The document outlines the processes and systems involved in coal management at thermal power plants, focusing on coal consumption, transportation, and handling. It details the various means of coal transport, including roadways, railways, and ropeways, and discusses the equipment used for coal management, such as conveyors and crushers. Additionally, it highlights problems faced in coal handling processes as well as the classification of coal grades based on calorific value.

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