2. PROJECT REPORT
ON
EXTENDED COAL HANDLING PLANT
PACKAGE FOR
PAKRI BARWADIH COAL MINING
BLOCK ,NTPC Ltd.
SUBMITTED BY :
SHIKHAR SINDHU
BRANCH-MANUFACTURING SCIENCE AND TECHNOLOGY
(2012-2017)
IIT KHARAGPUR
PROJECT GUIDANCE BY:
SANCHIT DUA (MANAGER)
------------
SIGNATURE
3. CONTENTS:
ACKNOWLEDGMENT
ABOUT NTPC
ABOUT LOCATION
BREIF DESCRIPTION OF PROJECT
SCOPE OF THE PROJECT
ELECTRICAL SYSTEM/EQUIPMENT
MECHANICAL SYSTEM
4. About NTPC –
NTPC Limited (formerly known as National Thermal Power
Corporation Limited) is a Central Public Sector Undertaking
(CPSU) under the Ministry of Power, Government of India,
engaged in the business of generation of electricity and allied
activities. It is a company incorporated under the Companies Act
1956 and a “Government Company” within the meaning of the act.
The headquarters of the company is situated at New Delhi.
NTPC’s core business is generation and sale of electricity to state-
owned power distribution companies and State Electricity Boards
in India. The company also undertakes consultancy and turnkey
project contracts that comprise of engineering, project
management, construction management and operation and
management of power plants. The company has also ventured into
oil and gas exploration and coal mining activities. It is the largest
power company in India with an electric power generating capacity
of 42,964 MW. Although the company has 4llotte. 18% of the total
national capacity it contributes to over 27% of total power
generation due to its focus on operating its power plants at higher
efficiency levels (4llotte. 83% against the national PLF rate of
78%).
5. It was founded by Government of India in 1975, which held 75%
of its equity shares on 31 March 2013 (after divestment of its stake
in 2004, 2010 and 2013).
In May 2010, NTPC was conferred Maharatna status by the Union
Government of India. It is listed in Forbes Global 2000 for 2014 at
424th rank in the world.
Vision & Mission-
“ to be the world’s largest and best power producer, powering
india’s growth”
OVERVIEW
India’s largest power company , NTPC was set up in 1975 to
accelerate power development
Board of Directors
Shri Arup Roy Chaudhary believes in Project Implementation
through Proactive approach and his dictum is “Sankalp Suddah hi
Siddah”
Human Resources
People before PLF (Plant Load Factor) is the guiding philosophy
behind the entire gamut of HR policies at NTPC
6. Diversified Growth
NTPC’s quest for the diversification started about a decade back
with foray into hydro power
Future Goals
The National Thermal Power Corporation Ltd is on an expansion spree
to meet the power requirements of the country – it has targeted to add
14058 MW in 12th Plan (From FY13 to FY 17) of which it had already
added 4170 MW in the year 2012-13 and 1780 MW from April to 26
March 2014. Dr. Arup Roy Choudhury, Chairman and managing
director, NTPC, said that capacity addition through Greenfield projects,
expansion of existing stations, joint ventures and takeover of SEB
stations were on the cards.
NTPC also plans to go global. The public sector company has signed a
memorandum of agreement with the Government of Sri Lanka and
Ceylon Electricity Board for setting up a 500-MW (2x250 MW) coal-
based thermal power plant in the island nation. AnMoU has also been
signed with Kyushu Electric Power Co. Inc., Japan, for establishing an
alliance for exchange of information and experts from different areas of
the business. The company is also in the process of finalisingan MoU
with Nigeria for setting up power plants against allocation of LNG on
long-term basis for NTPC plants in India. NTPC has also been allotted
coal blocks namely, PakriBarwadih, ChattiBariatu, kerandari, Talipalli
and Dulanga. Besides these recently Ministry of Coal has vide its press
release dated 3 July 2013 has allotted 4 more blocks namely, Banai,
7. Bhalmuda, Chandrabila and KudanliLaburi. All these mines are The
National Thermal Power Corporation Ltd is on an expansion spree to
meet the power requirements of the country – it has targeted to add
14058 MW in 12th Plan (From FY13 to FY 17) of which it had already
added 4170 MW in the year 2012-13 and 1780 MW from April to 26
March 2014. Dr. Arup Roy Choudhury, Chairman and managing
director, NTPC, said that capacity addition through Greenfield projects,
expansion of existing stations, joint ventures and takeover of SEB
stations were on the cards.
NTPC also plans to go global. The public sector company has signed a
memorandum of agreement with the Government of Sri Lanka and
Ceylon Electricity Board for setting up a 500-Mw (2x250 Mw) coal-
based thermal power plant in the island nation. AnMoU has also been
signed with Kyushu Electric Power Co. Inc., Japan, for establishing an
alliance for exchange of information and experts from different areas of
the business. The company is also in the process of finalisinganMoU
with Nigeria for setting up power plants against allocation of LNG on
long-term basis for NTPC plants in India. NTPC has also been allotted
coal blocks namely, PakriBarwadih, ChattiBariatu, kerandari, Talipalli
and Dulanga. Besides these recently Ministry of Coal has vide its press
release dated 3 July 2013 has 7llotted 4 more blocks namely, Banai,
Bhalmuda, Chandrabila and KudanliLaburi. All these mines are having
estimated Geological Reserves of 5.7 Billion Tones. The Company has
also incurred a cumulative expenditure of Rs. 18360 million on these
mines till December 2013. As per the MOU dated 22 February 2014,
signed between NTPC, BSPGCL (Bihar State Power Generation
Company Limited) and LBCPL (LakhisaraiBijlee Company Private
Limited) NTPC will develop a 1320 MW (2 X 660 MW) Thermal Power
Project at Kajra (Lakhisarai district), Bihar
e having estimated Geological Reserves of 5.7 Billion Tones. The
Company has also incurred a cumulative expenditure of Rs. 18360
million on these mines till December 2013. As per the MOU dated 22
February 2014, signed between NTPC, BSPGCL (Bihar State Power
8. Generation Company Limited) and LBCPL (LakhisaraiBijlee Company
Private Limited) NTPC will develop a 1320 MW (2 X 660 MW)
Thermal Power Project at Kajra (Lakhisarai district), Bihar
Subsidiaries
NESCL The company was formed on August 21,2002. It is a wholly
owned subsidiary company of NTPC with the objective to construction
Business development
NTPC has identifiesd Joint Ventures, strategic alliances as well as
acquisitions and diversifications for business development
History
1975 to 1994
The company was founded in November 1975 as “National Thermal
Power Corporation Private Limited”. It started work on its first thermal
power project in 1976 at Singrauli in Uttar Pradesh .In the same year,
its name was changed to “National Thermal Power Corporation
Limited”. In 1983, NTPC began commercial operations (of selling
power) and earned profits of INR 4.5 crores in FY 1982-83. By the end
of 1985, it had achieved power generation capacity of 2000 MW.
In 1986, it completed synchronization of its first 500 MW unit at
Singrauli. In 1988, it commissioned two 500 MW units, one each in
Rihand and Ramagundam. In 1989, it started a consultancy division. In
1992, it acquired Feroze Gandhi Unchahar Thermal Power Station
(with 2 units of 210MW capacity each) from Uttar Pradesh
RajyaVidyutUtpadan Nigam of Uttar Pradesh. By the end of 1994, its
installed capacity crossed 15,000 MW
9. 1995 to 2004
In 1995, it took over the Talchar Thermal Power Station from Orissa
State Electricity Board. In the year 1997, Government of India
conferred it with “Navratna” status. In the same year it achieved a
milestone of generation of 100 billion units of electricity in a year. In
1998, it commissioned its first naptha-based plant at Kayamkulam with
a capacity of 350 MW. In 1999, its plant in Dadri, which had the
highest plant load factor (PLF) in India of 96%, was certified with ISO-
14001. During 2000, it commenced construction of its first hydro-
electric power project, with 800 MW capacity, in Himanchal Pradesh.
In 2002, it incorporated 3 subsidiary companies: “NTPC Electric
Supply Company Limited” for forward integration by entering into the
business of distribution and trading of power; “NTPC VidyutVyapar
Nigam Limited” for meeting the expected rise in energy trading;
“NTPC Hydro Limited” to carry out the business of implementing and
operating small and medium hydro-power projects. In the same year its
installed capacity crossed 20,000 MW.
Listing: NTPC got listed on BSE and NSE on 5 November 2004.
Against the issue price of INR 62 per share, it closed the first day of
listing with INR 75.55 per share. On the day of listing, it becomes the
third largest company in India in terms of market capitalization.
2005 to present
In October 2005, the company’s name was changed from “National
Thermal Power Corporation Limited” to “NTPC Limited”. The
primary reason for this change was the company’s foray into hydro and
nuclear based power generation along with backward integration by
coal mining. In 2006, it entered into an agreement with Government of
Sri Lanka to set up two units of 250 MW each in Trincomalee in Sri
Lanka. During 2008 and 2011, NTPC entered into Joint Ventures with
BHEL, Bharat Forge, NHPC, Coal India, SAIL, NMDC and NPCIL to
expand its business of power generation. By the end of 2010, its
installed capacity crossed 31,000 MW.
10. Operations-
NTPC operates from 55 locations in India, one location in Sri Lanka and
2 locations in Bangladesh.
Headquarters: In India, it has 8 headquarters (HQ):
NTPC Plants and their capacity-
The total installed capacity of the company is 41,794 MW (including
JVs) with 17 coal-based and seven gas-based stations, located across
the country. In addition under JVs (joint ventures), six stations are
coal-based, and another station uses naphtha/LNG as fuel
Sr. No. Headquarters City
1 NCRHQ Delhi
2 ER-I HQ Patna
3 ER-II HQ Bhubaneshwar
4 NRHQ Lucknow
5 SR HQ Secunderabad
6 WR-I HQ Mumbai
7 WR-II HQ Raipur
8 Hydro HQ Delhi
12. PowerProject
19 NTPCBongaigaon Assam 750 MW
20
LARA SuperThermal
PowerProject
Chhattisgarh 4000 MW
Coal Based (Owned through JVs)
Sr. No. Name of the JV Location State
Inst.Capacity in
Megawatt
1
NSPCL.Joint
venture with SAIL.
Durgapur WestBengal 120
2
NSPCL.Joint
venture with SAIL.
Rourkela Orissa 120
3
NSPCL.Joint
venture with SAIL.
Bhilai Chhattisgarh 574
4
NabinagarPower
GeneratingCo.
Pvt.Ltd. NPGC.
Jointventure with
Bihar State
ElectricityBoard.
Aurangabad Bihar 1980
5
Muzaffarpur
Thermal Power
Station(MTPS).
Jointventure with
Bihar State
ElectricityBoard.
Kanti Bihar 110
6
BhartiyaRail Bijlee
CompanyLimited.
Jointventure with
IndianRailways.
Nabinagar Bihar 1000
7
Aravali PowerCPL
JV withHPGCL &
IPGCL
Jhajjar Haryana 1500
8
NTECL JV with
NTPC& TNEB
Chennai 1500
Total 6904
13. Gas based
Sr. No Project State
Installed Capacity in
Megawatt
1 NTPCAnta Rajasthan– Baran 413
2 NTPCAuraiya Uttar Pradesh 652
3 NTPCKawas Gujarat 656
4 NTPCDadri Uttar Pradesh 817
5 NTPCJhanor Gujarat 648
6 NTPCKayamkulam Kerala 350
7 NTPCFaridabad Haryana 430
8 RGPPL (JV) Maharashtra – Ratnagiri 1940
Total 5895
Hydel
The company has also stepped up its hydroelectric power (hydel)
projects implementation. Some of these projects are:
1. Loharinag Pala Hydro Power Project by NTPC Ltd: Loharinag
Pala Hydro Power Project (600 MW i.e.150 MW x 4 Units) is
located on river Bhagirathi (a tributary of the Ganges) in
Uttarkashi district of Uttarakhand state. This is the first project
downstream from the origin of the Ganges at Gangotri. Project was
14. at advance stage of construction when it was discontinued by
Government of India in August 2010 .
2. TapovanVishnugad 520MW Hydro Power Project by NTPC Ltd:
In Joshimath town. The project is under construction.
3. LataTapovan 130MW Hydro Power Project by NTPC Ltd: is
further upstream to Joshimath. This project is under environmental
revision.
4. Koldam Dam Hydro Power Project 800 MW in Himachal Pradesh
(130 km from Chandigarh )This project is under advanced stage of
construction.
5. RupasiyabagarKhasiabara HPP, 261 MW in Pithoragarh,
Uttarakhand State, near China Border. This project is yet to be
given investment approval.
Environment Policy and Management
For NTPC, the journey extends much beyond generating power right
from inception, the company had a well defined environment
CenPEEP
Toward reduction of Greenhouse Gas (GHG) Emission from Indian
thermal power plant, NTPC has been promoting
Ash Utilization
Ash utilization is one of the key concerns at NTPC. The Ash
Utilisation Division, set up in 1991, strives to derive maximum
Afforestation
Maintenance of ecological balance and a perfect environment has been
of utmost impoertance at NTPC
15. NTPC Ltd.
Pakri Barwadih Coal mining Project
Ujjwal complex, Pugmil Road
Hazaribagh
LOCATION Barkagaon and kerakar blocks, Hazaribagh district
Jharkhand North eastern part of the karanpuru coal field
Longitude of 85°10’ to 85°13’ E Latitude of 23°51’30” to 23°55’30” N
ROAD 120 km from Ranchi
RAIL the nearest rail station Koderma railway station on Howrah-
Delhi 90 km of the project site. The coal field is likely to be connected
by a new railway network under initial phase of execution from
Gomoh-Daltonganj railway line of SE railway and also from Howrah-
Delhi railway line at Koderma of eastern railway
AIR The nearest airport at Ranchi is located at a distance of 130 kms
of the project site
LAND REQUIREMENT
Non forest 4681.18 acre
Forest 2051.13 acre
Total 6733.31 acre
COAL RESERVE
Geological 1436 MT
16. Mine able 519.34 MT
PRODUCTION 15MTPA
TYPE OF MINE Open cast
LIFE OF MINE 39 years
The Project
The Pakri-Barwadih Coal Mining Project is going to acquire about
8787 acres of land of which about 6286 is private land including
residential and agriculturalland and the rest is permanent land
17. BRIEF DESCRIPTION OF PROJECT
This description pertains to the work of installation of extended coal
handling plant for handling and transportation of (~) 50mm size coal
from transfer point TP-6 at a designated place to fast loading silo at
loading and by cross country conveyer system. The brief description of
the envisaged system is as follows :
1. Crushed coal of (~) 50 mm size shall be transported from mine by a
cross country conveyer system upto TP-6 which is being constructed
separately by the owner. From this transfer point , the scope of work
of CHP under this package starts. The package shall have double
stream conveyors of capacity 2500 TPH . It shall cater to 15 million
tons per annum coal throughout of mines
The conveyor shall be routed at an elevation point of min 6.0 m
above ground along the corridor. At locations of crossing of rail
lines or where an existing road runs across the conveyor corridor the
conveyor corridor the conveyor shall be routed at an elevated level
with minimum head room clearance of 8 mtr from top to road/rail
From transfer point TP-6 double steam troughed belt conveyor
shall convey (-) 50 mm coal through a series of conveyor points and
transfer points to silos
Future provision of ground bunker has also been envisaged for
which inter connection provision from TP-10, TP-11 & TP-12 has
been kept
2. Coal received at TP-6 hsall be conveyed directly to fast loading silos
through conveyor 6A/B, 7A/B, 8A/B, 9A/B, 10A/B, 11A, 11B, 12B
passing through transfer points TP7,8,9,10,11 & 12 conveyor 11A
will feed silo A & conveyor 12B will feed silo B. Future provision
for conveying the coal from TP-10 to silo through series of
conveyors and transfer points passing through ground bunker , TP-
18. 11 & TP-12 has been envisaged . For the necessary provision at TP-
10 & TP-12 to be kept.
3. Two nos. of fast loading silos shall be of 4000T capacity suitable for
flood loading of Indian railways rakes. The silos shall be of RCC
construction with two nos. per weigh bins of 149 m³ nominal flush
capacities. The fast loading system shall comprise 8 nos. of silo
discharge gates and 8 nos. maintenance/isolation gates. Two nos.
flow flow control gates shall be provided in silo along with
telescopic swing chutes for loading of Indian railways rakes.
4. Air cannon system for arch breaking along with air
compressor,piping and automation shall be provided for silo.
Continuous level indication for silo maintenance shall be provided
of ultrasonic type single climbing scaffold for silo maintenance shall
be provided . R&P type elevator shall be provided to acess various
floors of silo
5. Service road shall be provided along with cross country conveyor
corridor along with lighting and realted works. The conveyor
corridor shall be adequately compacted of each conveyor for ease of
movement of light vehicles
6. The rated capacity of each conveyor in scope of this package is 2500
TPH
7. Belt scales (BS-1;2) shall be mounted on conveyor 11A & 12B to
meet coal received at TP-6 and conveyed for further transmission
8. At each transfer point i.e. TP-6,7,8,9,10 and 11 feeding chutes of
dischanging conveyors shall have provision of feeding any of
downstream conveyor s by means of motorized flap gates
9. At TP-13 & TP-14 automatic coal sampling section(CSU) is
provided for sampling of coal
10. Coal of size (~) 50mm shall be fed to fast loading silo
continuously. Before starting the loading process silo shall be kept
filled up at least 65% of silo level coal from the loading hopper is
drawn to pre weigh hoppers of 72 tones capacity through
hydrauclically operated slide gates. Coal from these pre weigh
hoppers is discharges into moving railway wagons/MGR wagon
slider it through the swing chute arrangement
19. 11. Two nos. in motion weigh bridge (WB-1,2) one each at approach
each & exit side of each silo shall be installed to measure the load of
empty rake received at the silo & loaded rakes leaving the silo
12. In entire coal handling plant all conveyors shall be controlled &
monitored by PLC control system for which CHP control room is
being constructed by the owner separately in TP-6,For fast loading
silo, PLC based batching system complete with various sensors shall
the silo, Fast loading silo shall have its own control room and shall
be provided by the bidder
13. For control of fugitive dust, plain water dust separation is
envisaged for potential dust generating points. Auxiliary service like
service water system, ventilation system, cooling water system and
portable water system is proposed for entire coal handling plant to
be provided by the bidder
14. Fire detection, fire alarm and protecting/fighting system is also
envisaged for the entire scope of the package
20. SCOPE OF THE PROJECT
Conveyor 6A/B of each of 2500 TPH rated capacity receive
ing coal from owner’s conveyor at TP-6 complete with
conveyor supporting structures short supports
Troughed belt conveyors. Belt cables 6 A/B; 7 A/B; 8 A/B; 9
A/B ;10 A/B; 11 A/B ;12 B each of 2500 tph rated capacity
TP-7,8,9,10,11,12,13,14 complete with all mechanical
;electrical equipments to be housed
Two no. of belt scales; one no. of coal sampling unit
One no. rack & pinion type elevators at each silo for acess to
various operating floors of silo
Two no. of coal loading silos each of 4000 tones capacity
Two no. of electronic in-motion weigh bridge
Presssurized ventilation systems for all switch gear rooms;
MCC rooms & hydropak rooms
Air conditioning of control room; office room; remote i/o
panel room in each mcc/switchgear room
Two nos. belt vulcanization machine of adequate size
complete with all 20ccessories
21. ELECTRICAL SYSTEM/EQUIPMENT
MOTORS- All HT and LT motor with lugs and glands
415V MCCs/SWITCHGEAR/DISTRIBUTION
BOARDS-415V motor control centres, AC & DC
distribution boards/fuse boards, local push button
stations for all dries and local motor starters as required
by system and equipment
Outgoing feeder shall be segregated stream wise and
equally distributed on each bus section of MCC
Two nos. of 125A switch fuse feeders (total load
50KVA) shall be provided in each of the bus of above
indicated MCC
CABLES-All power cables (19/33kv, 6.6/6.6kv and
1.1kv grade), control cables,instrumentation cables, fiber
optics cables, signal cables and any special cables for
completeness of system
ILLUMINATION SYSTEM-Illumination system for
complete internal and external lightning of associated
plant and equipment like TPs, Conveyors, Switchyard,
22. Switchgear & control buildings, workshop, pump house
etc and roads
CABLING; EARTHING AND LIGHTNING
PROTECTION- Cabling viz. cable laying along with
cable accessories , cable trays with supporting structures,
termination & joining kits ,trenches ,duct banks etc
required for cables to be supplied by contractor ,cable
trays laid along conveyor galleries shall be of perforated
types and shall provide cable tray covers
Earthing/grounding and lightning protection for plant
and equipment
TRANSFORMERS-33/6.9 KV; ONAN transformers
and
6.6/433 KV ,ONAN transformers
6.6 KV SWITCHGEAR-6.6 KV switchgear is used,
spare feeders shall be provided as per electrical single
line diagram
6.6KV CAPACITOR BANK-6.6 KV capacitor bank
shall be provided at each 6.6KV switchgear location so
that overall power factor shall remain 0.95
23. BATTERY-Two sets of 110 V DC, 100 AH(min) lead
acid plante type/60 AH(min.) Ni-Cd battery. Each set
consists of two nos. battery chargers
BATTERY CHARGERS-Two sets of 110 volt, 50
A(MIN) float cum boost chargers are used. Each set
consist of two nos. of battery chargers
PLC AND CONTROL PANELS-Main control desk
with HMI ,video screens; PLC panels; remote i/o
stations; UPS; 24V DC battery and battery chargers for
control of entire coal handling equipment including silo
equipment and HT and LT switchgear
Local control panels for belt weighers; coal sampling
units ;fast loading silo ;sump pumps ;DS/DE ventilation
etc as required for system, CHP control desk with HMIs
shall be provided in silos as per PLC configuration
drawing
CLOSED CIRCUIT (CCTV) SYSTEM;
TELEPHONE & PUBLIC ADDRESS SYSTEM-
CCTV system with 32 nos, cameras ; public address and
telephone system for coal handling plant
24. 33KV SYSTEM-33kv outdoor off-load isolator with
earth switches on pole structure & 33KV indoor circuit
breaker
25. MECHANICAL SYSTEM
BRAKES-Brakes shall be providing for
decelerating of driven equipment/conveyors as
per requirement .They are mandatory for H.T
drives involving scoop type coupling
BELT CONVEYOR SYSTEM- All belt
conveyors shall be furnished and erected along
with necessary supporting structures;
platforms and on ground or overhead galleries
;trestle structures with foundation footings;
carrying and return idlers; automatic take-ups;
pulleys; drive motors with suitable reduction
units and couplings; belting; feeder hoppers;
transfer chutes; flap gates; hydraulic couplings
and other necessary accessories
DRIVE EQUIPMENTS-Drive equipments
like electric motors; gearboxes; fluid
26. couplings; flexible couplings and other
accessories shall be provided for belt conveyor
system; paddle feeders; mobile trippers;
various pumps of dust suppression/extraction
system; fans for ventilation system and other
equipments
BELT SCALES- Belt weigh scales for
measurement of coal flow rate and quantity
shall be provided at specified loactions system
shall be complete with flow rate indicator;
totalizer; control panel etc. It should be
designed for continuous automatic weighing
;metering and printing of coal flow. It is
provided with self diagnostic feature for
troubleshooting of entire belt scale system
CHP BUILDINGS- Various buildings in coal
handling plant like transfer houses; crusher
27. house; control rooms and MCC rooms are
completed . All CHP buildings shall have
sufficient space to accommodate the entire
equipment like head end; drive unit and tail
unit of various conveyors; crushers; hoppers;
chutes; control equipment etc.
COAL SAMPLING UNIT- Coal sampling
unit shall be complete with necessary
samplers; crushers; flap values; chutes;
hoppers; belt feeders and sample collectors etc
to give samples from any of two streams
running at guaranteed capacity
IN-MOTION WEIGH BRIDGE- Two
weighbridges shall tentatively be located on
railway track before after silo. The system
shall indicate and print tare, gross and net
weight for each wagon in train. It shall also
28. indicate and print and of all the trains receives
in a day to know quantity of total coal being
received daily.
