The presentation describes the coal Handling Plant of a Thermal Power Station. The auxiliaries and operational features also described in the slides. It is very useful for the new trainee engineers in the Power Plants

1. 3/12/2020
WELCOME
TRAINEE
ENGINEERS

2. 3/12/2020
DESCRIPTION
& WORKING
Manohar
Tatwawadi

3. 3/12/2020
 Coal is a principle fuel in thermal plant.
 Coal is consumed in large quantity.
 Hence layout of CHP should be
simple,robust,reliable and low maint.

4. 3/12/2020
CONSUMPTION OF COAL
GENERATION PER HOUR PER DAY/SET
210 140 MT 3360 MT
500 330 MT 7920 MT

5. 3/12/2020
CONSUMPTION OF COAL(KTPS)
GENERA
TION
PER
HOUR
PER
DAY/
SET
No. OF
SETS
TOTAL
REQRT.
IN mt.
120 MW 80 MT 2000
MT
4 8000
210 MW 140 MT 3360
MT
3 10000
TOTAL 420 MT 10000
MT
7 18000

6. 3/12/2020
CONSUMPTION OF COAL(CSTPS)
GENERA
TION
PER
HOUR
PER
DAY/
SET
NO. OF
SETS
TOTAL
210 140 MT 3360
MT
4 14440
500 330 MT 7920
MT
3 23760
TOTAL 420 MT 10000
MT
7 38200
STORAGE CAPACITY OF COAL YARD = 5,00,000 MT
ESTIMATED COAL REQUREMENT = 7 MILLION TON.

7. 3/12/2020
3 SECTIONS OF CHP
 Management of Coal
 Transportation of Coal
 Handling of Coal

8. 3/12/2020
CONSTITUENTS OF COAL

9. 3/12/2020
COAL - A Comparison
AGENCY
CAL
VALUE
ASH %
COAL
MILL OPN
BHEL 4500
Kcal/Kg
15 % 4 Mill Opn.
MSEB 2800 –
3500
Kcal/Kg
30 – 40 % 5 Mill Opn.

10. 3/12/2020
Management of Coal
 Central Govt.
 CIL
 WCL
 Railway
 Mah.State

11. 3/12/2020
TRANSPORTATION OF COAL
MODE OF COAL TRANSPORT
1. ROADWAYS
2. RAILWAYS
3. ROPEWAYS

12. 3/12/2020
ROADWAYS
Coal is carried in trucks.
8-10 mt coal per truck.
Requires more time and manpower.
Coal mines should be near (100-150 km).
Coal is lost / waste in transit.
 Hence not in use for large power stations.

13. 3/12/2020
RAILWAYS
 Unloaded with the help of WAGON TIPPLER
 One Rack consist of 58 Wagons.
 Each wagon contains 58 MT of coal.
 13/25 wagons can be tippled in an hour.
 Wagon movements are controlled by “Bettle
Chargers”
 Demurrage charges on racks.
 Most popular mode of transport.

14. 3/12/2020
WAGON TIPPELERS
WAGON TIPPLER
SIDE TIPPLER ROTORY TIPPLER

15. 3/12/2020
SIDE TIPPLERS
 57” ROTASIDE ELECON MAKE TIPPLERS
 CAPACITY : 13 Wg/HR.
 Wagon is unloaded in side hopper
IN HAIL
OUT HAUL
BETTLE CHARGER
BETTLE CHARGER
LOADED WAGONSLOADED WAGONS
UNLOADING HOPER

16. 3/12/2020
SIDE TIPPLERS
 57” ROTASIDE ELECON MAKE TIPPLERS
 CYCLE OF OPERATION :
– 1. Gross weight----------- 15 Sec.
– 2. Tippling ( 1400 )-------- 90 sec.
– 3. Pause--------------------- 5 Sec.
– 4. Return--------------------- 90 Sec.
– 5. Tare weight-------------- 15 Sec
– =============================
TOTAL TIME REQD.----- 210 Sec.

17. 3/12/2020
RING / ROTORY TIPPLERS
 High capacity Tipplers
 Capacity : 25 Wagons/Hr.
 Time Reqd. : 60 Sec.
 Wagon is unloaded in hopper under the
tippler.

18. 3/12/2020
TRACK HOPPERS
 Provided for 500 MW Units at CSTPS.
 Unloaded in track hoppers
 Holding capacity of track hopper = 4500 MT
 Max. size of coal = 600 mm.
 BOBR wagons are used.
– (Bottom Opening Bogie on Rails)

19. 3/12/2020
ROPEWAYS
 Coal Mines should be in vicinity of P.S.
 Assured supply of coal @ 100 - 250 T/H.
 Economical
 MSEB Property.
 High Maint.

20. 3/12/2020
ROPEWAYS ( Contd)
TYPE OF ROPEWAYS
MONO-RAIL BI-CABLE
BUCKET TYPE
TRAM CAR TYPE

21. 3/12/2020
MONOCABLE ROPEWAY
Cap : 100 T/h
Bucket Cap : 1.0 T/H
Haulage RopeBuckets

22. 3/12/2020
Bi-CABLE ROPEWAY
(Bucket Type)
Track Rope Haulage Rope
Bucket

23. 3/12/2020
Bi-CABLE ROPEWAY
( Tram Car Type )
Track Rope
Haulage
Rope
Line Cap : 250 T/H
Car Cap : 2.5 T/H
Return Side Track Rope

24. 3/12/2020
SILEWARA GROUP OF
ROPEWAYS
A B
D
P C
E
KORADI
KAPARKHEDA
PATAN
SAWANGI PIPLA VALANI SILEWARA
PA -MONO-CABLE(BUCKET)
AB -BI-CABLE(TRAM CAR)
BD -BI-CABLE9TRAM CAR)
CD -BI-CABLE(BUCKET)
DE -BI-CABLE(TRAM CAR)
LENGTH- 4.0 KM
BUCKETS - 92 (16 Parking)
LINE CAP- 75 T/H
BUCKET CAP-1.0 T
Hal.Rope - 33 mm
Speed - 168 m/min
LENGTH- 1.5 KM
BUCKETS- 32
LINE CAP-200 T/H
BUCKET CAP-2.5 T
Speed - 600 ft/min
HR-25 / TR-43/32 mm.
LENGTH-1.75 KM
BUCKETS- 63(57 Parking)
LINE CAP-200 T/H
BUCKET CAP-1.8 T
Speed - 650 ft/min
HR-25 / TR-48/33 mm
LENGTH-3.0 KM
BUCKETS-129
LINE CAP-200 T/H
BUCKET CAP-2.5 T
LENGTH- 3.0 KM
BUCKETS- 67
LINE CAP- 200 T/H
BUCKET CAP-2.5 T

25. 3/12/2020
K - K ROPEWAY
KAMPTEE
BINA
KORADI
K
K
LENGTH - 6.6 KM
CAPACITY - 200 T/H
BUCKETS - 120
BUCKET CAP - 1.8 MT
HR-28 / TR-54/34 mm
LENGTH - 7.0 KM
CAPACITY - 275 T/H
BUCKETS - 150
BUCKET CAP - 1.8 MT
HR-28 / TR-54/34 mm

26. 3/12/2020
Concept of MGR Railway
Coal mines near to the power
station.
Power Station Property
Most economical mode.
Low maint.
Existing at CSTPS

27. 3/12/2020
MGR
POWER STATION
COAL MINES
Railway
wagon
Rails

28. 3/12/2020
GENERAL LAYOUT OF CHP
Wagon tippler
Crusher House
Bunkers
Tripper Trolley
Conv. Belts Vibrating
Screens
Crushers
Feeders Surge
Hopper

29. 3/12/2020
STACKING / RECLAIMING
CYCLE
Bunkers
Stacking Belts
Reclaiming
Belts
Crushed
Yard
Non-
Crushed
Yard
From 3 R’s
Crusher House
Bunkering
Belts
By-Passed Coal

30. 3/12/2020
CHP : Auxiliaries and Equipments.
Conveyor System
Wagon Tipplers
Coal feeders
Crushers
Coal trippers
Stacker-Reclaimers
Protection System.
Interlocks
Operating Cycle

31. 3/12/2020
Conveyor System
• Conveyor Belts
• Idlers
• Pulleys

32. 3/12/2020
Conveyor Belt
System
HEAD PULLEY
TAIL PULLY
CONV. BELT

33. 3/12/2020
Conveyor Belt
System
HEAD PULLEY
TAIL PULLY CONV. BELT
IDLERS
RETURN SIDE

34. 3/12/2020
DIFFERENT LAYOUTS
OF THE CONV. BELTS
• Moves along the centre of its axis.
PLAN VIEW

35. 3/12/2020
DIFFERENT LAYOUTS
OF THE CONV. BELTS
• Moves along the centre of its axis.

36. 3/12/2020
DIFFERENT LAYOUTS
OF THE CONV. BELTS
• Moves along the centre of its axis.

37. 3/12/2020
CONVEYOR BELTS
 Construction:
 Rubber+ Cotton Threads.
Rubber + Fiber Threads
Rubber + Steel Wires
 Ply Rating :
 4 Ply
 5 Ply
 6 Ply

38. 3/12/2020
BELTS : Ply Rating
1ply
2 ply
3 ply
FIBRE

39. 3/12/2020
Belts : Quality
 Long Life
 Strength
 Toughness
 Light
 Elastic
 Pliability

40. 3/12/2020
BELTS : Labeling
1050/48/5/3/1.5/B/ L
WIDTH WT/ UNIT
LENGTH
NO.OF.
PLY
TOP RUBBER
THICKNESS
BOTTOM
RUBBER
THICKNESS
CLASS
LENGTH
900 mm
1050 mm
1200 mm
1400 mm

41. 3/12/2020
BEELTS : Tensioning
3 TYPES
1.Screw Operated
2.Winch Operated
3. Gravity Take-ups

42. 3/12/2020
BELTS : Automatic Gravity Take-ups
To maintain slack side tension
To permit length variation due to belt
stretch/shrinkages
Removal of starting jerks
Extra length for vulcanizing.

43. 3/12/2020
BELTS : Automatic Gravity Take-ups
Bend Pulley
Counter
Weights
Tensioning
Pulley
Guides
Conv. Belt
Head
Pulley

44. 3/12/2020
IDLERS
Consists of 3 rollers
Rollers are fitted with bearings/Life sealed
bearings.
Profile makes an arc of a circle to avoid
sharp bends to increase belt life.
Fitting arrangement : 2 types
Fixed
Detachable

45. 3/12/2020
IDERS : Diagram
Roller
Conv.Belt
Brackets
Return Idler

46. 3/12/2020
DETACHABLE IDLERS

47. 3/12/2020
IDLERS : Types
 Carrying Troughing Idlers
 Carrying Troughing self aligning Idlers
 Return Plain Idlers
 Return self aligning Idlers
 Impact Idlers.

48. 3/12/2020
IDERS : Diagram
CARRYING TROUGHING IDLER
Roller
Conv.Belt
Coal
Brackets
Return Idler

49. 3/12/2020
RUNNING OUT OF THE BELT
 MISALLINGNMENT BETWEEN HEAD & TAIL PULLEY
 MISALLINGNMENT OF THE IDLERS
 LOCKING OF TRAINING IDLER
 UN-EVEN LOADING OF COAL ON THE BELT
 IMPROPER VALCANIZING JOINT
 DEFLECTION IN SUPPORT TOWERS
 CHOKING OF CHUTES

50. 3/12/2020
SELF ALLIGNINING IDLERS

51. 3/12/2020
IMPACT IDLERS
Why do U need Impact
Idlers?
BELT
Coal falling from
heighted chute
Marks

52. 3/12/2020
IMPACT IDLERS
Rubber Rings
IDLER
Falling
Coal
Vertical Chute

53. 3/12/2020
PULLEYS :
 These are of heavy cast iron
 Driving pulleys are faced with ferodo or
similar frictional materials.
 The diameter of pulleys are large enough to
reduce the belt stresses.
 Width of the pulleys are 150 mm more than
belts.

54. 3/12/2020
SNUB PULLEYS :
 To relieve load on adjacent return idler
 To increase arc of contact with the main
pulley avoiding belt slipping.
Snub
Pulley
Return Idlers
Conv. Belt

55. 3/12/2020
BELT CLEANING DEVICE
Rubber scrappers are provided at the
head end pulley
Prevents coal dust to carry to return idlers.
Head Pulley
Rubber Scraper
Springs
Fixing Plate
Conv.Belt

56. 3/12/2020
BELT SAFETY
• Removal of Ferrous Materials.
• Magnetic separators are provided
– Fixed Overhead Magnets
– Rotating Magnets

57. 3/12/2020
ROTATING MAGNETS
Magnet Rotating Belt
Conv.
Belt
Ferrous Mat.

58. 3/12/2020
BELT SAFETY
• Removal of Non-Ferrous Materials.
– Stone lifting Manual contract

59. 3/12/2020
PROTECTIONS FOR BELT
CONV.
• PULL CHORD
• BELT SWAY SWICH
• ZERO SPEED SWICH
• MOTOR PROTECTION

60. 3/12/2020
COAL FEEDERS
 Vibrating Feeders
 Vibrating Screens

61. 3/12/2020
VIBRATING FEEDERS
Provided at Coal input points
Electro-magnetic type
Coal feeding rate can be monitored as per
requirement

62. 3/12/2020
VIBRATING SCREENS
Mechanical
Fixed rate of feeding
In Crusher House
Eccentricity
Vibrating Screen
Driving Unit
Coal
Bypass
To
Crusher

63. 3/12/2020
COAL CRUSHERS
• Primary Crushers : up to 600 mm
• Secondary Crusher : 600 to 100 mm
• Final Crushers : Up to 25 mm

64. 3/12/2020
COAL TRIPPERS
Traveling Type
Traveling Trolley
BUNKERS
Rails
A B C D E F
Conv.Belt

65. 3/12/2020
OPERATING SEQUENCE OF
CHP
 DIRECT TO BUNKER
 DIRECT TO STACK
 STACK TO BUNKER ( RECLAIMING)

66. 3/12/2020
PROBLEMS FACED IN CHP
 DESIGN PROBLEMS :
Cal. Value
Ash %
 RAINEE SEASON PROBLEMS :
Chute choke ups
Mud
Coal yard -Slurry formation
 OTHER MISCH. PROBLEMS :
Snapping of belts/ropes
 Derailment of coal wagons
 Oversized coal / Muddy Coal.

67. 3/12/2020

68. 3/12/2020
GRADES OF COAL
SR.NO. GRADE CAL. VALUE
Kcal/Kg.
1 A More Than 6200
2 B 5601 - 6200
3 C 4941 - 5600
4 D 4201 - 4900
5 E 3361 – 4200
6 F 2401 – 3360
7 G 1301 – 2400
8 H Below 1300

69. 3/12/2020
PULL CHORD SWITCH

70. 3/12/2020
BELT SWAY SWICH