHED TO (-) 5cm
MIXING THOROUGHLY
REJECT REJECT
MIXING THOROUGHLY
REJECT REJECT
CRUSHED TO 12.5mm
(BY JAW CRUSHER)
CRUSHED TO 3.3 mm
(BY A PALMAC TYPE OF REDUCTION MILL/ OR JAW CRUSHER)
REDUCED TO 2KG
PULVURIZE AND PASS THROUGH 212µ MESH

1.5 Kg TO LABORATORY SAMPLE
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B) PREPARATION OF TOTAL MOISTURE SAMPLE AND

DETERMINATION OF TOTAL MOISTURE:
a) Part – 1 Sample shall be analyzed jointly at the Delivery Point for

determination of Total Moisture as per IS: 1350(Part –I) - 1984.
b) For rail supplies, rake wise Surface Moisture shall be determined at
loading end. For supplies by modes other than rail, Surface Moisture
shall be determined jointly at loading end on daily basis.
c) The samples shall be divided into two parts and shall be sealed in
two previously weighed air tight plastic containers duly labeled and
coded as Set-I ™ and Set-II™ (the weight shall include any sealing
material to be used also) immediately. Weight of each part of such
sample shall be minimum 5 kg. The second set Set-II™ of Coal
samples shall be set aside as referee sample. All the containers
shall be sealed at the time of sample collection in such a manner
that there is no loss of moisture. All the containers, after the
collection of the sample and sealing, shall be individually weighed.
All the weights, before and after the collection of samples shall be
jointly recorded.
d) An empty tray measuring 4 feet x 3 feet shall be weighed. The
sample for joint analysis shall be spread in this tray. The weight of
Coal of the tray shall be recorded.
e) This tray containing the sample shall be kept under joint lock in a
room/laboratory furnished with either ceiling fans or with exhaust fan
for drying the sample for 24 hours. If the sample is not reasonably
dry the period of drying may be extended to further periods of 24
hours, till the sample is dry.
f) The tray shall be weighed again and weight noted. Again the sample
shall be kept for drying for about 2 hours and again weighed and this
process shall be repeated till constant weight is achieved. This
would normally take 2-4 hours. The final weight shall be taken and
loss in weight that is W1 in the 1st stage of air drying shall be
recorded.
g) This sample shall now be crushed to -12.5 mm size in a crusher.
Coning and quartering shall be done to reduce the sample quantity
to 5 kg.
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h) This sample of -12.5 mm of approximately 5 kg shall be weighed

and kept in an oven at ambient temperature of 380C for about 2
hours. Again weight shall be taken and the process of heating
cooling and weighing shall be continued till constant weight is
reached.
i) The loss in weight shall be recorded as W2 that is the loss of weight
after 2nd stage drying.
j) This sample of approximately 5 kg after the 2nd stage of drying shall
be crushed to -3.35 mm size and the same shall be reduced to half
Kg. by quartering and coning.
k) Out of the half kg of sample 10 gms of Coal sample shall be taken in
a weighed glass dish and kept in the drying oven at 108 +/- 20C for
about 90 minutes.
l) The dish shall be cooled and weighed. Heating, cooling and
weighing shall continue till constant weight is reached.
m) The loss of weight shall be recorded as W3 that is the weight loss in
3rd stage drying.
n) Based on the above procedure, the Total Moisture shall be
computed jointly.
o) All tools and tackles, plastic bags, sealing compounds and other
items required for collection, preparation, storage and analysis of the
sample shall be provided by the Seller.
3.3 Imported Coal quality determination :
Quality determination of imported coal is done at Load port, Discharge

port and at NTPC power station. However, Quality of coal is final
based on the inspection results of the samples taken at NTPC power
station and payments thereof are based on such determination at
Power station.
The supplier ensures the appointment of NABL (National Accreditation

Board for Testing and Calibration Laboratories) accredited Independent
Inspection Agency (ies) (IIA) (not more than three (3) agencies during
the currency of the Agreement) with an intimation to NTPC for draft
survey, sampling and quality analysis at Load Port, Discharge Port and
NTPC Power Station before the commencement of first consignment.
The costs of inspection including coal-sampling analysis at various
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points i.e. Load Port, Discharge Port and NTPC power station including
the fee for Inspection Agency is borne by the supplier.
NTPC at its discretion and cost can also appoint an Independent

Inspection Agency to carry out Sampling and Quality analysis at Load
Port/ Discharge Port. NTPC at its discretion and cost can also
nominate their representative to witness sampling and analysis at
Load Port/ Discharge port.
Sampling and Testing of coal samples drawn at Load Port/ Discharge Port:
Coal samples at Load Port and Discharge Port is drawn, prepared and
analyzed by IIA in accordance with relevant ASTM Standards.
Sampling and Testing of coal samples drawn at NTPC's Power Station end:
Coal samples at NTPC's power station end, is drawn from each rake
and prepared for analysis by IIA in the presence of NTPC
representative in accordance with the relevant ASTM Standards
The sample so drawn and prepared in presence of NTPC

representative is divided into four (4) parts within one (1) day of its
collection and is distributed as follows:
(e) One part of the sample is taken by NTPC for analysis at their
end.
(f) The second part of the sample is taken by IIA for analysis at
their end.
(g) The third part of the sample is retained as Referee Sample.

Such Referee Sample is kept under joint lock and joint custody
of IIA and NTPC, to be used for future reference and/or testing.
(h) The fourth part of the sample is taken for joint analysis by NTPC
and IIA for determination of total moisture and size.
IIA analyzes its portion of the coal sample for the parameters, drawn at
NTPC's Power Station end, at the laboratory (ies) as may be identified
by them.
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NTPC analyzes its portion of the coal sample for the same parameters
drawn at NTPC's Power Station end. IIA may also witness, with consent
of NTPC, the test carried out by NTPC at its lab.
For determining the Total Moisture and Size, NTPC and the supplier
undertake joint analysis at NTPC power station laboratory immediately
on receipt of imported coal. In case the analysis for total moisture and
size is not carried out immediately, such sample(s) is kept under joint
lock and joint custody of IIA and NTPC till determination of total
moisture & size. For correction of GCV for landed price, Ash for quantity
and Sulfur for penalty, test results of NTPC is considered and in case of
any dispute, test results of referee sample, if admissible, is considered.
NTPC submits its report to the representative of the supplier at site. In

case of any dispute, due to variance in test results of IIA and NTPC
beyond the limits permissible under the relevant ASTM (except for Total
Moisture and Size), and subsequent claim by the supplier for testing of
referee sample, the report of IIA should be provided to NTPC within
5(five) working days after receipt of NTPC report by the supplier or
10(ten) working days after distribution of sample whichever is later. In
such an event, Referee Sample is forwarded by NTPC to the Third party
laboratories having the facilities for coal analysis as per ASTM methods
and are under Council of Scientific and Industrial Research (CSIR) or
Government owned/ Government approved or has the accreditation of
National Accreditation Board for Testing and Calibration Laboratories
(NABL), Department of Science and Technology, India, for analysis.
If no dispute is raised by the supplier within five (5) working days after
receipt of NTPC report by the Successful Bidder or ten (10) working
days after distribution of sample whichever is later, no request for
consideration of referee sample is accepted subsequently. In such
cases, analysis report of NTPC is binding.
It is specifically agreed that the analysis results of such Referee Sample

by the above stated third party laboratories is binding on all parties and
the cost of testing of the Referee Sample at laboratory is borne by the
supplier.
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3.5 SAMPLE COLLECTION FROM CONVEYOR
For the purpose of sampling from conveyor , total quantity of the coal
lot, shall be divided into a number of sub-lots as per table 5.4 above .
A representative gross sample shall be drawn from each of the sublots
and shall be kept separately. Thus, there will be as many gross samples
as the number of sub-lots into which the lot has been divided’.
a) Quantity and number of increments to be collected is determined by
the size of lot as per table in 5.4
b) Sample shall be collected in increments of full cross section and
thickness of the stream in one operation.
c) If it is practicable to stop the belt periodically, increment may be
collected from the whole cross section of the stream by sweeping
the whole of the Coal lying between the sides of a suitable frame
placed across the belt. The frame should be inserted in the Coal
until it is in contact with the belt across its full width.
For final sample preparation firstly all the sample collected shall be
crushed to - 50 mm than thereafter preparation of sample shall be done
as per the procedure given at Sr. No 5.2.4
3.6 SAMPLE COLLECTION FROM STOCK PILE
Number of sub lots to be identified for the whole lot as per the table in 5.3
above and thereafter sample shall be collected as under
The surface of each sub-lot shall be leveled and one point for
approximately every 250 MT of material in the sub-lots shall be chosen
at random for taking gross sample as per the following procedure:
a) In case height of the stock pile is not more than 1.5 metre, the
material shall be collected at every selected point by taking the
whole section of Coal from top to bottom over the area of a
circle of 30 cm diameter.
b) In case the height of the stock pile is more than 1.5 metre, the
sample shall be collected at every selected point by taking the
material over an area of a circle of 30 cm diameter and up to a
depth of 1.5 metre
For final sample preparation firstly all the sample collected shall be
crushed to - 50 mm than thereafter preparation of sample shall be
done as per the procedure given at Sr. No 5.2.4
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4.0 GROSS CLORIFIC VALUE BASED GRADING SYSTEM
Pursuant to the decision of the Govt. of India to switch over from existing
Useful Heat Value (UHV) based system of grading and pricing of Non
Coking Coal of the country to fully Gross Calorific Value (GCV) based
system w.e.f. 01.10.2012 , different GCV bands has been identified for
pricing of coal are as mentioned below.
5.0 COAL ANALYSIS PROCEDURE - PROXIMATE ANALYSIS
GCV BAND RANGE GCV BAND RANGE

G1 > 7000 G10 > 4300 - 4600
G2 > 6700 - 7000 G11 > 4000 - 4300
G3 > 6400 - 6700 G12 > 3700 - 4000
G4 > 6100 - 6400 G13 > 3400 - 3700
G5 > 5800 - 6100 G14 > 3100 - 3400
G6 > 5500 - 5800 G15 > 2800 - 3100
G7 > 5200 - 5500 G16 > 2500 - 2800
G8 > 4900 - 5200 G17 > 2200 - 2500
G9 > 4600 - 4900
By definition, proximate analysis of coal consists of the determination,

by prescribed method, of moisture, ash, volatile matter and fixed carbon
(by difference). Unless otherwise specified, the term "proximate
analysis” does not include determinations of Sulfur or phosphorous or
any determinations other than those named. The proximate analysis of
coal, originated in response to the industrial demand for laboratory tests
of the relative amount of certain compounds, either present in coal or
derived from it, that affect the following three classes
(1) Water or moisture
(2) Mineral impurities that remain in a somewhat altered condition as
ash when the coal is burnt
(3) Organic or combustible matter, which is approximately represented
by volatile matter and fixed carbon.
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Coals, especially those of low rank, are hygroscopic to various degree,

and absorb or lose moisture according to the humidity and temperature
to which they are exposed. Hence, any moisture determination, which is
carried out without reference to a standard humidity and temperature, is,
to a degree, unsatisfactory. A separate determination of moisture in the
air-dried material shall be made at the same time as the ash and volatile
matter are determined.
The results of proximate analysis are generally recorded as a
percentage of air-dried material. The results are then converted on any
other specified condition for which separate moisture determination
shall be carried out by the specified method.
Sample received in the laboratory for analysis shall be re-sieved to
verify that all the material passes through a 212 micron IS sieve and
then air dried for 24 hours, mixed and bottled.
Certain coals may be found to give irregular results on analysis. In such
cases, and for analytical work only, the analysis sample should be
further ground to pass through a 125 micron IS sieve and remixed. This
final grinding is normally found to ensure reasonable agreement
between repeat determination. The normal method of mixing coal in
laboratory is to roll it on a sheet of rubber cloth and turn it over at
intervals with a large spatula or flat spoon. This method is not entirely
satisfactory, since the movement of coal tends to cause segregation.
The difficulty may be overcome in part by spreading the mixed sample
in a thin layer and filling the analysis bottle by means of small
increments taken with the spoon from places spaced uniformly over the
surface of the layer.
5.1 Moisture
5.1.1 Inherent Moisture
Applicability
This method applies to laboratory samples of coal crushed to pass
through a 212 micron IS sieve. The method is also used in determining
the moisture for coal equilibrated at 40 0 C and 60% relative humidity. In
order to avoid oxidation of coal and for precision, arrangements shall be
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made to pass a current of nitrogen (free from oxygen and preferably

preheated) through the oven at a rate, sufficient to change the
atmosphere, three to five times per hour.
Apparatus
a) Air-oven - Ventilated drying oven in which a constant and uniform
temperature of 108±2 0 C can be maintained.
b) Weighing vessel, approximately 10 cm2 in area, made of silica,
glass or stainless steel with ground edges and fitted with ground
covers.
Procedure
Heat the empty vessel at 108 ± 20 C and weigh after cooling for 20
minutes in a desiccator. Uniformly spread about two grams of coal,
passing 212 micron IS Sieve, in the weighing vessel, so that there is not
more than 0.15 g of the material per sq.cm area, and weigh again.
Uncover the vessel in the drying oven and heat at a temperature of 108
± 20 C until there is no further loss in weight. This normally takes 1 to
1.5 hours. Replace the cover, cool in desiccator for about 20 minutes,
and weigh.
Calculation, Reporting Results
Express the loss in weight due to drying as a percentage of the total
weight of the sample and report the result as the percentage of
moisture in the sample “as analyzed.”
Total Moisture
The coal which has been exposed to contact with water in the seam or
in a washery, or wetted by rain, may carry free or visible water . This
water plus the moisture within the material is referred to as total
moisture.
Applicability
This method applies to a special moisture sample of 1 kg of coal
crushed to pass a square mesh screen conforming to designation 12.5
mm of IS : 460 and sealed in a non-corrodible container.
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5.1.2 Stage - One (Air-Drying)

Apparatus - Non-corrodible metal trays approximately 1000 sq cm in
area and large enough to hold the entire sample.
Procedure -
Accurately weigh the sample and the container to the nearest 0.5 gm.
Transfer the sample from the container to the weighed metal tray and
spread the material evenly on the tray. Weigh the empty container, set it
aside to dry in air, transfer any coal remaining in the container after
drying to the metal tray before the second stage of drying, and record
the loss in weight. Allow the material to air-dry at atmospheric
temperature in a well ventilated place free from dust. Take the drying to
be complete when the change in weight during an hour is less than 0.1
percent of the sample. Record this weight.
Stage - Two (Oven Drying)

Apparatus:
a) Ventilated drying oven- in which a constant and uniform
temperature of 108±20 C can be maintained.
b) Weighing vessel - shallow, approximately 40 sq.cm in area made
of silica, glass or stainless steel, with ground edges and fitted
with ground cover.
Procedure
Heat the empty vessel at 108±20. C and weigh after cooling for 20
minutes. Crush the air-dried material to pass 2.80 mm IS sieve. Spread
uniformly in the weighing vessel about 10 g of the crushed material to
not more than 0.15 g per sq.cm and weigh. Heat the uncovered vessel
in the drying oven at a temperature of 108 ±20 C until there is no further
loss in weight. this normally takes 1.5 to 3 hours. Replace the cover,
cool in a desiccator for 20 minutes and weigh.
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Calculation and Reporting of Result

Air-Drying
Express the loss of weight, due to air drying of moisture from both the
damp container and the sample, as a percentage of the original weight
of the material. The figure obtained represents the percentage of free
moisture (x) removable by the process of air-drying.
Oven drying
Express the loss in weight on oven drying the sample as a percentage
of the total weight of sample placed in the oven. In this case the figure
obtained represents the percentage of moisture remaining in the air-
dried material (y).
Total moisture content of the original sample = x+ y (1-x/100)
5.1.3 Method Recommended for determination total moisture of coal

(Based on ASTM D3302)
Always a separate moisture sample of around 5kg is collected on
incremental basis and immediately sealed in an airtight container.
Raw sample collected is immediately transferred to a metal tray and its
Wt. is recorded. The sample is allowed to air dry. Percent air dry loss is
measured as A.
Air dried sample which is then crushed to 12.5mm top size and further
air dried or oven dried at 10°C above ambient temperature for 2hrs and
& the Weight is recorded.
Percent of second stage air dry loss is measured as A1
Sample is then further crushed -2.8mm size, mixed properly.
Around 10 gm of crushed sample is spread uniformly in a
weighing vessel. The uncovered vessel is heated in a drying oven at a
temperature of 108 ±20 C until there is no further loss in weight. This
normally takes 1.5 to 3 hours. Then the vessel with sample is covered
and cooled in a desiccators for 20 minutes and weight is recorded.
Percent of oven dried moisture loss is measured as R
Calculation and Reporting of Result
Air dry loss (ADL) = A1*{(100 –A)/100} + A
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Total Moisture = R *{(100-ADL)/100} +A DL

Where
A = first stage air dry loss, Weight %, of uncrushed coal
A1 = Second stage air dry loss, Weight %, of crushed (-12.5mm) coal
R = residual moisture, Weight %.
Benefits of recommended method:

Total Moisture is the moisture in coal as it exists at site, at the time, and
under the condition it is sampled. Total moisture constitutes surface
moisture in coal as well as residual moisture in coal. Surface moisture is
prone to evaporation and loss depending upon ambient condition when
exposed.
At present 1kg of total moisture sample is separated after crushing it to
size of 12.5 mm. During the process some of the surface moisture may
be lost and actual value of total moisture is affected.
Where as in recommended method, separate total moisture sample is
collected and sealed in air tight container. Initial weight of total sample
collected is recorded and allowed to equilibrate with ambient and initial
moisture loss % is computed.
Sample is then subjected to crushing to 12.5mm top size. It takes care
of probable moisture loss during crushing without equilibrating it with
ambient.
Thus recommended method is expected to give more accurate value of
total moisture of coal as it is sampled.
5.1.4 Moisture at 400 C and 60% Relative Humidity

The moisture content of air dried coal varies and depends upon the
temperature and relative humidity of the air to which it is exposed. As
such it is necessary to determine the moisture content of different
samples of coal under standard conditions. For this purpose, the coal is
grinded to pass through 212 – micron IS sieve and equilibrated in an
atmosphere of 60% RH and 40 0 c. The moisture determined under
these conditions shall be taken as the reference moisture for all
purpose.
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Applicability
This method applies to a laboratory sample of coal crushed to pass
through a 212 micron IS Sieve.
Apparatus
a) Air oven: Ventilated drying oven in which a constant and uniform
temperature of 108±20 C can be maintained.
b) Weighing Vessel: Shallow vessel approximately 10 sq. cm. in
area, made of silica, glass or stainless steel with ground edges
and fitted with ground cover.
Procedure
Take about 5 g of laboratory sample of coal to pass through a 212
micron IS Sieve, in a beaker or conical flask of 100 ml capacity. Pour
about 20 ml of water on the sample and wet the coal by gently swirling
the beaker or flask. Put the beaker or flask on an asbestos centered
wire gauze and apply a small flame underneath, and allow the contents
to boil very slowly for about 15 minutes. Filter off the water using a
qualitative filter paper and then remove the visible water, as far as
possible, by pressing the wet coal in between folds of blotting or filter
paper. Take about 1.5 g of the wet coal in a previously heated, cooled
and weighed silica or glass capsule with a ground flange type lid and
spread the coal in a uniformly thin layer so that the weight of coal per
sq.cm in the capsule does not exceed 0.15g. Place the uncovered
capsule and the lid in a desiccator, the bottom portion of which is half
filled with a solution of Sulfuric acid in water to give a relative humidity of
60 percent at 40 0 C. Put the lid on the desiccator and leave the whole
thing for 24 hours and then withdraw and break the lumps and spread
the coal with a spreader. Replace the lid and leave for next 24 hours.
Withdraw the capsule after covering, cool it on metal plate for next 24
hours. Withdraw the capsule after covering, cool it on metal plate for 20
minutes, and weigh. Note this weight and return the capsule with lid to
the desiccator and leave it there for another 24 hours under the same
conditions. Repeat the process of weighing and returning to desiccator
till the change in weight does not exceed 0.001 g. Note the final weight.
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Put the capsule in air oven maintained at 108±20 C and determine the
moisture as described previously.
Precision: The results of duplicate determination shall agree within the
following limits:
Moisture Precision Repeatability/Reproducibility

Upto 3 % 0.1 unit 0.2 unit
Over 3 % 3 % of arithmetic mean 6% of arithmetic
of duplicate values mean of duplicate values
5.2 Volatile Matter

5.2.1 General
The volatile matter of a coal is of particular importance in assessing the
use for which the coal is suitable. By itself or in conjunction with other
characteristics the volatile matter on a dry mineral-matter-free basis is
used for coal classification. The volatile matter is the loss in weight less
that due to moisture, when coal is heated under standard conditions.
The test is empirical and, in order to ensure reproducible results, it is
essential that the rate of heating, the final temperature and the overall
duration of the test should be carefully controlled. it is also essential to
exclude air from the coal during heating to prevent oxidation and,
therefore, the fit of the lid of the crucible is critical. The moisture content
of the sample should be determined at the same time as the volatile
matter so that the appropriate corrections can be made.
5.2.2 Method
The crucible method adopted here consists of heating out of contact
with air of a weighed quantity of air-dried sample of coal at a
temperature of 900 ±100 C for a period of seven minutes. Oxidation has
to be avoided as far as possible.
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5.2.3 Apparatus
a) Crucible and lid
A cylindrical crucible is used with a well fitting lid, both of fused
silica, or of other suitable ceramic material or platinum, provided
the latter two give the same result as that obtained with a silica
crucible. The silica crucible and lid shall weigh 10 to 14 gms. and
have dimensions approximating to those given in the fig 2. The fit
of the lid is a critical factor and the lid for a particular crucible
should be selected so that, when placed in position the maximum
horizontal clearance at any point round the lid of the crucible is
0.5 mm. After selection, each crucible and lid should be given a
distinguishing number or mark.
b) Stand
The stand on which the crucible is placed in the muffle furnace
should be such that the approximate rate of heating can be
achieved.
c) Muffle Furnace
Gas or electrically heated, in which a zone of constant and
uniform temperature of 900 ± 100 C can be maintained. It should
be closed at the back, provided with a chimney and have at the
front, a well-fitting door, preferably hinged and of the plug type.
The position for the crucible stand shall be chosen within the
zone of uniform temperature, and this exact position shall be
used in all tests. The heat capacity of the muffle furnace shall be
such that, with an initial temperature of 9000 C and with an empty
crucible in position a minimum temperature of 8900 C is regained
within three minutes from the time of insertion of a charged
crucible and stand. Normally, the furnace shall be designed
specifically either for receiving one crucible and its stand at a
time, or for multiple determinations using a number of crucibles
in one stand.
Note: The temperature of 9000 C is to be attained as closely as
possible and the tolerance of ±100 C is specified so as to
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meet inherent errors in the temperature measurements

and lack of uniformity in the temperature distribution.
d) Pyrometer
The temperature characteristics of the furnace are checked with
an unsheathed thermocouple, of wire not thicker than 1 mm. The
thermojunction is inserted midway between the base of the
crucible in its stand and the floor of the furnace. If the stand
holds more than one crucible, then the temperature under each
crucible is checked in the same manner. If desired, a sheathed
thermocouple may be permanently installed in the furnace with
its junction as close as possible to the centre of the zone of
uniform temperature; in this case its temperature readings should
be correlated at frequent intervals with those of unsheathed
couple which is then only inserted when necessary. (Fig-7 Page-
22of IS-1350 part-I 1992)
Note: The temperature/emf relationship of a thermojunction
maintained at elevated temperature gradually changes with time.
e) Asbestos Discs -25 mm diameter, I mm thick.
f) Reagents
Desiccant: fresh or freshly regenerated and self indicating silica
gel. Other suitable desiccants are activated alumina or
anhydrous calcium sulphate or Benzene- reagent grade.
5.2.4 Procedure
Use air-dried material passing through a 212 micron IS Sieve. Adjust
the temperature of the zone of the muffle furnace, containing the stand
and empty crucible (s) to 900±100 C as indicated by the correctly
located unsheathed thermocouple, or to the equivalent temperature as
indicated by the sheathed thermocouple.
Depending on the heating properties of the furnace available, heat at
900 ± 100 C for 7 minutes either one crucible and lid or the requisite
number of crucibles and lids to fill the stand. Remove the crucible (s)
from the furnace, cool first on metal plate for 5 minutes and then in a
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desiccator for 10 minutes. Weigh each empty crucible and lid and weigh
accurately into each crucible 1.00 to 1.01 gm of sample. Replace the lid
and tap the crucible on a clean hard surface until the sample forms a
layer of even thickness on the bottom of the crucible. Place the charged
crucibles(s) with lid (s) in a stand and transfer to the muffle furnace and
leave for a period of exactly 7 minutes. Remove, cool and weigh the
crucible (s) in the same manner as for the empty crucible (s).
Note: - If multiple determinations are being made, any vacant places
in the stand are to be filled with empty crucibles.
5.2.5 Calculation
Calculate the volatile matter of the sample on ‘air dried’ as follows:
% volatile matter, V = 100 (W2-W3)/(W2-W1) -M1
Where,
W1 = Weight in grams of empty crucible and lid,
W2 = Weight in grams of empty crucible plus lid and
sample before heating,
W3 = Weight in grams of empty crucible plus lid and
sample after heating
M1 = % moisture in the sample on air-dried basis.
5.2.6 Precision
The results of duplicate determinations in one laboratory shall agree to
within 1% of the arithmetic mean of the duplicate values of the volatile
matter and those between different laboratories within 1.5% of the
arithmetic mean of the duplicate determined value of the volatile matter.
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5.3 Ash
5.3.1 Outline of the Method
The sample is heated in air to 500 °C for 30 minutes, from 500 to 815
°C for a further 30-60 minutes and maintained at this temperature until
constant in weight.
5.3.2 Apparatus
a) Muffle Furnace
Capable of giving a substantially uniform zone at 5000 C in 30 minutes
from cold, of being raised to 815±100 C in a further 30 to 60 minutes
and of maintaining this latter temperature at the end of the run up
period. For coals containing more than four percent of carbon dioxide
the final temperature should be 850±100 C. The ventilation should be
such as to give about five air changes per minute.
Note: - The necessary rate of air change can be obtained by fitting a
chimney about 20 cm high to the back of the muffle and leaving
the front door of the muffle open by 1.25cm. If the chimney
cannot be fitted to the back of muffle, the required ventilation
can be obtained by fitting an insulating brick as a door, leaving a
clearance of 12.5 sq cm as air inlet, and carrying a silica tube
passing to the back of the muffle to withdraw air; which is
vented through a vertical light - alloy tube 2.5 cm in diameter
and 50 cm in length, also fitted into the insulating brick. The
ventilation rate may be checked by using Pitot tube or by
providing that six 2 gm samples of coal can be ashed
completely in an hour.
b) Dish
Of silica, porcelain or platinum, 10 to 15 mm deep, with a lid of
such a size that, with the amount of sample used, the thickness
of the coal layer does not exceed 0.15 gm/cm2.
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5.3.3 Procedure
Thoroughly mix for one minute the air-dried material, ground to pass
through a 212 micron IS Sieve preferably with a laboratory mechanical
mixer. Weigh a clean dry empty dish and lid. Into the dish weigh
accurately about one to two grams of the material according to the size
of the dish. Distribute the material so that the thickness of the layer
doesn’t exceed 0.15 g per sq. cm. Insert the uncovered dish into the
muffle furnace at room temperature, raise the temperature to 500 0 C in
30 minutes and to 850±100 C in a further 30 to 60 minutes and maintain
at this temperature for 60 minutes. Cover the dish with its lid if the ash
is light and fluffy, remove from the muffle furnace and allow to cool, first
on a cold metal slab for ten-minutes and finally in a desiccator standing
at the side of the balance. Weigh after the dish has been in the
desiccator for 15 minutes. Re-ignite at the same temperature until the
change in weight is less than 0.001 g. Brush out the ash and reweigh
the empty dish. Obtain the weight of the ash by difference.
5.3.4 Calculation
Ash, percent by weight = 100 (W3-W4)/(W2-W1)
Where,
W1 = Weight in grams of empty dish plus lid,
W2 = Weight in grams of dish plus lid and sample,
W3 = Weight in grams of empty dish plus lid and ash,
W4 = Weight in grams of dish plus lid after brushing out
the ash and on reweighing.
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5.3.5 Precision
The results of duplicate determination should agree within the following
limits:
Ash Precision
Repeatability Reproducibility
Upto 10% ±0.2 units ±0.4 units
Over 10% ±2% of the arithmetic mean ±3% of the arithmetic mean
of the duplicate values of the duplicate values.
5.4 Calorific Value of Coal

5.4.1 General
The CV of coal is generally determined by calorimetric bomb immersed
in an isothermal water jacket.
The calorific value as determined by this method is the gross calorific
value of coal at constant volume expressed in calories per gram.
Temperature Dependence of Calorific Value - The calorific value of
coal decreases with increase of temperature. The magnitude of
dependence varies between 0.1 and 0.3 cal/g 0 C, correction for
variation in temperature of determination is therefore, usually negligible.
The coal is burned in a bomb calorimeter of known heat capacity. The
principal observation is that of a temperature rise which, when corrected
for the errors of the thermometer and multiplied by the effective heat
capacity at the mean temperature of the chief period, gives the heat
release. Further, allowance is necessary for (a) the cooling loss (b) the
heat gain due to the heat released by the ignition system and (c) the
heats of formation of Sulfuric and nitric acids from Sulfur dioxide and
nitrogen.
This method is applicable to all bituminous coals provided sufficient
excess of oxygen is present to ensure complete combustion. With
bombs near the upper limit of size, an initial oxygen pressure of 25
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atmospheres is sufficient when using one gram of sample but for

smaller capacity bombs it may be necessary to increase the initial
oxygen pressure to 30 atmospheres or to reduce the weight of the
sample to 0.8 g. A redetermination of the capacity for the use of the
higher pressure is not necessary. The heat capacity varies slightly with
the crucible in use; adjustments may be based on the calculated heat
capacities (mass x specific heat) of the different crucibles used on the
basis of the following specific heats :
Platinum : 0.03 cal/g deg C
Nickel- Chromium alloy : 0.11 cal/g deg C
Silica : 0.18 cal/g deg C
5.4.2 Apparatus
Combustion Bomb
A high pressure bomb, preferably of the three-piece Berthelot type with
separate cup, cap and union nut. The cup and cap are machined from a
rolled bar of an austentic chromium-nickel-molybdenum steel resistant
to intercrystal-line corrosion. The union nut, which does not come into
contact with acidic gases, should be made of free-cutting austentic steel
with a 0.5 percent proof stress of not less than 2000 kg/sq.cm. This
ensures that bomb will be capable of (a) burning completely one gram
of coal using an initial oxygen pressure of 30 atmospheres and (b)
withstanding, with an adequate safety factor but without excessive
mass, the maximum pressure likely to be produced. The union nut shall
not be made of the same type of austentic steel as that used for the cup
and cap, this is important to prevent damage due to seizing of the
threads, aluminium bronze is given as an alternative to low
molybdenum (free cutting) austentic steel and, if used, may be plated to
improve the finish.
The bomb shall also be :

a) Of 250 to 350 ml capacity (existing bombs of upto 500 ml
capacity, if resistant to intergranular corrosion, may be used but
their replacement is advised);
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b) Of not more than 3.25 kg weight; and

c) Capable of withstanding under test, for ten minutes and without
permanent deformation, an internal pressure of 210 kg/sq.cm..
Calorimeter Vessel
The calorimeter vessel for containing the bomb shall be of plated
copper or brass, polished on the outside and fitted with a cover. It shall
hold two liters of water with bomb covered with water, to a depth of at
least two centimeters above the lid of the bomb.
Water-jacket
A water-jacket should be provided for containing the vessel and this
may be of the static, isothermal, or adiabatic type. The vessel should be
insulated from the jacket by being supported on the minimum amount of
a non-conducting material, preferably on a three-point support. The air
space between the vessel and the jacket should be approximately 1 cm
to eliminate convection currents. The water-jacket should be provided
with a cover.
The static water-jacket should contain at least 12.5 liters of water to
eliminate the effect of external temperature change on the temperature
in the calorimeter.
The isothermal jacket should be provided with means of keeping its
temperature constant throughout the determination to within ±0.10. C.
The adiabatic jacket is fitted with either electrode or immersion heaters
capable of supplying energy at a rate sufficient to heat the water
contained in the jacket so that its temperature is maintained within 0.10
C of the calorimeter vessel temperature after the bomb has been fired.
The sensitivity of the temperature control system is such that the
temperature drift of the calorimeter vessel, when in balance at 200 C,
does not exceed 0.00050 C.
Stirring Arrangement
The water in the calorimeter shall be efficiently stirred by a constant
speed motor and a constant rate of stirring, such that the temperature
readings plotted against time shall approximate to a smooth curve
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which in the preliminary and the after periods, shall be as a straight line.
To ensure this the stirrer shall operate at a speed slightly greater than
the minimum necessary. The stirrer shaft shall contain, at or above the
level of the cover of the calorimeter vessel, a non-conducting section to
prevent transmission of heat to or from the calorimeter.
Thermometer
The thermometer shall be of 60 range and duly certified by the National
Physical Laboratory or any other Institution recognized by the Bureau of
Indian Standards. It shall be graduated to 0.010 C and used with
certified Corrections which shall be given to within 0.0020 C at intervals
of not more than 0.50 C. The thermometer shall be tapped before each
reading in order to prevent the mercury thread form sticking. If a
thermometer of the Beckman type is used, and the certificate of testing
does not show the changing value of three degree, due to the variable
amount of mercury in the bulb, determinations of the water equivalent
shall be carried out to various temperature, say, when the zero of the
thermometer corresponds to 100 C, 150 C, 200 C (about), etc, and the
appropriate value, found by interpolation, shall be used when
calorimetric determinations are made. A solid stem thermometer is
preferable.
Thermometer Viewer
A viewer with a magnification x 5 shall be used to permit the reading of
temperatures by estimation to 0.001 0 C. A cathetometer may be used
to avoid the possibility of parallax error: with a single fens in a tube,
parallax errors shall be avoided by ensuring that the operator’s eye is at
the correct level and by illuminating the scale through a circular hole in
the tube and not a cut-away aperture at the end of the tube.
Crucible
While a variety of shapes of crucibles are suitable, it may be desirable,
in order to avoid ejection of ash during the determination, to use a
crucible with the walls vertical or tapering inwards and upwards.
Alternatively, the coal briquette may be covered by a few silica ships
approximately 10 x 5 x 1 mm to prevent ejection of the combustible
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material or ash. The crucibles may be of silica, nickel-chromium or

platinum having flat base with a diameter of about 25 mm and a height
of not more than 20 mm. Silica crucibles should be about 1.5 mm thick
and metal crucibles about 0.5 mm thick. To reduce any error from
incomplete combustion when testing high ash coals, a shallow crucible
of nickel-chromium foil about 0.25 mm thick is recommended.
The production of carbon smears when determining effective heat
capacity with benzoic acid may be avoided by the use of a smaller
nickel-chromium crucible, about 0.25 mm thick, 15 mm in diameter and
7 mm deep.
Ignition Circuit
An electrical supply of 6 to 12 volts, for igniting the sample with the
controls mounted on a wall or bench and not on the calorimeter shall be
used. An ammeter may be included in the circuit to indicate breakage of
the firing wire.
The circuit may conveniently consist of a six-volt battery connected
through an open key. If the supply is provided by means of a
transformer, a 5-ampere fuse shall be fitted in the secondary circuit.
Caution
The firing switch should not be mounted on the calorimeter.
Timer
A timer, reading in minutes and seconds, shall be fixed in a convenient
position. A stopwatch may also be used.
Pressure Regulator and Pressure Gauge

A regulator shall be provided to control filling of the bomb, and a
pressure gauge 0 to 5 x 106 N/m2 (50 atm) fitted to indicate the
pressure in the bomb. To avoid overfilling of the bomb, a relief valve or
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Note: - Normally 1 g of coal will be required. For high ash coals, the use
of 0.75 g of the sample and the shallow crucible of nickel-
chromium toil should reduce errors of incomplete combustion. If
considered desirable, the sample may be previously compressed
into a cylindrical pellet before weighing. Bituminous coals can
often be burnt with more certainty when compressed. With a
silica crucible the use of mica is unnecessary. Coals containing a
high percentage of inorganic matter give a fused residue which
may enclose a considerable proportion of unburnt carbon. In
such cases, combustion in a crucible, the bottom of which is
covered with a thin layer of coarsely powdered quartz, is
recommended. The quartz breaks up the fused ash into minute
globules, thus minimizing the proportion of unburnt carbon: it
also facilitates the removal of the residue if it should appear
desirable to determine the quantity of unburnt.
Connect a piece of firing wire tautly across the terminals of the bomb.
Tie a known weight of cotton to the firing wire and arrange the ends
of the cotton so that they touch the sample.
Note:- For convenience, a measured length of cotton of known weight

per unit length may be used : the length used in each
determination of calorific value should be the same as used in
the determination of effective heat capacity of the system.
Use of one milliliter of water in the bomb is recommended. Assemble
the bomb and charge it slowly with oxygen to a pressure of 3.0 x 106
N/m2 (30 atm) without displacing the original air. Put sufficient water in
the calorimeter vessel to cover the flat upper surface of the bomb cap.
This quantity of water should be the same. within 1 g, as that used in
determining the mean effective heat capacity. The temperature of the
water shall be about 2.5 0 C lower than that of the water jacket.
Note: Use of one ml water in bomb is recommended. Any other
quantity upto 5 ml may be used provided the same quantity is
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used in all determinations of both heat capacity and calorific

value.
Transfer the calorimeter vessel to the water-jacket, lower the bomb into
the calorimeter vessel and check that the bomb is gas-tight. If gas
escapes from the bomb, discard the test.
Assemble, start up the apparatus and keep the stirrer and the
circulation arrangements in continuous operation throughout the
determination. Use a constant rate of stirring. After an interval of not
less than ten minutes, read the temperature to 0.001 0 C and continue
the reading for five minutes that is, the preliminary period, at equal
intervals of not more than 1 minute, tapping the thermometer lightly
during the 10 seconds interval prior to each reading. If, over a period of
five minutes, the average deviation of the individual values of the rate of
change of temperature is less than 0.00072 deg C per minute, close the
battery circuit momentarily to fire the charge and continue the
observations of the temperature at intervals of similar duration to those
of the preliminary period. If the rate of change of temperature is not
constant within this limit, extend the preliminary period until it is
constant.
In the chief period, which extends from the instant of firing until the time
after which the rate of change of temperature again becomes constant,
take the earlier readings to the nearest 0.01 0 C since it will not be
possible to take the earlier readings to 0.001 0 C. Resume the reading
to this precision as soon as possible. Determine the rate of change in
the after period (which follows the chief period) by taking readings at 1
minute intervals for at least five, preferably ten minutes.
Note:- It is desirable to keep the jacket temperature and the room
temperature as close to the calorimeter temperature as
possible, hence the jacket and room temperature should be
recorded.
Remove the bomb from the calorimeter vessel, release the
pressure and dismantle the bomb. Examine the bomb interior
and discard the test if unburnt sample or sooty deposits are
found.
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Wash the contents of the bomb into a beaker with distilled water. Wash
the underside of the bomb cap and the outside of the crucible with
distilled water; add the washings to the beaker. Dilute to approximately
100 ml and boil to expel carbon dioxide. While still hot, titrate with
standard barium hydroxide solution using phenolphthalein solution as
indicator. Add 20 ml of sodium carbonate solution, warm filter and wash
the precipitate with distilled water. When cold, titrate the filtrate with the
hydroxide solution using phenolphthalein solution as indicator. Add 20
ml of sodium carbonate solution, warm, filter and wash the precipitate
with distilled water. When cold, titrate the filtrate with the hydrochloric
acid solution, using the methyl orange solution as indicator, ignoring the
phenolphthalein colour change.
Note:- These titrations may be omitted if the Sulfur content of the
coal and nitric acid correction is known.
5.4.5 Corrections
The following corrections are made to experimental observations.
Thermometer Corrections
If a mercury-in-glass thermometer is used the corrections prescribed in
the certificate issued with the thermometer are applied to the observed
firing temperature to and the final temperature tn.
Cooling Correction
The cooling correction includes the effects of the heat interchange
between the vessel and the jacked due to conduction, convection and
radiation, and of the heats of stirring and evaporation. This is minimized
by having (a) the temperature of the water in the vessel below that of
the water in the jacket at the time of firing and within ±1.0 0 C,
preferably ±0.5 0C, of it at the end of the chief period; (b) a low heat of
stirring: and (c) a low loss of evaporation. The correction shall be
determined as follows by the use of Regnault-Pfaundler formula or the
Whitaker formula which gives, for a representative series of coals, a
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mean correction differing by not more than one part in 1000 from that
given by Regnault-Pfaundler formula.
i) The Regnault-Pfaundler (R-P) correction:

Correction = nv’ + (v”-v’) { n-1
(t)+1/2 {t°+tn)-nt’}
(t”-t’)
= nv’+ KS
Where,
n = number of minutes in chief period (5 to 10 minutes
v’ = rate of fall of temperature per minute in the
preliminary period. (If the temperature is rising
during the preliminary period then v’is negative)
v” = rate of fall of temperature per minute in the after
period;
t” = average temperature during after period;
t’ = average temperature during preliminary period.
to = firing temperature;
E1n-1(t) = sum of the temperatures (t1,t2,t3,....tn-1) recorded
during the chief period;
t1,t2,t3,..tn = successive temperatures recorded during the chief
period. The final temperature, tn, is the first
temperature after which the rate of change is
constant;
1/2 (to+tn) = mean of firing temperature to and temperature tn at
the end of the chief period after which the rate of
fall becomes constant again;
k = (v”-v’)/(t”-t') is the ‘cooling constant’ of the calorimeter system
which shall be determined for each set of condition:
and S = the expression within the brackets.
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Form the nature of the formula it is seen that the temperature difference
(tn -to) to which this correction is added to obtain the corrected
temperature rise is not necessarily the maximum observed rise. In fact,
within reasonable limits, the corrected temperature rise should be the
same irrespective of how far tn is taken along the cooling curve,
provided that the period of uniform fall of temperature has been
reached.
ii) Whitaker correction

In place of the Ragnault-pfaunder cooling correction, which is
cumbersome, the Whitaker Correction may be adopted, provided
that it has also been employed to find the water equivalent or the
heat capacity of the apparatus. The heat capacity will be found by
the Whitaker correction to be about 0.25 to 0.3 percent lower than
the value given when R-P correction is used- a difference of 7 to 9 in
3000.
To employ the Whitaker correction ten temperature readings are
taken in the after period in order to obtain a more reliable value of
the cooling rate per minute. If this rate be denoted by dt and the time
from the instant of firing to any chosen temperature reading in the
steady cooling period be x minutes, then the cooling correction is
simply ( x X dt) 0 C. The ‘observed rise’ is the difference between the
temperature at the instant of firing and the temperature taken x
minutes later (as above) in the cooling range. It is not necessary; nor
is it desirable, to take the actual maximum temperature reading.
Generally, a temperature taken 2 or 3 minutes provided that dt is
constant.
Note:- Of the two corrections, the Whitaker formula is preferable.
It is simpler; ii is equally accurate and there is far less chance of
arithmetical error in the calculations.
Heat of ignition
The heat release from the cotton and firing wire is subtracted from
the total heat release. The heat release from the cotton is calculated
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from the weight, after drying at 105 0 C, of a known length of cotton

thread, and using the calorific value of cellulose (4180 cal/g).
Determine the weight of a piece of wire equal in length to the
distance between the poles of the bomb, and calculate the heat
release by allowing 335 cal/g for nickel chromium wire, or 100 cal/g
for platinum wire.
Heat of formation of acids

The heat gain due to the formation of Sulfuric acid and nitric acid is
subtracted from the total heat-released. These corrections amount to
3.60 cal/ml of 0.1 N Sulfuric acid and 1.43 cal/ml of 0.1 N nitric acid
present in the bomb washings and are calculated as follows:
Sulfuric acid correction = 3.60 (a+b-20) cal; and
Nitric acid correction = 1.43 (20-a) cal
where,
a = vol in ml of 0.1 N hydrochloric acid used
b = vol in ml of 0.1 N barium hydroxide used
Correction for unburned carbon
If unburned carbon is suspected, its heat equivalent, on the basis of 1
mg of carbon equals 8 calories shall be added to the determined heat
release. Unburned carbon is determined as the loss in weight on
ignition of the residue from the crucible.
5.4.6 Calculation
The following example illustrates the method of calculation using the R--
P correction.
Calculations using R-P correction:
Weight of crucible + thread = 5.2984 g
Weight of crucible + thread + coal = 6.3017 g
Weight of air-dried coal = 1.0033 g
Mean calorimeter temperature = 26.5 0 C
Effective mean heat capacity at 26.5 0C = 28.71 cal/0 C
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Correction for Sulfur (0.71%) in coal = 16 cal

Temperature calorimeter jacket = 26.7 0 C
Temperature of thermometer = 24.6 0 C
Room temperature = 26.6 0 C
Moisture = 1.90%
Ash = 12.1%
Time Minutes Temperature Correction using R-F

0 C formula
0 1.881 t’ = 1.883
Preli- 1 1.882 v’ = -0.001
minary 2 1.883 n = 8
Period 3 1.884 nv’ = -0.008
4 1.885
5 1.886 (t0)
6 3.250 (t1) S=( 1
n-1
’(t)+1/2 (t0+tn)-nt’)
= 29.212+3.126-15.064
7 4.160 (t2) = 17.274
Chief 8 4.315 (t3)
Period 9 4.362 (t4)
10 4.376 (t5)
11 4.377 (t6)
12 4.372 (t7)
13 4.366 (t8 =tn) t” = 4.330
14 4.360 v” = 0.006
15 4.354 k = (v”-v’)/t”-t’)
16 4.349 = 0.007 / 2.447
After 17 4.343 = 0.002861
Period 18 4.336
19 4.330
20 4.324
21 4.318
22 4.312 cooling correction= nv’+KS
23 4.306 = 0.0494-0.008 = 0.0414
24 4.300
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Uncorrected temperature rise (tn-t0) = 2.480 0 C

Add cooling correction = 0.0414 0 C
Add thermometer correction = 0.014 0 C
Corrected temperature rise = 2.5354 0 C
Heat liberated = 2871x2.5354
= 7279 cal
Subtract nitric acid correction = 8 cal
Subtract correction for heat of ignition = 21 cal
Heat from 1.0033 g of coal = 7250 cal
Heat from 1.0000 g of coal = 7226 cal
Subtract Sulfur correction = 16 cal
Calorific value of air-dried coal = 7210 cal/g
Rounding off
Round off the mean of the values or the single value to the nearest 10 cal/g.
5.4.7 Precision
The results of duplicate determinations in one laboratory should agree
to within 25 cal/g, and those between different laboratories to within
50 cal/g.
Effective Mean Heat Capacity
This is the heat required to effect unit temperature rise in the system
under the conditions of a calorimetric determination. It has a
temperature dependence since the specific heats of the constituent
parts of the system vary with temperature ; and 25 0 C has been chosen
as the reference temperature because of its use in thermal calculations,
and because of the specific heat of water in the range of 25 0 C of 25 0
to 40 0 C is constant within +/- 0.002 cal/ 0C
A known weight of benzoic acid of certified calorific value is burned in
oxygen in bomb calorimeter, which is to be used eventually in the
determinations of calorific value of coal. To the heat of combustion of
benzoic acid are added the heats of combustion of firing of wire and
cotton thread , and also the heat of formation of nitric acid. At least five
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complete determinations of the effective heat capacity should be carried

out and their mean calculated and reported.
The result shall be reported at 25 0 C as the mean of at least 5 values
with a range not exceeding 0.3 % of the mean value; it will then be
correct to within 3 cal/ 0 C
When any part of the system is changed , the mean effective heat
capacity is re determined at intervals not longer than six months. Where
a change to the system is not involved ,the re determined mean should
be within 5 cal/ 0 C of that previously determined. If the difference is
more than 5 cal/ 0 C, then the procedure should be carefully rechecked.
5.5 REPORTING OF RESULTS

The results of proximate analysis and calorific value may be reported in
the following manner, making use of the recommended symbols.
5.5.1 Air - Dried Basis

Proximate analysis and calorific value of coal shall be determined on
the air-dried laboratory sample of coal.
The following symbols shall be used without any suffix.
M = Percentage of moisture in the sample
A = Percentage of ash in the sample
V = Percentage of volatile matter in the sample
F = Percentage of fixed carbon in the sample
Q = Calorific value of the sample
S = Percentage of total Sulfur in the sample.
It is to be noted that the volatile matter V, is the total loss recorded

minus the moisture given off on drying at 108 ±2 0 C.
Fixed carbon F, = 100-(M+A+V)
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5.5.5 Dry Mineral Matter Free Basis

The symbols indicated in (1) shall be used with suffix dmf. The results
on the dry mineral matter free basis are then obtained as follows –
Fdmf = F x 100
100-(M+1.1A)
Vdmf = 100-Fdmf
The following points may be noted while making calculation on dmf
basis.
A) The above calculation assumes that mineral matter is equal to
1.1 Ash and Sulfur less than 1% and CO2 less then 0.5%.
In obtaining Sdmf allowance shall be made for 5% as FeS2 and
sulphates. It is only the organic Sulfur , which can be expressed
on a dmf basis.
B) In obtaining Cdmf, it is necessary again to ensure that in the total
‘C’ figure given from ultimate analysis the C present as
carbonate has been deducted.
In evaluating Hdmf , similarly the allowance of the ash is
necessary for the water of hydration. This reduces to 1/9
converting CV to dmmf basis the heat evolved due to the
combustion of pyrites in burning to SO2 should be subtracted
from the CV as analyzed. The value to be deducted on this score
is 27.8 Sp. Cal / g. where Sp. Is the percentage of S in pyrites.
As the pyrites content in most Indian coals is low (less than
0.5%) this correction is seldom necessary.
5.6 Criteria for Rejection of Suspect Test Results

5.6.1 General
It may sometime happen that a test result is obtained which deviates
considerably from the other test results and therefore arouses suspicion
that it may have arisen from a mistake in sampling or sample
preparation, rather than the course of normal variation. In the case that
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the chemist has confirmed a mistake has occurred during analysis, the
test result must be rejected irrespective of its magnitude. If, however,
only a suspicion exists, it may be desirable to determine whether such a
result may be rejected or whether it must be accepted as part of the
normal variation expected.
5.6.2 Criteria
The following procedure may be followed for determining the
acceptability or rejectability of the suspect test results.
Arrange all the test results obtained by analysing ‘n’ laboratory samples
in the ascending order of magnitude and designate them X1, X2, ....... .,
Xn, where X1 is the smallest and Xn the largest test results.
If Xn is suspect, calculate the value of K1 from K1 = (Xn - Xn-1)/(Xn-X1)
If X1 is suspect, calculate the value of k2 from K2 =(X2 - Xn-1)/(Xn-X1)
If the calculated value of K1 or K2 exceeds the corresponding value

given in the following Table the suspect result shall be rejected. The
above procedure can also be repeated to remove the suspected test
results other than the first removed.
TABLE
VALUES OF CRITERION K1 OR K2
Sample size (n) Value of K1 or K2
3 0.941
4 0.765
5 0.642
6 0.560
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5.6.3 Example
In an investigation on ash percentage of coal, the following test results
are obtained.28.9,26.9,26.8,26.7,26.1
It is required to find out whether 28.9, which deviates rather unduly from
the others could be considered as suspect.
The test results when arranged in ascending order, are:
26.1, 26.7, 26.8, 26.9 and 28.9
According to the criterion given in
K1=(28.9 - 26.9)/(28.9-26.1) = 2.0/2.8 - 0.714
Since this value of K1 exceeds the corresponding tabulated value 0.642
for sample size 5, the test result shall be rejected.
6.0 COAL ANALYSIS PROCEDURES - Ultimate Analysis of Coal

The ultimate analysis of coal means the analysis of coal expressed in
terms of its carbon, hydrogen, nitrogen, Sulfur, oxygen, phosphorous
and sometimes chlorine and vanadium contents. The ultimate analysis
has important practical application in combustion calculations and heat
balances.
6.1 Determination of Carbon and Hydrogen
BIS has given following three methods :-

I) The central fuel research institute method
II) The liebig method
III) High temperature combustion method
The CFRI method is an approximate method but can be used as a

routine method. The Liebig and high temperature combustion method
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are accurate methods. The details of High temperature combustion is

given below:-
The High Temp. Combustion Method

Principle:
The sample is burnt in a rapid current of oxygen at a high temperature
(135 0 C) in an impervious tube, all the hydrogen is converted to water
and carbon to carbon dioxide water is absorbed by magnesium
perchlorate (anhydrone) and CO2 by soda-asbestos. At the
temperature both Sulfur and chlorine are tapped by a roll of silver
gauze. Nitrogen dioxide is not formed under these conditions and no
special precautions are therefore necessary.
Apparatus:
Purification Trains:
Two, one for absorbing water vapour and carbon dioxide present in the
oxygen used for the combustion and other for similarly treating the air
used for sweeping out the absorption train before and after a
determination. Assemble each train in the following order:-
a) Anhydrous magnesium perchlorate (anhydrone)
b) Soda-asbestos
c) Anhydrone-For absorbing the water evolved in the reaction
between CO2 and soda-asbestos.
Combustion Device consisting of the following :
a) A furnace – Capable of carrying a tube approx. 25mm outside
dia and heating it over a length of approx. 12.5 cm to a max of
1350 0C.
A combustion tube – 70 cm (approx.) and 20mm I.D. (approx.)
made of refractory aluminous porcelain not permeable to gases
at 1400 0C.
c) A combustion boat – of Iron-free unglazed porcelain capable of
withstanding a temperature of 13500C. dimension (approx. ),
60m x 12.5mm x 10mm length width depth.
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An absorption train – For absorbing the water and CO2 evolved by

combustion of the sample. Use Midvale tubes which provides a large
area of reaction, to reduce the back pressure in the apparatus and to
avoid the danger of leakage through the rubber sleeve carrying the
pusher. Assemble the train in the following order –
a) Anhydrone – Water absorbent (evolved during combustion)
b) Soda-asbestoes – CO2 absorbent
c) Anhydrone – Water absorbent (evolved in the reaction between
CO2 and soda asbestos)
Flow Motors –Two Nos. –One capable for measuring rates of flow upto
300 ml / min and other upto 250 ml / min.
U-gauze – To measure the resistance of the system.
A heat-resisting Stopper – Made of Chloroprene for connecting the

absorption train to the combustion tube.
A Silica Pusher – For pushing the boat into the furnace. It is about 45
cm long, made from 6 mm dia silica rod flattened at one end with disc.
end 12 mm in diameter. The pusher passes loosely through a glass T-
piece, one end of which fits into the rubber stopper which closes the
inlet end of the combustion tube, the other being sealed with a rubber
sleeve through which the pusher slides. Oxygen is admitted through the
link of the T-piece. The pusher is marked from the disc end for
convenience in ascertaining the position of the boat in the combustion
tube during pushing.
Balance –Sensitive to 0.1 mg.
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Reagents –
i) Anhy. Magnesium Perchlorate (anhydrone) – for absorbing water
evolved during combustion.
ii) Soda-asbestos – In a midvale tube for absorbing CO2.
iii) Alumina-finely divided (0.1 mm)
iv) Sodium Borate solution – 0.05N.
v) Hydrogen Peroxide – 1.1 V/V neutral solution.
vi) Pure silver gauze – 710 micron
vii) Oxygen-hydrogen oxygen.
Preparation of the apparatus:
1) Preparation of Combustion Tube
Insert the combustion tube into the furnace so that it projects 7.50M at
the exist end. Wrap this projecting end with asbestos string to prevent
condensation of water in the tube. At the inlet end of the combustion
tube insert the silica pusher and connect it with oxygen supply.
Preparation and location of Silver gauze
Insert the roll of silver gauze (7.50M long) having sufficient diameter to
ensure a close sliding fit in the combustion tube, into the exit end of the
combustion tube to a distance of about 7.5 cm. Connect a bubbler
containing H2O2 against the sodium borate solution. Move the silver
gauze roll in 5 m. stages and repeat the test until a position is found
where the volume of the sodium borate solution corresponding to the
end point is not more than 0.2 ml. Note its exact position.
Procedure:
Set the furnace to the temperature at 13500C and confirm that silver
gauze roll is in its correct position. Admit O2 to the apparatus 30
minutes before the temperature reaches 13500C and adjust the flow to
300 ml / Min. Mix the coal sample (212 micron size) thoroughly. Spread
about 0.5 gms. of the sample evenly over the bottom or a dried boat and
weigh accurately. Cover with about 0.5 gm. of alumina. Connect a
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previously weighed absorption train and insert the charged boat into the
combustion tube to a position such that its centre is 22.5 mm from the
centre of the hottest zone. With the silica pusher fully, replace the
rubber stopper and continue to pass O2 six one minute periods push the
boat forward about 3.75 cm, with drawing the silica pusher each time to
prevent distortion, after the last push the centre of the boat should be at
the centre of the hottest zone. Allow the boat to remain in the hottest
zone for a further 4 minutes. Disconnect the absorption train, connect it
to the purification train and purge it for 10 minutes with purified air at the
rate of 200 to 250 ML / Min. Disconnect the absorbers, close the taps
and stopper the central side arms and allow to cool.
Wipe and remove the guard stoppers and weigh the absorbers. The
midvale tubes should be protected from contamination when not
connected to apparatus by closing the taps and fitting guard stoppers of
plugged rubber tubing to the open limbs. A bent Ni-Cr wire may be
used to withdraw the heated boat, which is conveniently pulled on to a
thick sheet of asbestos.
Calculation :
Calculate the percentage of C and H by mass, as follows :
a) C = 27.29 (m2/m1)
C1= C-0.273 CO2
b) H = 11.19 m3/m1
H1 = H-0.119M – (0.1A x 0.1119)
Where –
m1 = Mass in gm of the sample taken for the test
m2 = Increase in mass in gm. of absorbers D&E
m3 = Increase in mass in gm. Of absorber C, less the moisture in the
alumina used
M= Moisture in the sample as analyzed, expressed as a percentage.
CO2 =Carbon dioxide in sample, expressed as a percentage
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C = Total carbon in the sample is analyzed, expressed as

percentage.
C1 = Total carbon less that present as a carbon dioxide, expressed
as a percentage.
H =Total hydrogen in the sample analyzed expressed as a
percentage.
H1 =Total hydrogen less that present as moisture expressed as a

percentage.
A = Percentage of ash in coal sample as burnt.
Expression of Results
The mean of duplicate determinations shall be reported to the nearest
0.1% for the carbon determination and to the nearest 0.01% for the
hydrogen determination.
Precision of Determination
Repeatability – For carbon ±0.25% absolute
For Hydrogen±0.12% absolute
Reproducibility – For carbon ±0.6% absolute
For Hydrogen ±0.25% absolute
6.2 Determination of Sulfur
6.2.1 Principle
Sulfur in coal is found in three combinations
1) Sulphate Sulfur
2) Organic Sulfur
3) Pyritic Sulfur
Determination of these forms are not important for power Station
purposes. Thus total Sulfur is being determined by Eschka method in
which 1 gm. Of coal is burned by heating in a crucible with Eschka’s a
mixture (MgO + Na2Co3) in an oxidising atmoshpere to convert Sulfur
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into soluble sulphate which are determined as barium sulphate

gravimetrically.
Simultaneously moisture should be determined.
Quantity of Sample –depends upon Sulfur content of coal as given
below:
Expected S-content % by weight Quantity of sample(gm)
0.1 and upto and including 5 1
Above 5 and upto and including 10 0.5
Apparatus
1) Crucible platinum 50 ML. Capacity
2) Silica Plate – plate 6 MM thick
3) Muffle furnace temp. 800 ± 25°C
4) Air-oven temp. 130 ± 10°C
Regents –
1) Eschka’s mixture – Mix. Two parts by weight MgO with one part of
anhy. Na2CO3. Size 212 micron, bulk density, shall not be greater
than 0.50 g / ml.
2) Concentrated HCl- as per IS:265, 1962
3) K2SO4 solution – Dissolve 0.0060 gm of K2So4 in DM water and
dilute to one liter.
10ML K2SO4 Ξ 0.0080 gm of BaSO4 Ξ 1.033ML of 0.1N Na2S2O3
4) BaCl2 Soln – Dissolve 100 gm of pure crystalline barium Chloride
(BaCl2-2H20) in DM water and dilute it to one liter.
5) Methyl red indicator – Dissolve 0.1 gm of methyl red in 60 Ml of
rectified spirit and dilute to 100 Ml with water.
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6) Ammonia Soln. – Sp. Gr. 0.90

7) Hydrogen peroxide – 30% (W/V)
Procedure
Preparation of solution –
Cover the bottom of the 50 Ml crucible uniformly with 0.5gm of eschka’s
mix. Weigh approximate quantity of the coal (212mm size) and mix it
with 2.5 gm of eschka mixture and brush it into the crucible and cover it
uniformly with one gram of eschka mixture. Place it into the muffle
furnace, raise the temperature to 800 ±25°C in about one hour and than
heat for 90 minutes. With draw the plate with crucible and cool
Transfer the ignited mixture completely from the crucible to a beaker
containing 25 to 30 Ml. of water. If unburnt particles are present reject
the determination, washout the crucible thoroughly with about 500 Ml.
Of hot D.M. Water and add washing to the contents of the beaker.
Extraction by Acid.
Add sufficient amount (about 17 ml) of concentrated HCl into the beaker
and warm it to dissolve the solid matter. Boil for 5 minutes to expel CO2
and filter through a filter pad, collect the filtrate in a 400 ml. conical
beaker. Wash the residue on the filter pad with four 20 ml. portion of
hot DM Water. To the combined filtrate and washing add 2 to 3 drops of
methyl red indicator and then add cautiously NH4OH solution until the
colour of the indicator changes and a trace of ppt is formed. Add
sufficient amount of conc. HCl to just redissolve the ppt and then add 1
ml In excess.
Precipitation of BaSo4
Make up the solution to 300 ml. (approx.) with DM water. Cover the
beaker and heat until the solution boils and then reduce the heating until
boiling ceases. Then add 10 ml.. BaCl2 (within 20 seconds) from a
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pipette into the middle of the solution with stirring. Keep on heating just
below boiling point for 30 minutes. Filter the solution using whatman
No.42 or under suction using asbestos in a Gooch crucible (dried for 1
hour at 130°C and weighed).
Wash the filter with hot DM water (250 ml..) until the effluent is free from
chlorides.
Ignition
Place the wet filter paper in platinum crucible on a silica plate and insert
into the muffle furnace at room temp. and raise the temperature to 800 ±
25°C. Keep the crucible at the temperature for 15 minutes cool and
weigh. Carryout a blank determination under the same condition but
omitting the material. Pipette 10 ml. Of K2SO4 solution to the filtrate
after extraction. Deduct the wt. of the Ba2SO4 found in the blank
determination less the BaSO4 equivalent of the K2SO4 added, from the
wt. obtained in the test determination.
Calculation
5% by wt. = 13.74(A-B+0.0080)
W
Where –
A= Wt. In gms of Ba2SO4 found in the determination.
B= Wt.. in gms. of Ba2SO4 found in the blank determination
W= Wt. In gms of the material taken for the test.
Precision
The results of duplicate determinations should agree to the following
limits.
5% by wt. Within lab. Between lab.
Upto 2 +0.02 +0.05
2 to 10 +0.04 +0.05
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6.3 Determination of Nitrogen

(SEMI – MICRO KJELDAHL METHOD )
Principle:
Nitrogen in coal is an insert substance, which takes no part in
combustion process. It may be estimated by the kjeldahl method of
heating the coal with concentrated Sulfuric acid to destroy the organic
materials, the presence of a catalyst (selenium, mercuric, sulphate,
vanadium pentoxide) ensures that all the nitrogen is rapidly converted to
(NH4)2 SO4. When cool, excess NaOH is added to free the ammonia,
which may then be stoam distilled and collected for estimation in the
condensate by titration with standard acid solution. There are two types
of Kjeldahl methods macro and semimicro. In practice because of the
shorter times of digestion and the smaller scale of apparatus semi-micro
method have been preferably used.
Apparatus –
1. Digestion Flask – Made of hard glass preferably pistol shaped
with a light blown-glass preferably pistol shaped with a light
blown-glass stopper fitting loosely in the neck of the flask. Bulb
cap. 50 Ml.
2. Distillation Apparatus – Any suitable distillation apparatus of hard
glass fitted with a splash head to arrest the passage of any
entrained NaOH solution from the distillation flask.
3. Receiver – A wide necked, flat bottomed conical flask of 100 Ml.
Capacity
4. Burette – of 25 Ml. Capacity
5. Heating Arrangement – A suitable electric digestion unit to heat
simultaneously one or more flasks inclined at about 350C from
the vertical.
Reagents :
1. Conc. H2SO4 – as per IS:266:1961(revised)
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2. Mixed catalyst – 32 parts K2SO4, 1 part Se Powder and 5 parts of

HgSO4 by mass. Ground in a mortar and mixed thoroughly.
3. Alkaline Na2S Solution – Dissolve 20 gm of Na2S.9H2O in water,
dilute to 50 Ml. and add 600 Ml. Of NaOH solution.
4. Standard H2SO4 – Approx. 0.01N
5. Saturated boric acid, solution-Dissolve 60 gm. Of boric acid in 1
liter of hot water. Allow to stand for 3 days decant and use the
clear solution.
6. Mixed Indicator Solution
a) Dissolve 0.125 gm of methyl red in Solution. 100 ML. of rectified
spirit.
b) Dissolve 0.083 gm. of methylene blue in 100Ml. of rectified spirit.
Mix equal volumes of (a) and (b) immediately before use.
7. Sucrose – Pure, free from nitrogenous substances.
Procedure –
Mix 212 micron size air dried sample. Weigh to the nearest 0-1 mg.
about 0.1 gm of the sample. Transfer it to the dry digestion flask. Add
2.0 gm. of the mixed catalyst and shake to mix. Add 4 ml. of conc.
H2SO4 and mix again.
Switch on the electric heating unit at approximately half load for 20
minutes and then at the max. load for 10 minutes before placing the
flask on the unit. When the solution becomes clear, continue boiling to
give a total digestion of 25 to 30 minutes to complete the conversion of
the nitrogenous compounds into (NH4)2 SO4.
During the digestion, steam out the distillation apparatus. Close the
connections to the distillation flask, and blow out the waste from the
previous distillation. Pour 20 Ml. of the alkaline Na2S soln. into he
distillation flask through the funnel, and rinse with water. Measure 2 Ml.
Of the basic acid solution into the receiver and add 4 drops of the mixed
indicator solution adjusting a block under the receiver so that the end of
the condenser tube dips blows the surface of the liquid.
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Allow the acid digest to cool for 5 minutes and dilute by adding 10 Ml. of
distilled water, in drops at first and shaking until the reaction is less
violent. Pour the diluted digest through the tap funnel into the distillation
flask, rinse the digestion flask into the tap funnel with water, then rinse
the tap funnel with water. The total volume of liquid in the distillation
flask should not exceed half the capacity of the flask or frothing and
priming may occur.
Heat the distillation flask with a small flame and pass steam into the
apparatus. Distill for 5 minutes from the time steam enters the
condenser at a rate of about 4 ml. of distillate per minute. Lower the
receiver so that the condenser end is about 2.5 cm above the surface of
the liquid, and continue distillation for 1 minute longer. The contents of
the receiver should remain cold. Rinse the end of the condenser with
water. Titrate the ammonia present in the distillate with the standard
H2SO4 until the grass green colour changes to steel grey, a further drop
then giving the purple acid colour.
Carryout a blank determination in exactly the same manner, but using
0.1 g. of the sucrose instead of coal sample.
Calculation
N2% by mass = 1.4 N(V1-V2)
M
Where
N = Normality of standard H2SO4.
V1 = Volume in ml. of standard H2SO4 used in test.
V2 = Volume in ml. of standard H2SO4 used in blank
M = mass in gm. of the sample taken for the test.
Precision of determination
a) Repeatability – shall not exceed 0.05
b) Reproducibility – shall not exceed 0.10
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6.4 Determination of Total Chlorine (ESCHKA METHOD)

Principle
Chlorine is a significant constituent of coal because there is a
correlation between chlorine content of the coal and the 0ree of gas side
boiler fouling. A weighed sample is mixed with Eschka Mixture and
heated at a specified temperature in an oxidizing atmosphere. The
chlorine extracted from the incinerated Eschka mixture is determined by
a modified volhard procedure.
Apparatus -
a) Crucible – Porcelain, silica or platinum crucible of 30 Ml. Capacity.
b) Muffle furnace – Electrically hated, capable of maintaining a
substantially uniform hot zone at 675 ± 25°C and with good air
circulation.
Reagents – Reagent grade chemicals shall be used in all tests.
1) Eschka Mixture – Thoroughly mix. 2 parts by weight MgO with 1
part of anhy. Na2CO3.
2) Ferric Amm. Sulphate Indicator solution – Add just sufficient conc.
HNO3 (sp.gr.1.42) to cold saturated soln. of ferric Amm. Sulphate
(FeNH4 (SO4)2 12H2O ) to remove the brown colour.
3) Nitric Acid (1+1) – Mix. Equal volumes of HNO3 (sp. Gr. 1.42) and
DM water.
4) Nitrobenzene.
5) Standard solution of potassium thiocyanate (0.025N) – Dissolve 3
gm. of KCNS in D.M. water, dilute to 1 lit. and standardize against
0.025 N AgNO3 soln. (0.025N).
6) Standard AgNO3 Solution(0.025N)
Procedure – Eschka method
1) Preparation of sample – Accurately weigh about 1 gm. Of the air
dried coal, ground to pass a No. 66 sieve and mix. Intimately with
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3 gm. Of Eschka mixture in the 30 Ml. Crucible. Cover with 2

gm. Of Eschka moisture.
2) Combustion – Place the crucible in a muffle furnace and
gradually raise the temperature to 675 = - 25°C within about 1 hr.
Maintain this max. temperature for one and a half hr. then
withdraw the crucible. Stir with a platinum or steel wire and
examine to see whether any unburned coal remain. If any is
found return the crucible to the furnace for an additional half hour
or until no unburned coal remain.
3) Preparation of Chlorine Solution
Transfer the incinerated mixture quantitatively to a beaker. Add
a small quantity of hot water, then cautiously add 40 ml. of HNO3
(1+). Cover the beaker with a watch glass, swirling and stirring
the contents occasionally expedite solution. Filter the solution
through a rapid filtering, hardened, and acid washed filter paper.
If a low-ash coal is being tested it may not be necessary to filter.
4) Titration of Chorine
a) Potentiometric Titration – Titrate with 0.025N AgNO3 solution
using silver and silver chloride electrode and determine the
end point with the potentiometer.
b) Volhard Titration – Add 20.0 Ml. of the 0.025N AgNO3 soln.
Mix. and let stand for 15 Min. Cool to room temp. Add 5 to
10 drop, of the FeNH4(SO4)2 soln. and titrate with the KCNS
soln. The end point of the determination is is reached when
the solution becomes faintly orange pink in colour.
5) Blank Determination –Carryout the blank determination under the
same condition but omitting the coal. The same method of
chlorine determination as used in the analysis.
Calculations –
a) If potentiometric titration was used
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chlorine % by weight = 0.0886(A-B)

C
Where –
A = mls AgNO3 required for titration of the sample.
B = mls AgNO3 required for titration of blank.
C = grams of sample used.
b) If Volhard titration was used –
Chlorine % by weight = 0.0886 (B-A)
C
Where –
A = mls KCNS required for titration of the sample
B = mls KCNS required for titration of the blank
C = grams of sample used.
Precision –
The results of duplicate determinations carried out at different times in
the same laboratory, by the same operator, with the same apparatus, on
representative portions taken from the same sample after the last stage
of reduction process should not differ by more than 0.03% chlorine.
6.5 Determination of Mineral Matter in Coal
The mineral matter or inorganic constituents of coal are generally the
sum of all constituents of coal that are not the part of the organic coal
substance that C, H, N, O, & S (organic) or moisture associated with
coal. Particularly in high ash coal the determination of mineral matter is
very important because for low ash coals, difference between the
results expressed on dry, ash-free and on dry-mineral free basis is not
very significant, but for high ash coals the difference is appreciable.
Principle
This is a direct method for determination of mineral matter in coal. The
coal sample is partially demineralised by treatment with HCl and HF
acids under such condition that the coal substance remains unaffected.
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The loss in mass of the coal is recorded and the insoluble part of
mineral matter determined by ashing the partially demineralised coal.
Iron content of the ash is also determined to calculate pyrites in
extracted coal.
Apparatus
All the apparatus should be made of PVC or HDP.
1. Beaker – a 200ml. with cover slip.
2. Thermometer packet – tube, sealed at one end to carry a
thermometer.
3. Stirrer
4. Wash bottle
5. Filter-width a sintered alumina filter plate.
6. Filter flask
7. Balance-sensitive to 0.01 mg.
Reagents
1. HCl – R.D. 1.155

2. HCl – 5 N (approx.)
3. HF – R.D. 1.14 or 1.13
Procedure
Take an air dried sample and ground it to pass a 212 micron IS sieve.
Mix it thoroughly by mechanical mean. Weigh accurately 6 g. of the
sample and add it into a beaker containing 40 ml. of the 5 N. HCl. Insert
the stirrer and the tube carrying a thermometer and place the cover slip
over the beaker. Place the beaker in a water bath, maintained at 550C
to 600C. Stir the contents at 5 minutes interval. Remove beaker after 45
minutes and allow – the coal suspension to settle for 10 minutes.
Decant the solution through the filter under suction. Wash any coal on
the filter water, drain and transfer the coal back to the beaker with the
aid of not more than 5 ml. of water. Care is required to avoid the loss of
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coal by splashing. Add 40 ml. of the HF to the beaker and repeat the
heat treatment and filtration as previously described. Rinse any coal on
the filter back into the beaker with not more than 5 ml. Water. Add 50
ml. Of 5 N. HCl to the beaker, replace it in the water bath and repeat
the heat treatment previously described. Decant the solution through
the prepared filtering device and wash the coal with water three times,
decanting each time. Transfer the coal entirely to the filter and wash 20
times with 25 ml portions of hot water each times. Remove any residual
coal from the beaker by means of a rubber tipped rod and cold water.
Drain the coal under suction for 5 to 10 minutes.
Note – The first HCl extraction is unnecessary for coals having CO2
content of less than 0.5%.
Dismantle the filter, break up the compacted wet coal and dry the filter
top and coal in a vacuum over at 50% and a pressure of 25mm Hg for
about 90 minutes. Remove and allow to cool in air to attain equilibrium
until constant weight is obtained. Generally an hours cooling shall be
required. Recover the coal and transfer as much as possible to a glass
stoppered bottle. Wipe the filter top and filter paper free from coal and
reweigh. Obtain the weight of extracted coal by difference.
Mix the extracted coal thoroughly and determine its moisture, ash and
chlorine as well as total Iron content of the ash. Determine also the
moisture content of the original sample. Calculate HCL content
equivalent to Cl2 content and the pyrites equivalent to the total Iron
content.
Calculation
All results should be quoted on a moisture free basis –
% of mineral matter MM = M1-M2+P+HCl+1.1A X 100
M1
and F = MM
A1
M1 = mass in grams of sample taken
M2 = mass in grams of sample after extraction
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Sieves: Wire cloth test sieves 1.18 mm, 600 micron and 75 micron with
cover and receiver.
Mechanical Sieving Machine – For vibrating above sieves by

importing a horizontal oscillatory motion of 25 to 30mm amplitude at rate
of approximately 300 cycles / min., rate of approximately 150 blows /
min. by a mass of 1.9 kg. Moving through a vertical distance of about
25mm under the influence of gravity.
Grindability Machine – It includes a stationary grinding bowl of steel,

with a horizontal track in which run 8 steel balls each 25.400 +-0.003
mm dia. The balls shall be driven by an upper grinding ring rotated at
19 to 21 rev. / min. The upper grinding ring is connected to a spindle,
which is driven by an electric motor through reduction gears. A total
mass of 29 ±0.2 kg shall be added to the spindle. The machine shall be
fitted with a revolution counter and an automatic device for stopping the
machine after 60±0.25 revolutions.
Sample preparation: Take about 1 kg. Coal of 4.75mm size, air dry
it and determine its weight to the nearest gram. Sieve the entire
amount on a set of nested sieves consisting of a 1.18mm 15 sieve on
top of a 600 micron 15 sieve by sieving batches of about 200 gm for 2
minutes in the sieving machine crush and sieve the material passes
through the 1.18 mm sieve. Discard that part of the portion passing
through the 600 micron sieve weight the coal passing the 1.18mm sieve
and retained on the 600 micron sieve. If the yield in this size range is
less than 50% of the dried portion, the coal thus prepared shall be
discarded and sample preparation shall be repeated starting with
another 1 kg portion of the 4.75 mm coal.
Mix thoroughly the 1.18mm by 600 micron size coal. Remove about
120 gm using sample divider and de dust by sieving for 5 minutes on a
600 micron sieve. Reduce the de-dusted material, using a sample
divider to not less than 50 gm.
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Test Procedure
Clean the grindability machine and space the balls as evenly as
possible around the grinding bowl. Weigh 50 ±0.01 gm of the de-
dusted, distribute it evenly in the grinding below. Assembly the top
grinding ring to the bowl, fasten the bowl in position to he driving spindle
making sure that the load is evenly applied. Reset the counter and
adjust the automatic stopping device so that the machine can operate
for 60 ±0.25 revolution. Start the apparatus.
When rotation has stopped, switch off the machine and dismantle the
bowl assembly. Empty the grinding balls and ground coal on to the
protective sieve. Brush any coal from the bowl and the balls into the
protective sieve. Brush any coal and dust from the inside and under
side of the protective sieve into the 75 micron sieve. Shake it for 10
minutes. Carefully brush any coal dust from the underside of the 75
micron sieve into the pan. Repeat the shaking and brushing for two
more times. Weight separately to the nearest 0.01 gm of the coal
retained on the 75 micron sieve and the coal passing the 75 micron
sieve. If the sum of these masses differs by more than 0.3 gm from the
initial mass of 50 ± 0.01 gm the test shall be rejected.
Calculations
Calculate HGI using the formula
HGI = 13 + 6.93 W
Where W = Weight of the test sample passing through 75 micron sieve
after grinding. In practice W is obtained by deducting from 50 gm the
weight of the ground sample retained of 75 micron sieve.
Carry out duplicate determinations on portions taken from the 1.150 mm
by 600 microns fraction.
Report the mean grindability index rounded to the nearest whole
number.
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8.0 TERMINOLOGY
Air-dried Coal
The sample of coal, which for the purpose of analysis, is exposed to the
atmosphere of laboratory to bring it in equilibrium with the humidity
conditions prevailing in the laboratory, so that the sample does not lose
or gain weight during weighing
Ash
Inorganic residue left, when coal is incinerated in air to constant weight
under specified conditions.
Coal, Run-of-mine
Unscreened coal containing all sizes, mainly 0 cm to 23 cm.
Coal, Large
Coal having nominal size 5-15cm the upper limit not exceeding 23 cm.
Coal, Small
Coal with nominal size 0 cm to 5 cm.
Fixed Carbon
Obtained by subtracting from 100, the sum of percentages by weight of
moisture, ash and volatile matter.
Gross Calorific Value
Number of heat units liberated when a unit mass of the fuel is burnt at
constant volume in oxygen saturated with water vapour; the original
material and final products being at approximately 25 0 C.
The residual products are taken as carbon dioxide, Sulfur dioxide,
nitrogen and water, the residual water other than originally present as
vapour being in the liquid state.
Note :- The gross calorific value at constant volume is the one
usually used in coal technology. It is assumed that all heat
produced is available, including the heat of condensation of
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any steam, resulting from the combustion of hydrogen in the

fuel, to water at room temperature.
Laboratory Sample
The quantity of coal obtained by reducing a gross sample by following a
specified procedure for laboratory testing.
Moisture
Water expelled in its various forms when tested under the specified
conditions.
Moisture Sample
A special coal sample to be used exclusively for the purpose of
determining total moisture
Moisture and Water
a) Free Water Plus Moisture.
Coal that has been exposed to contact with water in the seam or in
a washery, or coal wetted by rain or by water sprayed for coal dust
suppression may carry free or visible water. This water plus
moisture within the material is called total moisture.
b) Moisture In Coal Equilibrated at 400C and 60% relative
humidity :
The moisture content of air-dried coal varies and depends upon
the temperature and relative humidity of the air in which it is dried.
At times it is necessary to determine moisture content of different
samples of coal under comparable conditions. For this purpose the
coal is ground to pass through a 212 micron 15 Sieve and
equilibrated in an atmosphere of 40 0 C and 60% relative humidity.
c) Free Water or Visible Water:
Only the visible wetness of coal is included in this.
d) Moisture in Air-Dried Laboratory Analysis Sample of Coal:
The moisture content of the analysis sample is determined as a
part of proximate analysis and also whenever portions of sample
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are weighed later for other analysis and tests. If all the portions for
analysis are weighed under approximately the same conditions of
humidity, one determination of moisture will suffice, but a check is
desirable with high moisture coals.
Net Calorific Value
Number of heat units liberated when a unit mass of the fuel is burnt at
constant volume in oxygen saturated with water vapour, the original and
final materials being at approximately 25 0 C. The residual products are
taken as carbon dioxide, Sulfur dioxide, nitrogen and water vapour.
To convert gross calorific value to net calorific value, employ the
formula,
Nc = Gc - 53 H Where
Nc = net calorific value in cal/g
Gc = gross calorific value in cal/g
H = percentage of hydrogen present in the coal sample,

including hydrogen of moisture and water of combustion.
Proximate Analysis
Analysis of coal expressed in terms of percentages by weight of
moisture, ash, volatile matter and fixed carbon.
Sample Division
The process whereby a part to the sample is retained and remainder
rejected.
Sample Reduction
The process of crushing or grinding the sample to reduce the particle
size and of mixing and sample dividing in successive stages.
Volatile Matter
Total loss in weight minus the moisture when coal is heated under
specified conditions.
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Units of Heat
a) Absolute Joule :
The basic unit, equivalent to 107 ergs.
b) Mean Gram Calorie:
One hundredth part of the amount heat required to raise the
temperature of one gram of water from 0 0 C to 100 0 C. It is equal
to 4.1897 joules.
c) Gram Calorie (cal):
Amount of heat required to raise the temperature of one gram of
water from 14.5 to 15.5 0 C used as an international standard for
calorimetry. It is equal to 4.1855 joules and it differs from the mean
calorie by only one part in 1000, which is not significant enough to
require correction for practical purposes.
d) International Steam Table Calorie:
Equal to 4.1868 joules (exactly) and differs from gram calorie by
approximately 0.3 parts in 1000.
9.0 REFERENCES:
1. Modern Power Station Practice Vol-V CEGB U.K.
2. B.I.S. Numbers
IS: 436 (Part 1& Part 2)
IS: 1350(part-II) 1992
IS: 1350(part-IV.Sec-1) 1992
IS: 1350(part-I) 1992
IS: 1350(part-IV.Sec-2) 1992
IS: 4311-1967
IS: 4433-1979
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Section III IMPORTED COAL SAMPLING FORMAT
Station: ……………….. Rake Receipt Date: ………………. Time: ……………… Date: ……………………..
SN Rake RR No. Coal Total No. of No. of Wagons Wagon Nos. Sampling Tag No. Whether Tag No. Signatures
No. Source Wagons in selected for Sampling from where Date & of kept by Sample Sample Collected in Sampling Process
the Rake thro Book of Random samples are Time Sample Chemistry Dept. Collection the presence of Witnessed by CHP I/c
numbering collected Bag executive Agency Chem. Dept. (Name & Signature)
(Name executive (Name &
&Signature) Signature)
Note:
Sample to be collected from the Imported Rake as per the Sampling procedure for Imported Coal.
Sample to be collected from top, middle & bottom of randomly selected wagons(in case of overhead traction system, representative sample from BOBR wagons is
to be collected from bottom)
Sampling to be witnessed by Shift I/c of CHP Dept. and Chemistry Dept. executive.
There should be 3 tags with same tag no. for each set of sample; 2 nos. for the sample bags (inside & outside of sample bag) and 3rd with the Chemistry dept.
executive
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SECTION IV: GUIDELINES FOR OPERATION & MAINTENANCE OF

COAL HANDLING PLANT
CONTENTS
Page Nos.
1 PREAMBLE 110
2 REFERENCE / SUPERSEDED DOCUMENTS 110
3 OPERATION 110
3.1 GENERAL INSTRUCTIONS 110
3.2 PADDLE FEEDERS 113
3.3 CONVEYORS 114
3.4 CRUSHERS 114
3.5 STACKER RECLAIMERS 114
3.6 TRIPPERS 115
3.7 COAL SAMPLERS 115
4 MAINTENANCE 116
4.1 PREVENTIVE MAINTENANCE 116
4.2 PREDICTIVE MAINTENANCE 116
4.3 BREAK-DOWN MAINTENANCE 117
4.4 MAINTENANCE FACILITIES 118
4.5 MAINTENANCE OF BELT CONVEYORS 120
5 MAINTENANCE OF EQUIPMENT HISTORY 121
6 SAFETY 122
6.1 EQUIPMENT SAFETY 122
6.2 HUMAN SAFETY 123
7 FIRE PROTECTION 125
8 PERFORMANCE MONITORING 127
9 MODIFICATIONS RECORD 128
10 SEASONAL MAINTENANCE PLAN 128
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CONTENTS
Page Nos.
Appendix (1) 129

Appendix (2) 130
Appendix (3) 131
Appendix (4) 133
Appendix (5) 135
Appendix (6) 136
Appendix (7) 138
Appendix (8) 139
Appendix (9) 142
Appendix (10) 144
Appendix (11) 146
Appendix (12) 147
Appendix (13) 148
Appendix (14) 149
Appendix (15) 150
Appendix (16) 151
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3.1.7. For better equipment performance and safe operation, it is essential to ensure
that the equipment is operating satisfactorily while it is in operation. This
can be achieved by checking each and every part of the system. All
operation check-lists as per the format are enclosed as Appendices-
1(a),1(b),2(a),2(b),3,4and5.These check-lists are to be filled once in
day as appropriate.
3.1.8. The shift electrical operator shall also fill in the operation check-list, as per
the format enclosed at Appendix- 7
3.1.9. Based on the operation check-list, the Shift Charge Engineer will raise
fault cards to maintenance section identifying defects which require
rectification.
3.1.10. A change-over schedule is to be prepared and the equipment change-over
is to be followed as per the schedule, as far as possible.
3.1.11. The desk controller shall log the operation activities as per the format.
3.1.12. The Shift-Charge-Engineer shall maintain the following documentation.
a. PTW Register indicating the equipment for which the PTW is issued and
cancelled in the shift Appendix (8)
b. Equipment availability.
c. Log-book indicating the operating hours, forced outages and critical points
requiring attention.
3.1.13. In case of any emergency defect, the Shift Charge Engineer shall
immediately send the work order to the Shift Maintenance Staff.
3.1.14. All Metal Detectors and Magnetic Separators are kept in service.
3.1.15. Detectors/Separators should be inspected daily and foreign material
removed, where necessary.
3.1.16. The Shift Charge Engineer or his representative/shift Engineer shall monitor
that sump pumps provided at various locations are operated regularly during
the shift. Excess water should be pumped away, where necessary.
3.1.17. All Electrical systems should be maintained healthy. Availability of protection
systems requires special attention by Operation Engineers and these are to
be regularly monitored.
a. Hooters
b. Pull Cord switches
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c. Zero-speed switches
d. Belt sway switches
e. Chute block switches/ Chute choke switches
f. Crusher vibration monitoring equipment
g. Interlocks
h. PA system
i. Magnetic Separators
j. Metal Detectors
By-passing of these protections is to be avoided. In case of any problems in
any of the protection systems, these shall immediately be brought to the
notice of the Maintenance Department. For bypassing of protection the
procedures laid down in “Procedure for Regulating Bypassing of
permissive and protection” LMI/OPN/SYST/007 should be followed, which
is indicated in Appendix-(9)
3.1.18. Electro Mechanical Thruster Brakes/holdback devices in gear boxes installed
in long conveyors should be kept in good working order. If these are not
working it may cause non synchronous stoppage of different belts leading to
blockage of the transfer point chute.
3.1.19. Adequate lighting should be ensured in all the areas.
3.1.20. Frequent starts and stop should be avoided as far as possible and no
unwarranted operation should be carried-out.
3.1.21. The General Operation Instructions for the major equipments is given in
the Paragraphs-3.1.1 to 3.1.6. Before taking any equipment into service it is
to be ensured.
3.1.22. All Operation & Maintenance Engineers should read the O&M manual for
the Coal Handling Plant and implement the content of the document.
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3.1.23. Pile Management: Coal should be piled in such a manner that air can circulate
freely to dissipate heat. For crushed coal the pile should be packed thoroughly
to ensure the complete absence of air. Coal piles should be trapezoidal in
shape with their base having sufficient clearance from rails and drains. Height
of pile should not exceed the maximum designed value. Each pile should have
covered surface drains on both sides all along the length. Piles should be
regularly inspected for smoke/fire ignition of coal. Each pile should have fire
water hydrant value all around the periphery. Temperature of pile at different
locations can be measured at various depths so as to know the trend and to
decide as to which coal is to be reclaimed first. Coal in the pile should be
spread out in horizontal layers and not in conical heaps and compacted for
further stacking. The toe and the edge of the pile should be compacted to avoid
spontaneous ignition. An important aspect in the good management of coal
stack pile is the First in First out principle. Detailed guidelines of pile
management are mentioned in Section –V.
3.2. Paddle feeders
3.2.1. The Paddle Feeders feed the coal on the conveyor belt from the Track hopper
at a controlled rate. The paddle blades projected in the hopper slot scoop the
coal from hoppers and discharge it on the conveyor belt running below.
3.2.2. The following points need to be checked before taking any paddle feeder in to
service.
a. The paddle blades are free from any obstruction.
b. There is no leakage at gear boxes and fluid couplings and the oil levels are
correct.
c. There is no leakage of hydraulic oil, in the case of hydraulically driven paddle
feeders, and the oil levels are correct.
d. The cable reeling drum for correct winding and unwinding.
e. The paddle feeder is operating only in interlock mode.
f. Speed control mechanism of paddle feeder to be kept healthy.
g. Anti collision device if provided to be kept healthy.
h. Belt stop arrangement from Paddle Feeder to be checked for healthiness.
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3.3. Conveyors
3.3.1. Various conveyors are provided for transporting the coal from Track hopper to
Bunkers.
3.3.2. The following points need to be checked before taking any conveyor into
service:
a. There is no oil leakage at gear boxes/fluid couplings and the oil levels are
correct.
b. The Discharge and Receiving chutes are free from jamming and choking.
c. The Flap Gates are in correct positions.
d. All inspection doors are in the closed position.
e. All pull-cords are reset and the EPB is released.
f. The Alarm Siren is in working order.
g. A communication facility is available.
h. The lighting is adequate.
i. No. PTW is pending.
3.4. Crushers
3.4.1. Crushers are provided to crush the coal generally from (-) 250 mm size to
(-) 20 mm size.
3.4.2. The following points need to be checked before running any crushers.
a. The crusher shall be clear from any jamming.
b. All inspection doors are in the closed position and locked.
c. There is no leakage at gear box and fluid couplings and the oil levels are
correct.
3.5. Stacker Reclaimer
3.5.1. The Stacker Reclaimer is provided to stack the excess coal received from the
mines and to reclaim the coal when coal receipt is less from mines.
3.5.2. The following points need to be checked before taking Stacker Reclaimer into
service:
a. The track is clear from any obstructions.
b. There is no leakage from gear boxes, fluid couplings & hydraulic system.
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c. The oil levels are correct.

d. The availability of power supply is checked.
e. All operations components e.g. travel, slewing, Hosting etc. are available.
f. Brakes are clean and functioning correctly.
g. CRD cable is free from damage and any obstruction and is tensioned correctly.
3.6. Trippers
3.6.1. Trippers are provided on coal bunkers to receive coal from the conveyors and
feed it to the bunkers. The tripper is mounted on rails and feeds coal to the
bunkers for use on all the units.
3.6.2. The following checks are to be carried-out before taking the tripper into service:
a. The availability of supply.
b. The brakes are clean and functioning correctly.
c. The tripper discharge chute is free from jamming/blockage.
d. The CRD cable is free from any obstruction and is tensioned correctly.
3.7. Coal Samplers

3.7.1. In the coal handling plant coal samplers is provided to take a sample of coal-
as-received.
3.7.2. The availability of coal samplers is to be checked in each shift.
3.7.3. The following points need to be checked before taking coal samplers into
service.
a. The crushers are clear of any jamming.
b. There is no oil leakage from gear boxes, fluid coupling or the hydraulic system.
The oil levels are correct.
c. The sample collectors are empty.
d. Interlocks and protections are ok.
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4. MAINTENANCE
The over-all objective of planned maintenance is to achieve high reliability and

availability of the plant and to ensure safety of the equipment and the facility.
4.1. Preventive Maintenance
Preventive Maintenance is a periodical maintenance of the equipment to

minimize break-downs and increase the availability.
4.1.1. Scheduling of Preventive Maintenance
The equipments requiring Preventive Maintenance will be identified and the

periodicity of the work decided based on the type of equipment, application and
type of P.M. work etc. For better maintenance and effective utilization of
equipment, the periodicity could be weekly monthly, quarterly or half-yearly or
as per manufacturer’s recommendations.
4.1.2. Daily planning meeting is to be conducted for CHP in presence of MTP

representative. Apart from discussing plant status preventive maintenance
(PM) schedule for the next day is to be discussed and agreed upon.
4.1.3. The PM will be successful only if the PM is inspected by area in charge. To

ensure correct inspection, responsibility centers are to be identified (area
engineers) apart from random inspection by HOD (FM/CHP).
4.2. Overhauling and Preventive Maintenance scheduling for control panels, motors,
switch-gears and other protections are to be followed at regular intervals.
4.3. Predictive maintenance
4.3.1. The Maintenance Planning Department should carry out Condition

Monitoring, at decided frequency in the following areas
a. Crushers : once in a month
b. Conveyor : once every six month
c. Belt Mapping at 6 monthly intervals (for belt length more than 200m).
The Planning Department shall issue Work Order Cards for rectification or
preventive replacement of defective equipment. Belt condition should be
checked regularly by CHP .Belts should be replaced if rubber covering is
found worn out.
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4.3.2. Condition monitoring to be done as continuous process and the data

obtained is to be computerized /recorded to monitor the decay trend, if any.
4.3.3. All Operation check-lists are to be implemented regularly and the data
listed in the check-lists, to be processed by Shift Charge Engineer (Operation
Department) and accordingly predictive maintenance works to be identified
and fault cards should be issued to the maintenance departments.
4.4. Break-down Maintenance
4.4.1. Following are some of the major break-downs which occur in a Coal
Handling Plant.
a. Conveyor belt snapping

b. Pulley failures
c. Crusher hammers missing and high vibrations of crusher.
d. Damage to the equipment due to the presence of foreign materials in the
coal.
4.4.2. The above break-downs can be prevented by implementing the following:
a. In a conveyor belt, the number of joints should be kept minimum. Care

should be taken during vulcanizing for proper alignment to avoid swaying
of conveyor belt.
b. The conveyor belt to be examined regularly and if any weak joint is noticed, it
should be repaired immediately.
c. The hot vulcanization method of joining the belt is to be adopted. In

emergency conditions, cold vulcanizing can be adopted but joining the belt
by the use of clamps should be avoided.
d. Welding of all pulleys of bunker conveyors are to be Dye Penetrate tested

during Unit overhaul period, and corrective action is to be taken.
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e. Crusher vibration to be continuously monitored through vibration indicators

mounted in CHP control room. Vibration level of Crusher House structure
to be monitored and deflection of key members be recorded periodically.
f. A history of break-downs is to be maintained.
g. Belt cleaners should be made available and maintained in service

continuously.
h. No protections should be by-passed.
i. Magnetic detector and in-line Magnetic Separator/Suspended magnet

availability are to be ensured.
j. While greasing of the pulley bearing should be thoroughly cleaned by tarpin

oil and bearing should be checked for any damage before putting fresh
recommended grease.
4.4.3. Chutes are to be regularly inspected for checking the healthiness of steel
members.
4.4.4. Availability of resources, tools and plants.
In achieving effectiveness and efficiency in maintenance management

systems, the availability of resources, tools and plants play an important factor.
Besides Spare Parts, tested tools and plants should also be planned.
Frequently maintenance work is stopped due to the non-availability of skilled
manpower or certain special tools. These aspects should be properly planned.
4.5. Maintenance Facilities
The following maintenance facilities assist in reducing down-time and returning of

equipment to service promptly.
4.5.1. Permanently placed winches at Crusher House and high Transfer Points.
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4.5.2. Simple chain pulley blocks in all take-up platforms to hold the take-up in
position to relieve belt tension during vulcanizing, pulley lagging etc.
4.5.3. Providing a lift in the Crusher House & high rise Transfer Points where
frequent inspection is required.
4.5.4. Providing adequate number of pulley blocks at all Transfer Points.
4.5.5. Providing electric winches at all strategic locations for belt laying.
4.5.6. Providing a 24 V D.C. supply at all Transfer Points and Crusher House for
lighting inside the chutes, while inspection or replacement of the liners inside
the chute.
4.5.7. Providing access platforms for hoist maintenance.
4.5.8. Preventive maintenance and regular inspection and load test certification of
Hoists & winches should be done.
4.5.9. Providing access to Transfer Points to ensure easy transportation of

materials.
4.5.10. Regular cleaning of pulleys, coal flow chutes & gallery deck plate by dry
cleaning/ water washing etc.
4.5.11. Providing an access platform for operation and maintenance of Flap Gates.
4.5.12. Providing additional manholes in chutes for inspection and repair works.
4.5.13. Providing service-water system for cleaning.
4.5.14. Making available maintenance booths with welding Transformer, oxygen and
dissolved acetylene cylinders at strategic locations/Transfer points.
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4.5.15. Developing and maintaining a small site lubricant store in CHP area.
4.5.16. Maintaining a minimum stock of fast wear steel plates/components at CHP

workshop.
4.5.17. Provision of Electrical supplies for welding machines or vulcanizing

equipment.
4.5.18. Provision of stands for rolls of new conveyor belting to enable new belts to
be unrolled.
4.5.19. Provision of fixed rollers on underside of conveyor steel work to guide new
belt onto conveyors and old belts away from conveyors.
4.6. Maintenance of Belt Conveyors
For efficient and reliable operation of belt conveyors, the following criteria
should be followed:
4.6.1. Carry out a systematic and careful inspection of individual parts.
4.6.2. Undertake regular and proper lubrication of mechanisms.
4.6.3. Essential major and minor repairs should be carried-out promptly.
4.6.4. The alignment of pulleys should be thoroughly checked after replacement.
4.6.5. Idlers should be used throughout the length of conveyor. Care must be taken
to see that all idlers and rollers rotate freely and are fixed rigidly to their
supports.
4.6.6. Periodic checking should be carried-out to ensure that:
a. The belt runs centrally.
b. The belt is properly tensioned.
c. The belt joints are strong.
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4.6.7. Care should be taken to ensure that the skirt board does not touch the belt.
The recommended quality of rubber sheet should be used. Worn skirt rubber
to be replaced immediately to prevent spillage.
4.6.8. The correct counter-weights should be maintained on all conveyors and

adjusted in accordance with design data. Also ensure freedom of their
movement.
4.6.9. Maintain correct oil level in Fluid Couplings to avoid slippage, overloading,
and also to maintain proper torque. This is to be checked and corrected during
PM checks.
4.6.10. Take up area is to be kept clear of coal all the time.
5. MAINTENANCE OF EQUIPMENT HISTORY
5.1. History of equipment to be maintained: -

a. Hammer life
b. Motor
c. Crusher bearing
d. Coupling
e. Rotor
f. Stacker Reclaimer
g. Pulleys
h. Paddle Feeder
i. Pulley bearings
j. Vibratory feeders
k. Belts
l. Gear drive
m. Trippers
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6. SAFETY
6.1. Equipment Safety
6.1.1. The following points need to be followed for the safe operation of equipment.
a. Do not start any equipment in a jammed condition.
b. Start equipment with proper clearance from the local operator after a
thorough inspection.
c. Stop the equipment immediately if any abnormality is found.
d. Ensure the safety-guards on all rotating equipment in position.
e. Bypassing of any protection should be in accordance with the Operation

Directive Procedure for Regulating the Bypassing of permissive and
protection OD/OPS/SYST/005.
f. The Desk controller should be informed about the equipment under permit
and the PTW should be displayed in the Control Room.
g. Operate all the equipments in accordance with the manufactures

instructions and any special instruction from the operation-in-charge.
h. Permit should be issued with the signature of Senior authorized person.
i. Oral instructions should not be given and the PTW number should be
entered in the register.
j. The lockout box system should be used while issuing permit and cross
permit on the same equipment.
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6.1.2. The following points need to be observed for safe maintenance of the
equipment:
a. Maintenance should be undertaken only when the permit is issued by the

authorized person.
b. Only correct tools should be used together with tackles and rigging tools
required for the particular type of work and equipment.
c. Oils and Gases are to be handled with care.
d. Hot permit is to be taken for cutting/welding works. Fire prevention
equipments are to be provided and used e.g. fire hose, portable extinguisher.
Presence of CISF staff and after completion of any welding /cutting activity
proper quenching of hot surfaces and combustible materials like coal,
conveyor belt, pulley lagging etc. should be ensured. Thereafter proper
inspection is to be carried out by area Engineer / foreman before cancellation
of work permit.
e. Follow the instructions, detailed in the work specification to ensure safety

during work.
f. Use the correct scaffolding /safety belt while working at heights.
g. Remove all tools, tackles & unwanted material after completion of
maintenance.
6.1.3. All tools & tackles are to be tested and healthiness to be certified by
authorized person.
6.2. Human Safety
Human safety is a very important factor in any industry. It plays a vital role in
production and productivity and utmost care must be taken to implement all
necessary safety requirements.
The following are the general safety guidelines that apply in the Coal Handling
Plant.
a. Use only cross over to cross the conveyors.
b. Keep away from the rotating equipment e.g. Couplings, fans, etc.
c. Wear protective safety equipments.

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d. Do not open the Man holes and Inspection doors of the

Crusher/Chutes/Coal samplers while in operation.
e. Use only approved and tested tools for maintenance.
f. Walk-ways should be free from obstruction and adequately lit throughout the
plant.
g. Stair-case steps and hand-rails should be properly arranged with proper toe-
guards.
h. Floor openings are to be properly covered, side openings for doors, and hoists
should have hand-rails.
i. Sufficient walking space should be provided at the drive area of

equipment.
j. All electrical installations and panels are to be kept closed.
k. Welding connections are to be taken from the sockets provided.
l. Ensure fencing of all the Gravity take off areas in ground/internal to floors.
m. Periodic checking of hoists and lifts should be carried out.
n. Ensure all guards are secure in place.
o. The available conveyor start alarms should be used and tested regularly.
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7. FIRE PROTECTION
7.1. Coal Handling Plants are prone to fire accidents due to fine coal dust
accumulation and chute jamming .
7.1.1. The following facilities are to be installed and maintained to detect fire in
Coal Handling Plant:
a. Linear heat sensing cable all along the conveyor with an associated alarm
system in Control Room.
b. Infra-red fire detection cameras at all strategic locations especially on reclaim

conveyors, for detection of moving fires.
c. Emulsifier-bulb sprinkler system or Medium velocity water spray system

along with quartz bulb type detection-cum-actuation system for automatic
fire detection and protection.
d. Fire hydrants at Coal stock yard Track hopper area Transfer Points.
e. Fire alarm system to be installed throughout the coal handling plant.
f. The use of fire retardant conveyor belt is recommended.
7.1.2. The following facilities are to be installed for fire protection:
a. Fire hydrant lines at all strategic locations with necessary hoses and
couplings. Minimum hydrant water pressure at all locations must be 3.5
Kg/cm2. Routine monitoring of hydrant/sprinkler water pressure at 4/5
strategic locations must be done, provision of permanent pressure gauges
to be made and appropriate log sheets be maintained.
b. Portable fire extinguishers for all types of fire.
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7.1.3. All personnel should be trained in the use of fire extinguishers and fire
fighting and should be instructed not to light unauthorized fires during cold
weather.
7.1.4. Emergency instructions should be prepared and displayed in the Control

Room.
7.2. The whole Coal Handling Plant should be inspected by the Safety and Fire Fighting
group regularly. Corrective action should be initiated for any defects found and
reasons for prolonged isolation/permit investigated.
7.2.1. Fire hydrant and sprinkler pressures should be monitored, daily.
7.3. Various Fire Accident Committee recommendations are to be studied and

implemented to avoid recurrence of such fires.
7.4. Good housekeeping helps in reducing fire hazards. The following practices should
be established in order to maintain good housekeeping in the coal handling plant.
7.4.1. Removal of all metal and belt scrap, debris and coal form all Transfer Points
and galleries.
7.4.2. Clean all cable-trays, bracings and not accessible points regularly.
7.4.3. Providing packing for all manholes to prevent leakages.
7.4.4. Water should be sprinkled before sweeping and water washing of galleries
should be carried out periodically.
7.4.5. All spillage or accumulation of coal should be removed regularly.
7.4.6. All DE and DS system to be kept healthy and in running condition.
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8. PERFORMANCE MONITORING
The performance of the plant Operation and Maintenance are to be monitored to

improve the efficiency and increase the availability and reliability, of the plant. The
performance is monitored Daily, Weekly, and Monthly as mentioned hereunder.
8.1. Daily performance monitoring: Daily performance of plant utilization, reasons for
outages, equipment availability and fire hydrant pressures at the farthest locations
are to be monitored.
8.2. Weekly performance monitoring: All the work order cards raised and completed in
the week are to be monitored and analyzed to identify any delay in completion
8.3. Monthly performance monitoring: The overall performance of the plant for the
month is monitored in respect of the following:
a. Availability of equipment.
b. The Crusher hammer life.
c. Crushing hours of each crusher during the month.
d. Spares consumption e.g. belt and hammers, fluid coupling, gear boxes etc.
e. Belt jointings, pulley laggings done.
f. Major works attended during the month.
g. Utilization factor of CHP
h. Availability of auxiliary equipment.
i. Any spares reclaimed .
j. Availability of protection.
8.4. An Action Plan of various works is to be made.
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9. MODIFICATION RECORDS
All modifications carried out on various equipment should be recorded and history be
kept. Requirement of such modifications, nature of problems faced and effect of
modifications should be mentioned. Before carrying out any modifications
specific approval should be obtained.
10. SEASONAL MAINTENANCE PLAN
Before the arrival of summer and rainy season specific work program should be
prepared and executed to ensure smooth operation of the plant. Before the rainy
season, per-monsoon plan is to be prepared and functioning of all sump pumps should
be ensured.
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Appendix - 1
COAL HANDLING PLANT: OPERATION CHECK LIST

LOCATION: TRACK HOPPER NO….. Date....................
EQUIPMENT: PADDLE FEEDERS Shift....................
Sl.No. Details PF-…. PF-…. PF-…. PF-….

01. Paddle drive condition
a) Gear box leakage and oil Level
b) Paddle Regulator condition
02. Travel drive condition
a) Gear box oil leakage and oil level
b) Fluid coupling leakage
03. C.R.D. cable conditions
04. Blade condition (No. of missing blades,
bend blades etc.)
05. Skirt rubber condition
06. Coal accumulation (if any)
07. Availability of interlocks
08. Lighting problems (if any)/ Availability
of D.C. emergency lighting in TH
09. Telephone/P.A system
10. Any other abnormalities
11. Availability of fire fighting system
12. Sump pumps
Name & Signature of the Operator:
Remarks: .................................................
Name& Signature of Shift Engineer:
ACTION TAKEN
Signature: ................................................
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Appendix -2
LOCATION: Crusher House:….. ; Equipment: Crushers; Date …................
Fire Hydrant Pressure ….................kg/cm2 at top floor Shift
Sl.No. Details CR -…. CR -…. CR -…. CR-….
01. Gear box oil level
02 Gear box temp. (by physically
touching-OK/high -
03 Scoop oil Leakage
04 Cooling water availability
0 Vibrations (if any)
Bearing temp. (By physically
touching plummer block) OK/high
5 Scoop pump availability
06 Vibrating/Grizzly Feeders on Crushers
07 Chute puncture (if any
08 P.A. system
09. Air cannons on vibrating feeders of
crushers
10. D.E. system
11. Poor lighting areas
12. Coal accumulation areas
14. Availability of fire fighting systems
15. Availability of D.C. emergency
lighting
Name & Signature of the Operator:
Remarks: .................................................
Name& Signature of Shift Engineer:
ACTION TAKEN
Signature: ................................................
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Appendix-3
Location: TP........................................ Date....................
Conveyors:……………… Shift ....................
Fire Hydrant Pressure at Top Floor ..............Kg/cm2
Sl.No. Details Conv:…. Conv:…. Conv:…. Conv:….

1 Drive condition
1.1 Gear box oil level temp (Physically
touching OK/ not OK)
1.2 Fluid coupling leakage
1.3 Coupling guards
1.4 Vibration (if any)
2 Belt condition (L/O, damage etc.)
3 Roller/pulley damage (exact location)
4 Chute puncture (if any)
5 Rubber condition
6.1 Pull cord
6.2 Belt sway
6.3 Zero speed
6.4 Belt scrapper
6.5 Inspection doors
7 P.A. system
8.1 CBMS/ILMS/SMS
8.2 Metal Detectors
9 Poor lighting areas
10 Coal accumulation area
(exact location)
11 Dust Extraction system
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Sl.No. Details Conv:…. Conv:…. Conv:…. Conv:….

12 Dust Suppression system
13 Air cannons
14 Any other abnormalities
15 Availability of fire fighting systems
Signature of the Operator.

Name : ......................................................
ACTION TAKEN
Signature:.................................
Remarks :
Signature of Shift Engineer

Name : .....................................................
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Appendix-4
COAL HANDLING PLANT : OPERATION CHECK LIST
LOCATION : BUNKER LEVEL Date ....................
Unit No.: Shift: ....................
FIRE HYDRANT PRESSURE......................Kg/cm2
Sl.No Details Conveyor Conveyor

01. Drive condition
a) Gear box oil level
b) Gear box Temp. (OK/high)
c) Fluid coupling oil leakage
d) Coupling guards
e) Vibration (if any)
02. Belt condition (L/O, damage etc.)
03. Roller/Pulley damage (exact location)
04. Chute puncture (if any)
05. Skirt rubber condition
06. a) Pull cord
b) Belt Sway
c) Zero speed
d) Belt scrapper
07. P.A. system/telephone
09. Coal accumulation area
(give exact location)
10. Condition of trippers
11. Bunker grills damage (if any)
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14. Bunker level
15. Availability of d.c emergency lighting
Time/Bunker A B C D E F G H J K
Initial : hrs
Final : hrs
Signature of the Operator.

Name : ......................................................
Signature of the Controller

Name : ......................................................
ACTION TAKEN
Signature : ...........................................
Remarks
Signature of Shift Engineer.
Name : ......................................................
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Appendix-5
COAL HANDLING PLANT : OPERATION CHECK LIST
LOCATION : STACKER/RECLAIMER Date........................
Shift .......................
Sl.No. Details Stacker/Reclaimer No.
01. a) Travel drive condition
b) Travel brake condition
02. a) Slewing drive condition
b) Slewing brake condition
03. Bucket wheel condition
04. a) Boom luffing system
b) Cabin luffing system
05. Boom conveyor
a) Belt condition
b) Skirt rubber condition
c) Pull cords
d) Damaged rollers
06. a) Power cable reeling drum
b) Control cable reeling drum
07. Availability of interlocks
08. Telephone
10. Coal accumulation areas
(exact location)
(Motor failure etc.)
12. Availability of auto greasing system
Signature of the Operator. Signature of the Controller
Name : ...................................................... Name : ...............................................
ACTION TAKEN
Remarks :
Signature of Shift Engineer. Signature : ...............................
Name :...................................................... Name .......................................
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Appendix-6
COAL HANDLING PLANT

ELECTRICAL OPERATION-LOG SHEET
Date ..................... Shift ....................
1. EQUIPMENT ISOLATED DURING THE SHIFT
SL. NO. PTW. NO. EQUIPMENT ISOLATION DETAILS
01.
02.
03.
04.
05.
2. INCOMERS/BUS COUPLERS IN SERVICE
a) Low Tension Motor Control centre at Transfer Point No......
b) Low Tension Motor Control centre at Transfer Point No.....
c) Low Tension Motor Control centre at Transfer Point No.......
d) High Tension Boards
e) LT MCC in control room
3. EQUIPMENT/MODULES IN SERVICE POSITION
a) Conveyors :
b) Trippers :
c) Paddle Feeders:
d) Crushers :
e) Stacker/Reclaimers :
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4. AVAILABILITY OF FIRE FIGHTING:

SYSTEM NEAR MCC'S
5. REMARKS
Signature of the Electrical operator.

Name: ......................................................
Signature of the Engineer.

Name : ......................................................
ACTION TAKEN
Signature :.................................................
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Appendix-7
COAL HANDLING PLANT

WALK DOWN CHECK LIST FOR PADDLE FEEDERS
IDLE : RUNNING :
STATUS
POINT
PF: …. PF: …. PF: …. PF: ….
Paddle gear box oil leakage
Fluid Coupling oil leakage
Paddle Coupling pads condition
Paddle blades
i) Condition
ii) Numbers available
Performance of regulator
Vibrations, if any
Cable Reeling Drum problem if any
Hydraulic oil level and leakage
Skirt board/skirt rubber condition
Condition of the mouth sealing doors
Whether feeling is at
centre, while in operation
Scraps/coal accumulation, if any
Lighting on paddle feeder
Ladder damage, if any
Electrical
i) Interlocks availability
ii) De-interlock switch availability
iii) Emergency Push Button availability
Any other defects
NOTE : The checklist include points pertaining to running as well as idle Paddle Feeders. Where
not applicable, indicate N/A
SIGNATURE
ACTION TAKEN
Signature :.................................................
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Appendix-8
COAL HANDLING PLANT

WALK DOWN CHECK LIST FOR CONVEYORS
IDLE : RUNNING :
Sl.No. POINT STATUS

IDLE CONVEYOR RUNNING CONVEYOR
1. Gear Box oil level/leakage.
2. Fluid Coupling oil leakage
3. Brake Condition
4. Abnormal vibration at drive
end/tail pulley/bend pulleys (if
any)
5. Safety guards for
i) Fluid Coupling
ii) Gear Flexible coupling
iii) Gravity Take-up
iv) Head-end return side guards
6. Belt running with sway
i) Under no load
ii) Under load
7. Whether feeding is at centre of
conveyor or not?
8. Belt joint defects, if any
9. Pulley's lagging condition
10. Deflector plates availability
11. Belt scrapers availability and
it's effectiveness.
i) External scrapper at
discharge pulley
ii) External scrapper at head-end
return side
iii) Internal scrapper at tail- end
12. Deck plates condition
13. Seal plates condition
14. Abnormality of rollers
operation
a) Carrying
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Sl.No. POINT STATUS

IDLE CONVEYOR RUNNING CONVEYOR
coal dust accumulation on cable
tray
30. Other points (such as gallery
vibration, openings to be clo-
sed, missing hand-rails etc.)
31. Coal accumulation on idle
conveyors
32. Adherance to safety norms
during O&M activities, if being
carried out
NOTE : The check-list include points pertaining to running as well as idle conveyor. Where not
applicable, indicate N/A.
Signature :
Date of Inspection :
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Appendix-9
(CHP OPERATION)
WALK DOWN CHECK LIST FOR CRUSHING SYSTEM
CRUSHER HOUSE CRUSHERS IN OPERATION :
Sl. POINT STATUS

No. CR: …. CR: …. CR: …. CR: ….
A. CRUSHERS
0.1 Gear box oil level/ leakage.
0.2 Coupling oil leakage
0.3 Coupling guards provided
0.4 Condition of Crusher doors &
availability of door locking wedges
0.5 Missing kick-off plate bolts
0.6 Missing Hammers (if Crusher is
idle)
0.7 Punchers/Coal leakage points
i) Top cover
ii) Receiving chute
iii) Discharge chute
iv) Crusher Body
0.8 Abnormal vibrations, if any
0.9 Hydro-jet pump defects, if any
10. Condition of Crusher screen
11. Scoop pump defects, if any (such as
Terminal box cover missing etc.)
12. Water leakage, if any
B. VIBRATIBG FEEDERS/
GRIZZLY FEEDERS
01 Motors availability
02 Missing loose foundation bolts of
the motors.
03 Vibrating Feeder tray condition
(whether caking is there).
04 Electrical defects (such as missing
terminal box covers etc.)
05 VF screening performance
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Sl. POINT STATUS

No. CR: …. CR: …. CR: …. CR: ….
C. OTHERS
01 Rack and Pinion Gate condition
02 Inspection door defects (near RPG)
03 Dribble chute condition (punctures,
if any)
04 Walk-way/Stair-case defects, if any
05 Any other defects
06 Coal spillage, presence of scraps &
condition of house keeping
07 Condition of lighting
08 Availability of fire water hy-drant
pressure, fire fightingand fire
detection systems
09 Fire hazard, if any, including coal
dust accumulation on cable trays
10. Adherance to safety norms during
O&M activities, if being carried
out
NOTE : The checklist include points pertaining to running as well as idle crushers where not
(SIGNATURE)
DATE OF INSPECTION: Name : ...........................................
Design : ...........................................
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Appendix-10
COAL HANDLING PLANT - OPERATION

WALK DOWN CHECK LIST FOR STACKER RECLAIMERS
IDLE : RUNNING :
Sl.No. POINT S/R-I S/R-II S/R-III

0.1 BOOM CONVEYOR
a) Gear Box oil level/leakage
c) Brake condition
d) Damaged idlers
e) Belt running condition
f) Scrapper condition
f) Skirt rubber condition
- Drive - end
- Tail - end
h) Pull cord
0.2 BUCKET WHEEL
a) Gear box oil level/leakage
c) Damaged buckets, if any
0.3 BOOM LUFFING
a) Oil leakage, if any
b) Hydraulic Cylinder condition
0.4 SLEWING
a) Gear box oil leakage
b) Brake condition
0.5 CABIN LUFFING
a) Oil leakage, if any
b) Hydraulic Cylinder condition
0.6 TRAVEL
a) Gear box oil level/leakage
b) Brake effectiveness
c) Travel drives availability
0.7 Rail clamp condition
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Sl.No. POINT S/R-I S/R-II S/R-III

0.8 Hooter availability
0.9 Interlock availability
10. Walkway/Stair case damage, if any
11. Control C.R.D. condition
12. Power C.R.D. condition
13. Pulley condition
14. Fallen Rollers in tripper position
- Carrying
- Return
15. Belt running condition on tripper.
16. Impact table condition
(fallen rollers, if any)
17. Any other points.
NOTE : The checklist include points pertaining to running as well as idle Stacker/Reclaimers.
Where not applicable, indicate N/A.
(SIGNATURE)
DATE OF INSPECTION Name : ...….........................
Design : ....................................
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Appendix-11
COAL HANDLING PLANT
WALK DOWN CHECK LIST FOR TRIPPERS
TRIPPER IN OPERATION : TRIPPER NOT IN OPERATION :
Sl. POINT STATUS

No. TRIPPER-….. TRIPPER-……
1. Travel Drive condition
a) Motor fan cover availability
b) coupling bolts
c) Drive Chain
d) Gear box oil leakage
e) Cable reeling drum condition
f) Brakes effectiveness
2. Pulley condition
a) Discharge pulley
b) Bend Pulley
3. Belt lining-out on tripper, if any
4. Rollers fallen/damaged
a) Carrying
b) Return
5. Skirt rubber condition,
If provided
6. Chute puncture, if any
7. Bunker grill damage, if any
8. Tripper rail defects, if any
9. Tripper stoppers availability
10. Ladder damage, if any
11. Flap gate condition
12. Any other defects
NOTE : The checklist include points pertaining to be operation as well as idle trippers. Where not
(SIGNATURE)
DATE OF INSPECTION:
Name : ...................................
Designation : .........................
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Appendix-12
COAL HANDLING PLANT
Ref No.: Date :
Sub : Plant Improvement Activities
A. EQUIPMENT/SYSTEM :
B. PROBLEMS FACED :
C. PROPOSED MODIFICATIONS & :
IT'S ADVANTAGES
D. AREAS BENEFITTED
Safety/Reliability/ :
Reduction in Outages/ :
Improvement/Effectiveness/ :
Effective Operation/ :
Energy Conservation/ :
Pollution Control/Maint. :
Time reduction/Financial :
dealings, if any. :
E. APPROX. COST :
i) Cost of Spares :
ii) Labour Cost :
iii) Total Cost :
F. PROPOSED BY
SIGNATURE
Name : ...................................................
Designation :..........................................
Dy. Supdt. (CHP-0) /Dy. Supdt. (CHP-M) / Dy. Supdt. (CHP-Plg.)

Supdt. (CHP) / (CH0-0)
Senior Supdt. (CHP) / (CHP-0)
Dy. General Manager (Fuel Mgmt.)
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Appendix-13
COAL HANDLING PLANT

EQUIPMENT CHANGE OVER SCHEDULE
DAY EQUIPMENTS
FROM TO
MONDAY
TUESDAY
WEDNESDAY
THURSDAY
FRIDAY
SATURDAY
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Appendix-14
LIST OF PERMITS
Sl. No. PTW. no./ date Name of the Name of Work / Defect. Expected Date Date & Time of Remarks
& Shift Equipment. and time of Cancellation
completion
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TITLE
Appendix-15
EQUIPMENTS NOT AVAILABLE

1. Paddle Feeders :
2. Crushers :
3. Conveyors :
4. Trippers :
5. Belt Weighers :
6. Magnetic Separators :
7. Metal Detectors :
8. DE/DS/Ventilation :
DATE SHIFT :
Signature of Shift-incharge
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TITLE
Appendix-16
(A) PERMISSIVE/PROCTION/INTERLOCK(S) BYPASSING OF CHP

EQUIPMENTS:
Date: _________
1 Name of the protection/Interlock to be bypassed:
2. Category of protection/ Permissive:
3. Equipment affected:
4. Condition under which these can be temporarily bypassed:
5. Name and signature of the person issuing/authorizing bypassing: ------------ -------------
6. Name and signature of the person implementing bypass: ------------- ------------
7. Date and Time of bypassing:
8. Notification Displayed/ Instruction to SCE:
(B) RESTORATION OF ABOVE PERMISSIVE/PROCTION /

INTERLOCK(S)
1. Date and Time of Restoration: ----------------------------
2. Name of the person involved in restoration: ----------------------------
3Acknowledgement of SCE: ----------------------------
Review: --------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------
Signature of Reviewing Authority: --------------------------------------------------
Extension if required: -------------------------------------------------------------------
Signature of Extending Authority: ----------------------------------------------------
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Section – V: Coal Stock Yard Management
CONTENTS
Page No.
1.0 Preamble 153
2.0 Introduction 153
3.0 Pile Management 153
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SECTION V: Coal Stock Yard Management

1. PREAMBLE
1.1. This Guidance Note specifies the requirements for Management of Coal Stock
yard effectively, economically and safely.
1.2. Coal stock yard is a location where coal is stacked for future use in a coal based
thermal power plant.
2. INTRODUCTION
General Information
2.1. Coal stock yard is generally designed to cater requirement of 15 days coal for
MGR fed station, 30 days coal for Indian Railway fed station and 45 days for
coastal stations. Actual stacking capacity depends on availability of land, Angle
of repose of coal, permissible stack height for particular type of coal.
2.2. Coal stacking to be done in such a way to prevent cyclic deterioration in coal
quality, to prevent/minimize spontaneous ignition of coal, to prevent sliding of
coal particularly during monsoon and to help in ease of reclamation of coal
whenever required.
3. PILE MANAGEMENT
3.1. Coal stockyard should be designed in such a way that for maximum duration of
the year, the air strikes the width and not the length of the stockpile for minimum
interaction between coal and air. The pile should be compacted thoroughly to
ensure complete absence of air inside the pile.
3.2. Coal piles should be trapezoidal in shape with their base having sufficient
clearance from rails and drains. Height of pile should not exceed the maximum
designed value of 10m.
3.3. Each pile should have covered surface drains on both sides all along the length.
Inner wall of drain (towards pile) should have holes and should be back-filled
with graded gravel and stone chips.
3.4. Piles should be regularly inspected for high temperature of coal/any smouldering
coal and suitable action to be taken to pour water/remove burning coal. Each
pile should have fire water hydrant valves all around the periphery. The core
temperature of the pile should be monitored by measuring with a suitable
thermocouple.
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3.5. In case of frequent auto ignition incidences in coal stockyard temperature of

piles at different locations to be measured at various depths so as to know the
trend and to decide as to which coal is to be reclaimed first. Temperature of coal
stockpile can also be monitored by installing swiveling infrared camera on high
mast located strategically at one corner of stockpiles.
3.6. During stacking coal in the piles should be spread out in horizontal layers of 1-
1.5 m depth and not in conical heaps and compacted for further stacking.
3.7. Freshly mined coal should be stacked and old coal should be used. An important
aspect in the good management of coal stack pile is the First in First out
(FIFO) principle.
3.8. March-June is the critical period for spontaneous fires and close monitoring
should be done during this period by regular inspection measuring temperature
of coal stock pile.
3.9. In case freshly mined coal has to be stacked over old coal, latter’s temperature
should first be measured. If the temp. is more than 50°C coal should be
drenched with sufficient water.
3.10. Lumps and fines should be stacked together and compacted.
3.11. Before stacking, the coal should be visibly wet so that condensation of vapours
in the air never takes place. Rather evaporation of moisture from coal to
atmosphere should keep coal stockyard cool.
3.12. Each stockpile should be segregated into various segments and records of
period of stacking, quality of coal (GCV) should be maintained. Coal of these
segments should be used based upon requirement and period of storage (i.e. on
first IN, first OUT basis).
3.13. Stacking of coal is to be done layer by layer (each of 1 to1.5 m height) and
compaction of each layer by dozer is to be done separately to lessen the
chances of sliding down during heavy rains and of spontaneous ignition of coal.
3.14. Coal stockpiles are to be kept covered by polythene sheets during rainy season.
This will prevent stacked coal to become wet /sticky. The sheets are to be kept
in place against the wind by keeping empty cement bags filled up with coal on
them.
3.15. For yard covering polythene sheet are procured well in advance, so that stock of
these polythene sheets are available before June every year. Suggested
Specification of polythene sheet is as follows: HEAVY DUTY BLACK LDPE
POLYTHENE SHEET 35M X 5M X 0.25MM THICK, AS PER IS:2508
(REVISED) WEIGHT 46KG APPROX. MATERIAL CODE: M0350210179
3.16. Top surface of stacked coal to be sloped outward for ease of water draining.
There should not be any concave cavity over the top surface in order to avoid
formation of water pool over there. While compacting coal layers with dozer the
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sides don’t get compacted. Therefore, 3-4 m wide coal from inner wall of
stockpile is to be removed with stacker reclaimer.
Coal heap out

ward slope
Horizontal surface ‘A’
Guard wall
Yard Conveyor
In a few stations coal feeding gets hampered during rainy season due to sliding of coal
of yard to the conveyor and surrounding areas. In NTPC’s new stations guard walls
(with holes to allow flow of water to drains) are provided in the yard to prevent coal
sliding. Stations, where guard walls are not provided, may study the feasibility of
providing guard wall in the conveyor side (as shown in the picture). If found feasible,
the same may be constructed.
YARD COVERING IN ONE OF THE STATION
4.
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SIDE GUARD WALL IN THE COAL YARD TO PREVENT

COAL SLIDING- IN ONE OF THE STATION
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SECTION –VI: Proper blending of Coal
Imported coal (including high CV domestic coal) is being received for blending with
domestic coal. In order to achieve consistent combustion characteristics and
"smooth out" extremes for stable operation of boiler, it is desirable that coal being
fired is having uniform properties. A well homogenized coal is expected to increase
flame stability, decrease furnace steam side temperature fluctuations, and reduce
specific coal consumption. During the process of blending the coals are to be
intimately mixed together in a specific ratio to obtain a product with well defined
specific properties and of uniform quality. For making a homogenous mixture of
imported and domestic coal the following blending guidelines are to be
followed:
a. Imported coal is first to be stacked in identified yard at earmarked stockpiles.
b. Mixing of imported coal with domestic coal in track hopper is to be avoided.
c. GCV of imported coal lying in different stockpiles is to be measured at

regular intervals and record is to be made available in CHP Control Room.
d. Imported coal is drawn from stack yard through stacker reclaimer/

underground hopper and is mixed with domestic coal (being conveyed from
track hopper) at the merging transfer point in a pre-defined ratio. Further
homogenization for a more uniform product takes place in upstream transfer
points.
e. Belt weighers of evacuation conveyor stream from track hopper and stacker
reclaimer machines are to be kept operational with rated accuracy and good
communication between control rooms, paddle feeder operator, stacker
reclaimer operator is to be established for maintaining blending ratio.
f. For the purpose of blending ' Coal blending guideline' framed for the plant to
be referred.
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SECTION - VII: Monsoon Action Plan for Coal Handling Plants
1. Monsoon action plan should be prepared well in advance and the same
should be monitored in various forums like Daily Planning Meeting, ORT and
SMC etc.
2. Common practices which are followed during monsoon action plan are
a) At least one or two piles should be covered with polythene sheets. This
prevents stacked coal to become wet /sticky.
b) All the drains in CHP including those in stockyards are to be thoroughly

cleaned
c) Availability of all dewatering pumps is to be ensured.
d) Operation of all air canons (if provided) is to be ensured.
e) Chutes are to be thoroughly repaired with new mother plates/liner plates

for smooth flow.
f) Belt Scrappers are to be set right/replaced for proper functioning by

these.
g) Worn out pulley lagging is to be replaced.
h) Critical conveyors belt healthiness is to be checked and suitably

replaced.
i) Effective monitoring with sufficient executives manpower is to be done.
j) Adequate additional labors are to be deployed at all critical TP’s round

the clock during monsoon.
k) Crusher’s healthiness to be ensured by replacing with new hammers.
Gap between hammers and cage bar assembly to be adjusted for better
scrapping of coal.
l) Stacker reclaimers servicing to be done for ensuring 100% availability.
158

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NTPC Limited LMI KORBA

Manual on Supply, Sampling & Analysis, Handling and Storage of Coal

In Dec.’2011 during the discussions on coal issues Audit Committee of Board

Various existing manuals/guidelines (some as OGN/OIN) related to coal have

2.2 Superseded Documents

a) Care in Operation & Maintenance of Coal Handling plant: LMI-02-R5/

b) Coal as-Fired sampling procedure: LMI 01-R2/CHEM/OGN- OPS- CHEM-

c) Sample Preparation of Coal: LMI 04-R 4/CHEM/OGN-OPS-CHEM-006

Section I (A) Guidelines on Supply of Domestic Coal:

The FSAs may be referred which have explicit provisions of Quantity/weighment,

Section I (B) Guidelines on supply of Imported Coal

Sl. No. Contents Page No.

1.0 Quantity Determination 04

2.0 Quality Inspection 05

3.0 Adjustment on Quality Variation 08

4.0 Reconciliation / Adjustment 14

5.0 Payment Terms 14

6.0 Taxes and Duties 19

Annexure A1 Pricing methodology (For high GCV Coal) 22

Annexure A2 Pricing methodology (For low GCV Coal) 27

Manual on Supply of Imported Coal

1.0 Quantity Determination:

(ii) Quantity determination of imported coal is done at NTPC power

Gross Calorific Value (ADB) :

Gross Calorific Value (ARB) : 5000 Kcal/Kg

2.0 Quality Inspection:

on the inspection results of the samples taken at NTPC power station

NTPC submits its report to the representative of the supplier at site. In

It is specifically agreed that the analysis results of such Referee Sample

3.0 Adjustment on Quality Variations:

3.1 For of High GCV coal:

In the event of variations over the quality parameters from base

a) Total Moisture {As Received Basis (ARB)}

If the actual total moisture as per sampling/analysis through joint

Weight of Coal to be reduced

Weight of Coal to be reduced

(where A is coal received weight, B is percentage value of Total

No correction shall be applied in case of decrease in Total Moisture

b) Gross Calorific Value {Air Dried Basis (ADB)}

Corrections are done as follows:

Corrected landed price (for GCV < 5800)

If Sulfur content is above the base parameter value of Sulfur, a penalty

Sulfur content below the base parameter value of Sulfur is ignored.

If the size as per sampling/analysis through joint analysis process at

Weight of Coal to be reduced = (A*B/100)*0.1

(Where A is quantity of coal received at power station, B is increase of

(Example- If fines particles is 30%, then B =(30-25) = 5)

f) After adjusting the received quantity at Power Station for quality

g) For the purposes of adjustment of coal quality the samples is taken

3.2 For ‘Low GCV’ coal:

In the event of variations over the quality parameters from base

a) Total Moisture {As Received Basis (ARB)}

Weight of Coal to be reduced (For B>35) = A x2x0.13x(B-(Cx(100-

(where A is coal received weight, B is percentage value of Total

No correction shall be applied in case of decrease in Total Moisture

b) Gross Calorific Value {As Received Basis (ARB)}

For correction of contracted landed price, NTPC’s test results at power

A correction is done as follows:

Corrected landed price (for5000>GCV >= 4500)

(Contracted landed Price at NTPC station Per Metric Tonne)x (GCV

Corrected landed price (for GCV < 4500)

0.8x(Contracted landed Price at NTPC station Per Metric

Corrected FOB price (for GCV >5000)

Weight of Coal to be reduced = (AB/100)0.1

Weight of Coal to be reduced = (AB/100)0.1