Thermal Power Plant

1. COAL HANDLING PLANT
Presentation by
Ashrant Dass

2. RAIGRH THERMAL POWER PLANT CONSISTING OF 4RAIGRH THERMAL POWER PLANT CONSISTING OF 4
UNITS(4X250MW), EACH OF 250MW CAPACITY .UNITS(4X250MW), EACH OF 250MW CAPACITY .
IT HAS BEEN DECIDED TO BRING COAL FROM NEARBYIT HAS BEEN DECIDED TO BRING COAL FROM NEARBY
CAPTIVE MINES BY CONVEYOR SYSTEM. IN CASE OF ANYCAPTIVE MINES BY CONVEYOR SYSTEM. IN CASE OF ANY
BREAKDOWN IN THE CONVEYOR SYSTEM , COAL SHALLBREAKDOWN IN THE CONVEYOR SYSTEM , COAL SHALL
BE BROUGHT BY DUMPERS & UNLOAD THE SAME IN TOPBE BROUGHT BY DUMPERS & UNLOAD THE SAME IN TOP
DUMPER UNLOADING HOOPERS.DUMPER UNLOADING HOOPERS.
ALL EQUIPMENT OF COAL HANDLING PLANT SHALL BEALL EQUIPMENT OF COAL HANDLING PLANT SHALL BE
SUITABLE FOR 24 HOURS A DAY, ROUND THE CLOCKSUITABLE FOR 24 HOURS A DAY, ROUND THE CLOCK
OPERATION.OPERATION.

3. COAL FLOW DIAGRAM
JPL COAL MINES
CHP MINE END
CROSS COUNTRY
CONVEYOR
CHP PLANT END
COAL BUNKER
PULVERISER
BOILER

4. THE ENTIRE COAL HANDLING SYSTEM DIVIDED IN THREE
SECTION.
1. CHP-1 situated inside plant boundary, capacity 1500 TPH
2. CHP -2 situated mine end, capacity 1000 TPH
3. CHP-3 Cross country conveyor which collect crushed coal
from CHP Mine end at TP-5 and discharge the same at TP-3 of
CHP inside plant, capacity 1500 TPH

5. VIBROFEEDER HOOPER
STACKERRECLAIMER
MAGNETIC SEPERATOR
DUH
COAL SAMPLING UNIT BUNKER
METAL DETECTOR
BOILER

7. DUMPER UNLOADING HOPPER
DUMPER UNLOADING HOPPER RECEIVE COAL FROM OPEN COST COALMINES,
TRANSPORTED
BY TRUCKS AND WILL BE UNLOADED INTO HOPPER AMONG THREE SIDE AT A TIME.
DEVIDED
IN TWO SECTION EACH CAPACITY IS AROUND 120 MT.SIX DUMPER CAN BE DUMPED
INTO
HOPPER AT A TIME.MAXIMUM COAL SIZE 1000 MM.
CHAIN FEEDER- 2 NOS
A conveyor comprising one or two endless linked chains with crossbars
or flights at intervals to move the coal or mineral. The loaded side of
the conveyor runs in a metal trough, while the empty side returns along
guides underneath. The material is transported on the conveyor partly by
riding on the chain and flights and partly by being scraped along in the trough.
MAKE: SWETHA ENGG
TYPE: FLIGHT BAR TYPE CF-1/CF-2
CAPASITY: 1000 TPH

8. ABON SIZER
Low Speed Sizing Technology is the employment of a combination of high torque / low roll
speeds and tooth profiles to arrive at specified end product sizes with a minimum of fines
production.
ADVANTAGE:
ROM feed size up to 1500 mm (60”)
Capabilities in excess of 10,000 mtph
Minimal fines creation
Insensitive to clay and sticky materials
Pre-scalping of undersize not required
Exceptionally low headroom requirements
Simple infrastructure requirements due to minimal dynamic loads placed on the supports
and structure
Ability to start up under a full load
Long wear life of consumable components due to positive bite and minimal feed slip.
TYPE & SIEZE: LOW SPEED SIZER/6492 X 2884 X 1100 MM
MAKE: ABON
CAPACITY :1000 TPH
MANUFACTURER:ABON ENGG

9. COAL CRUSHER
 Ring granulator crusher having nos. of ring hammers mounted to rotor disc in a
suspension.Due to centrifugal action coal is being crushed between wear plate and
hammer and coal sizes is maintained by adjusting the wear plate.
 Coal will crushed into two stage, in fist stage coal will crushed 250 mm to 50 mm
and in second stage 50 mm to 25 mm.
 NOS OF RING GRANULATORTYPE CRUSHER – 04 Nos.
Model: 1017U
Capacity: 1000 TPH.
Manufacturer: L&T Limited.
Supplier: FFE Minerals, Chennai

10. BELT CONVEYOR – 1200 width (3141 Rmtr.)
Belt Conv. – 1A (length): 193 meter.
 Belt Conv. – 1B(length): 183 met.
 Belt Conv. – 2A/2B(length): 389 met. x 2 Nos.
 Belt Conv. – 3A/3B (length): 214 met. X 2 Nos
 Belt Conv. – 4A(length): 124 met.
 Belt Conv. – 4B(length): 113 met.
 Belt Conv. – 5A (length): 226 met.
 Belt Conv. – 5B (length): 232 met.
 Belt Conv. – 6A (length): 59 met.
 Belt Conv. – 6B (length): 65 met.
 Belt Conv. – 7A (length): 83 met.
 Belt Conv. – 7B (length): 72 met.
 Belt Conv. – 2C/2D (length): 117 met x 2 Nos
 Belt Conv. – 1C (length): 81 met.
 Belt Conv. – 1D (length): 86 met.
 Belt Conv. – 1N/1P (length): 92 met.
Belt Conv. – 8 (length): ( 1400 width) 438 mtr

11. TRAVELLING TRIPPER – 02 Nos.
Type: Motorized Traveling type
Capacity: 1000 TPH
Travel speed:15 m/min
Manufacturer: Domacls Engg. (P) ltd
Plant Location: CHP MENE END,TAMNAR
Industry: POWER
Major Equipment:
Material Handled: Coal
Process:
This 1400 wide tripper travels along a belt conveyor and discharges coal into a series of
storage bunkers along the path or at the end of the conveyor
Direct Bunker Loading: As the tripper moves along the conveyor, a position switch will
stop it directly over a bunker. The tripper fills the bunker evenly on both sides until a level
indicator inside the bunker tells the tripper the bunker is full. When the bunker is filled, the
tripper moves on to the next bunker.
Continuous Handling: As the tripper is moving and aligning over the bunkers, it does not
stop moving coal on the conveyor. While in transit the tripper feeds coal through its center to
a bunker at the end of the belt conveyor
PLC Controlled: All movements of the tripper are automatically controlled. However
manual control is available. Level indicators signal when the bunkers are empty or full

12. COAL SAMPLING UNIT
Location : Transfer point –5.
Quantity : 1 set.
Type : Automatic two stage.
Material handled : Crushed coal.
Material temp. : 50 degree c max.& 5 degree min.
Conveyor capacity: 1500 MTPH.
Belt width : 1400 mm.
Belt speed : 3.0 m/s

13. STAGES INVOLVING IN CHP
 Receiving ROM coal at DUH & reclaiming from hopper & feeding in to
primary crusher.
 Stage wise crushing i.e. primary, secondary, tertiary crushing.
 Pre screening & post crusher screening.
 Coal conveying on TP to next TP to meet process requirement.
 magnetic separation, metal detector, on line weighing, surge hopper,
intermittent storage & blending as per process requirement.
 Long distance transportation.
 Feeding in to boiler bunker.
 storage in stock yard & reclaiming from the stock yard.
 Yard mgt. like fire fighting , compaction, covering with tarpaulin,
drain network cleaning.
 CC camera for regular monitoring of plant & equipment.

14. DUH
CONV 1
TP 1
Suspended
Magnet in
Pent House
CONV 2
TP 3 CONV
3A/B
TP 4
CONV 5
CONV 6
CONV
5A
Stacker-Reclaimer
StockPile
StockPile
TP 3A
TP 4A
TP 5
CONV
4A/B
TRAVELLING TRIPPERS ON BUNKER FLOOR
ILMS
COAL FLOW DIAGRAM – CHP
INPLANT
RBF

15. INLINE MAGNETIC SEPARATOR – 3 Nos
Type: Electro Magnet, Inline arrangement.
Make: Power Build limited
mounted on Bc-3A ,3B, BC8
SUSPENDED MAGNET – 02 No.
Model: SMNR- 135/ 50 OA, SM 1 and SM-2
Manufacturer: Power Build limited
VIBRATING SCREEN – 02 No,
Type- Spring mounted,
Capacity- 500TPH,
mounted at screen house
METAL DETECTOR – 02 Nos.
Make:
Type: Electronic coil
Manufacturer: Electromag Device PVT. Ltd

16. INSTRUMENTATION IN CHP
PROTECTION INSTRUMENT
MEASURING INSTRUMENT
CONTROL ROOM INSTRUMENT

17. INSTRUMENTATION
Z E R O S P E E D B E L T S W A Y P U L L C H O R D
P R O T E C T I O N I N S T R U M E N T

18. CONTROL ROOM INSTRUMENTATION
 PLC based control system shall be
configured of 1:1 not redundancy having
CPU of word length 32 bits minimum &
serial data link interface module for
connecting input /output
modules,redundant communication
processors, memory modules & power
supply units.
 The power supply shall be derived from
single phase , solid state 240V +_1% A.C.
UPS with Ni-Cd type battery to provide
power to system for at least 30 minutes
in case of power black out.
 SYSTEM HARDWARE
SPECIFICATION
 Type : Enclosed self supporting.
 Enclosure class: IP-42
 Card mounting: 21” rack
 Harmony cycle time: 0.5 micro
second
 I/o port: DMA , Program control

19. METAL DETECTOR
Type : Electronic
Location : On conveyor belt no. 4A & 4B
Material handled by belt: Crushed coal of (-) 20 mm size.
Bulk density : 800 kg /cu.m for volume calculation & 1000 kg /cu.m for
weigh calculation .
Conveyor capacity : 1500 MTPH (Rated & Design)
Purpose of installation : To protect Coal mill.

20. VIBRATING FEEDER
Type : Electro-Mechanical
Location : Under dumper unloading hoppers .
Bulk density (volumetric) : 0.8 MT/cu.m
Capacity : 0-500 MTPH
 (equipment design) : 1.0 MT/ cu.m

21. MACHINE FEATURES
CAPACITY :-1500 TPH – (STACKING )
1500 TPH – ( RECLAIMING)
MACHINE WEIGHT :- 345 MT
BOOM LENGTH :- 41 MTR
DRIVE KW :- 8 x 7.5 KW ( LONG
TRAVEL)
BOOM CONVEYOR KW :- 1 x 110 KW
BUCKET WHEEL DRIVE :- 1 x 110 KW
SLEW DRIVE :- 2 x 11 KW
COUNTER WEIGHT :- 138 MT

22. MACHINE FEATURES
CAPACITY :-1500 TPH – (STACKING )
1500 TPH – ( RECLAIMING)
MACHINE WEIGHT :- 345 MT
BOOM LENGTH :- 41 MTR
DRIVE KW :- 8 x 7.5 KW ( LONG
TRAVEL)
BOOM CONVEYOR KW :- 1 x 110 KW
BUCKET WHEEL DRIVE :- 1 x 110 KW
SLEW DRIVE :- 2 x 11 KW
COUNTER WEIGHT :- 138 MT

23. Top of rail, EL(+)0416
ERECTED
EQUILISING BEAM
TRIPPER LEGS
ELECTRIC GANTRY
TREIPPER STRUCTURE
MAST STAY
UPPER MAST
INNER BOOM
LINK
SLEW DECK
SLEW RING
BASE FRAME
COMPENSATING
BEAMS
10-BOGIE WHEEL
ASSY
6-BOGIE WHEEL
ASSY
ERECTION STATUS OF STACKER-RECLAIMER
Cumulative achieved 368.07 MT out of 387 MT. For the month achieved
16.78 MT against a target of 36 MT.
BOOM LINK
BOOM
CONVEYOR
SLEW DRIVE GEAR
BOX
Cylinde
r
Final reading to send
EDRC for additional WT
if any
4 nos. of CWT
Bucket
Wheel
assembled
with Buckets
& Chute

24. 1950
11401005012
200
12
50
CONVEYOR 4A/4B CROSS-SECTION
TRAVELLING TRIPPER WHEELS

25. CONVEYOR 2 :
BELT LAYING COMPLETED

26. C2 – TAIL PULLEY C2 – FEED END SKIRT
C2 – HEAD C2 – GRAVITY TAKE UP

27. TRANSFER POINT 1 (TP 1)
TP 1- From DUH
TP 1-From TP 3
> Sheeting work Completed

28. COAL
HANDLING
PLANT
(INSIDE PLANT)
Larsen & Toubro
Limited,
The 9rd
November 2006