INDUSTRIAL TRAINING

ON

NTPC DADRI

submitted to:-Mr. A.S.PARMAR

Prepared by:-VIKAS Roll no.-0814340053 B.Tech (ME) 4th year

CONSTRUCTION AND WORKING OF COAL HANDLING PLANT

5/1/2012

INDEX Introduction. Availability of Coal in India. Transportation of Coal. Analysis of Coal. General Layout of CHP. CHP Auxiliary And Equipments

INTRODUCTION
What is CHP? CHP (C- Coal, H- Handling, P- Plant) Which properly handles the coal from its receipt to transferring it to bunkers. Objective of CHP : To

supply the quanta of processed coal to bunkers of Coal mills for Boiler operation. To Stack the coal to coal yard.

AVAILABILITY OF COAL IN INDIA.

Mostly E and F grade coal used in India. Blending Is Done To get Average D Grade.

Grade

C.V. ( K Cal / Kg. ) > 6200 5601-6200 4941-5600 4201-5940 3361-4200 2401-3360

% Ash + Moisture

A B C D E F

19.57 19.57 - 23.97 23.92 - 28.69 28.69 - 34.05 34.06 - 40.14

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40.14 - 47.10

TRANSPORTATION OF COAL
5 ways of Transportation.

Best and Cheap facility at Doorstep

1. Railways. 2. Ropeways. 3. Roadways. 4. waterways. 5. Airway.

Available only for TPS nearer to coal mines

Fear of thief

waterway may not be possible till TPS and Problem of recalling arises if coal dip in water Have to build Runway near TPS which is very costly.

Daily on an average around 30,000 Tone of Coal is required for a typical 2000 MW Station. The required coal is supplied through Rail wagon. If the power station is away from coal mines then it is fed through Indian Railway system other wise for pit head station it is done through Merry Go Round railway system

Main feature of MGR Loading System

This system calls for high-speed load- outstation at the mines It consists of one or two loading silos depending upon the coal requirement of the linked power station The capacity of the silos for the NTPC project varies between 2400 ton/4000 ton.
The silos are cylindrical and fed by twin belt conveyors. For accurate weighing of coal to each wagon, Load cells are provided with silos.

A sampling unit suitable size coal is provided at the feed point of the loading silo to collect samples for quality analysis

The loading operation of the coal rake takes place while it is moving under the silo at a speed of 0.8 k.m. per hr.

Wagons are provided with bottom discharge hoppers fitted with pneumatically operated automatic door actuating mechanism. Line side equipment is installed by the track hopper for initiating the opening of doors in groups of 10-14 wagons. The unloading operation of 60 tonne per load wagon takes about 20/30 seconds.

ANALYSIS OF COAL
Chemical

Analysis of Coal:-

Sample of coal is randomly collected from each rake and detailed chemical analysis, calculation of calorific value is carried out and is confirmed whether it is as per agreement with the coal mines or not.

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LOADING

1 May 2012

PMI Revision 00

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COAL UN LOADING
At NTPC end, Coal is unloaded in the Track hoppers. Track Hopper, normally of 200-250m length.

After placing the wagons on the hopper, electrical pulse is given to the pneumatic device for opening the bottom doors.

Coal rushes down due to its own weight. When the track hopper is empty, it takes only 20 seconds for unloading one wagon i.e. 60 Tons.

This coal falls on a T table, over which a paddle feeder runs and pushes the coal on to a conveyor.

TRACK HOPPER

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COAL-HANDLING SYSTEM:
Coal handling system is the arrangement for transferring of coal from coal-wagons to coal-bunker or coal stock yard. It also provide arrangement for separation of material impurities, crushing of coals, Coal sampling etc. In the coal handling system of NTPC stations, three coal paths are normally available Path A - direct conveying of coal from track hopper to boiler bunkers. Path B - from track hopper to stockyard 16 Path C - from stockyard to boiler bunkers. The storage facilities at the stockyards have been provided only for crushed coal.

COAL HANDLING PLANT LAYOUT

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COAL HANDLING
The coal handling system is designed to provide 100% standby for all the equipment and conveyors. The capacity of the coal handling system for super thermal stations varies from 1200 to 2000 t/h, normally, for a stage of 1000 MW,

GENERAL LAYOUT OF CHP

Wagon Tippler
Hopper

Crusher House
Surge Hopper

Feeder Conv. Belts

Vibrating Screens

Crushers

Tripper Trolley
Bunkers

CHP Auxiliaries

OPERATIONAL CYCLE
Bunkering Cycle

Stacking Cycle

Reclaiming Cycle

BUNKERING CYCLE
From W/T Crusher House
Surge Hopper

Vibrating Feeder

Crusher

Bunkering Belts

Bunkers

STACKING CYCLE
From W/T Crusher House
Coal Is not required if bunker is full or Due any maintenance

By-Passed Coal

Bunkering Belts

Stacking Belts

Bunkers

Crushed Yard

RECLAIMING CYCLE
From W/T
If Outer Supply of coal Is Not Present

Crusher House NonCrushed Yard Reclaiming Belts

Stacked Coal

Bunkering Belts

Bunkers

Crushed Yard

STACKER CUM -RECLAIMER

This is used for stacking and reclaiming the coal from stock yard. Generally two stacker claimers have been provided at each of the NTPC's projects. Their normal capacity is 200 tons per hour and maximum design capacity is 450 tons per hour. The stacker reclaimer generally consists of (a) bucket wheel or digging wheel (b) boom conveyor. While the belt conveyor carrying the coal for the stock yard is in the same direction but the direction of the boom conveyor with respect to stacking and reclaiming is opposite. Digging Wheel The digging wheel is use for cutting and lifting the coal from the stock yard to the belt used for transfering coal from the yard. The above transfer takes place in case of reclaiming the coal only.

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Stacker Reclaimer

STACKER CUM -RECLAIMER

During stocking operation, the coal from the crusher house is diverted towards the stockyard conveyor at a transfer point TP2/ TP3. The above conveyor discharges coal to the boom conveyor through a discharge chute. The boom conveyor, running in the forward direction, creates coal stacks. During reclaiming, coal from the stock yard falls on the boom conveyor with the help of the bucket wheel and the boom conveyor, during this period, rotates in backward direction. The coal from central chute falls on the conveyor belts used for transferring the coal from the stock yard. By this way, the coal moves on the underground conveyor belts connected to the main belts. A 6.6 KV motor is used for running the stacker-cumreclaimer and has a cable reeling drum on which flexible cable is wrapped.

STACKER CUM -RECLAIMER

This is used for stacking and reclaiming the coal from stock yard. Generally two stacker claimers have been provided at each of the NTPC's projects. Their normal capacity is 200 tons per hour and maximum design capacity is 450 tons per hour. The stacker reclaimer generally consists of (a) bucket wheel or digging wheel (b) boom conveyor. While the belt conveyor carrying the coal for the stock yard is in the same direction but the direction of the boom conveyor with respect to stacking and reclaiming is opposite. Digging Wheel The digging wheel is use for cutting and lifting the coal from the stock yard to the belt used for transfering coal from the yard. The above transfer takes place in case of reclaiming the coal only.

STACKER-CUM- RECLAIMER
.

Coal to/from stock yard Generally 2nos

Capacity ---200T/hr
Maximum---400T/hr
Bucket wheel Boom conveyor

WAGON TIPPLER

These are used to unload the coal wagons into coal hoppers in very less time (e.g. 20 wagons/hr. or more).
Weighing of coal is carried out at wagon tippler. Normally 55-60 metric ton of coal come in each wagon.

Wt of the coal =Wt. of loaded wagon Wt. of empty wagon

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TRIPPERS
1 May 2012

To stack material at desired bunker Provided with wheels which moves on rails parallel to conveyor.
Three types motorized tripper
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Belt propelled manually operated tripper

Winch driven tripper

WAGON TIPPLER DRIVE SYSTEM

Motor

Thruster Brake

G/B

Pinion Spur Gear

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GENERAL LAYOUT OF W/T

Wagon tippler

Mesh of 250 mm * 250 mm

Hopper

Vibrating Feeder

Conveyor Belt
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To crusher House

EQUIPMENT USED IN W/T

Water Sprinkler System. Dust Extraction System.

CONVEYOR BELT SYSTEM

Construction of Conveyor Belt Conveyor Belt Drive System Counter Weight Idlers Protection System

Interlocking Magnetic Separator

CONSTRUCTION OF CONVEYOR BELT

Synthetic rubber. 4 ply means 4 nylon net in between 2 mm thick rubber coating is used. At KTPS belt of 1000 mm width is used. Width varies from 500 mm -1400 mm.

Strength = 600 N 1000 mm

Net

CONVEYOR BELT DRIVE SYSTEM

Fusible plug Head End Pulley

Motor

G/B

Fluid Coupling

Filled with 3/4th oil

Tail End Pulley Belt Speed oSpeed before crusher 2.4 m/sec oSpeed After Crusher 2.7 m/sec

CONVEYOR BELTS
Made of diff. Layers or piles of fabric duck with rubber protected by a rubber cover on both sides & edges. Fabric duck are designed to withstand tension created in carrying the load . Nylon rubber cover protect the fabric duck. Material =fire resistant grade. Belt Width=1600 mm. Strength= 1000/1250 kN. Belt speed=3.2-3 m/s. Belt length=20km.
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IDLERS

Carry Side

Return Side

Self Alignment

Impact

Return Roller

Return Adjustment Roller

( Installed after every 25m )

Below Discharge chute ( rubber coating )

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ANGLE OF IDLERS

Angle 20

Merits No middle idler is overloaded

Demerits More Coal Derailed

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Coal not Derail.

Middle idler is overloaded

PROTECTION SYSTEM
Interlocking is used for safety purpose. If any belt fails all other belts stop working which are interconnected.

Magnetic Separator is used to remove metal particle from coal conveyed through conveyor belt for improving boiler efficiency.

SEPARATING FOREIGN MATERIAL FROM CONVEYOR

MAGNETIC SEPARATOR Any ferrous material on the conveyor will be lifted from the moving conveyor. No Tripping involved. MS is interlocked with Conveyor start up. When ferrous Metal is picked up, the MS is moved from the Conveyor, demagnatised and the metal piece is removed. METAL DETECTOR Any Metal with an area of 100 Sq Cm will be detected. Conveyor is tripped after detection. MD is not having interlock with start up. A sandbag is dropped near the Metal piece for easy location

CRUSHING MECHANISM IN CHP

Three Stage Crushing System is used in Plant.

1.Double Roll Crusher 2.Rotary Breaker Crusher 3.Impact Crusher

W / T No.4
600 mm

DRCR
250 mm Stage 1

RBCR
80 mm Stage 2

Impact

Stage 3

20-25 mm

DOUBLE ROLL CRUSHER ( DRCR )

Roller

Teeth

300 mm

250 mm

ROTARY BREAKER CRUSHER ( RBC )

Striking Plate Hole of diameter 100 mm

Stone shell

80 mm

IMPACT CRUSHER
5/1/2012

Coal Hammer

30 mm

Rotor

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TRACK HOPPER TO CRUSHER HOUSE

Below track hopper paddle feeder arrangement is provided to unload coal to coal conveyors. The 200mm coal as received at the track hopper is fed to the crusher house through 1A & 1B conveyors.

IN THE CRUSHER HOUSE

Vibrating Screen :The function of the vibrating screen is: To send the coal having size of less than 20mm to belt feeder through the bypass chute bypassing the crusher and To send the coal of more than 20mm size to the crusher.

CRUSHERS
To crush the coal from 200mmto 20mm size received from vibrating screen Crusher hammer are made of MAGNEESE STEEL . Hammer row -4(stage 1) (a)Row-1 & 2 =18 hammer each (b)Row-3&4=20 hammers each

No of hammer in each Crusherstage-1 = 76 hammers stage-2 = 92 hammers Weight of each hammer=18.5kg Crushing motor rating -740kw/3.3kv Life of hammer =4 lac MT of coal Normal capacity=600 tons/hr