1/31/2012

WELCOME
INDUCTION LEVEL
TRAINEE
ENGINEERS
1/31/2012
DESCRIPTION
& WORKING
1/31/2012
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.
1/31/2012
CONSUMPTION OF COAL
GENERATION PER HOUR PER DAY/SET
210 MW 120 MT 3000 MT
500 MW 300 MT 7000 MT


1/31/2012
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 120 MT 3000
MT
3 9000
TOTAL 420 MT 10000
MT
7 17000

1/31/2012
CONSUMPTION OF COAL(CSTPS)
GENERA
TION
PER
HOUR
PER
DAY/
SET
NO. OF
SETS
TOTAL
210 120 MT 3000
MT
4 12000
500 300 MT 7000
MT
3 21000
TOTAL 420 MT 10000
MT
7 33000
STORAGE CAPACITY OF COAL YARD = 5,00,000 MT
ESTIMATED COAL REQUREMENT = 7 MILLION TON.
1/31/2012
3 SECTIONS OF CHP
Management of Coal
Transportation of Coal
Handling of Coal
1/31/2012
CONSTITUENTS OF COAL
1/31/2012
COAL - A Comparison
AGENCY
CAL
VALUE
ASH %
BHEL 4500
Kcal/Kg
15 % 4 Mill Opn.
MSEB 2800
3500
Kcal/Kg
30 40 % 5 Mill Opn.
1/31/2012
Management of Coal
Central Govt.
CIL
WCL
Railway
Mah.State
MSEB
1/31/2012
TRANSPORTATION OF COAL
MODE OF COAL TRANSPORT
1. ROADWAYS
2. RAILWAYS
3. ROPEWAYS
1/31/2012
ROADWAYS
Coal is carried in trucks.
8-10 mt coal per truck.
Requires more time and manpower.
Coal mines should be near to PS
(100-150 km).
Coal is lost / waste in transit.
Hence not in use for large power
stations.
1/31/2012
RAILWAYS
Unloaded with the help of WAGON TIPPLER
One Rack consist of 52-56 Wagons.
13/25 wagons can be tippled in an hour.
Each wagon contains 55-58 MT of coal.
Wagon movements are controlled by Bettle
Chargers
Demurrage charges on racks.(11 hrs.)
Most popular mode of transport.
1/31/2012
WAGON TIPPELERS
WAGON TIPPLER
SIDE TIPPLER ROTORY TIPPLER
1/31/2012
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 WAGONS UNLOADED WAGONS
UNLOADING HOPER
1/31/2012
SIDE TIPPLERS
57 ROTASIDE ELECON MAKE TIPPLERS
CYCLE OF OPERATION :
1. Gross weight----------- 15 Sec.
2. Tippling ( 140
0
)-------- 90 sec.
3. Pause--------------------- 5 Sec.
4. Return--------------------- 90 Sec.
5. Tare weight-------------- 15 Sec
=============================
TOTAL TIME REQD.----- 210 Sec.
1/31/2012
RING / ROTORY TIPPLERS
High capacity Tipplers
Capacity : 25 Wagons/Hr.
Time Reqd. : 60 Sec.
Wagon is unloaded in hopper under the
tippler.
1/31/2012
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.
BOBRwagons are used.
(Bottom Opening Bogie on Rails)
1/31/2012
ROPEWAYS
Coal Mines should be in vicinity of P.S.
Assured supply of coal @ 100 - 250
T/H.
Economical
MSEB Property.
High Maint.
1/31/2012
ROPEWAYS ( Contd)
TYPE OF ROPEWAYS
MONO-RAIL BI-CABLE
BUCKET TYPE
TRAM CAR TYPE
1/31/2012
MONOCABLE ROPEWAY
Cap : 100 T/h
Bucket Cap : 1.0 T
Haulage Rope
Buckets
1/31/2012
Bi-CABLE ROPEWAY
(Bucket Type)
Track Rope Haulage Rope
Bucket
CAP : 200-275 T/H
BUCKET : 1.8 T
1/31/2012
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
1/31/2012
SILEWARA GROUP OF
ROPEWAYS
A B
D
P C
E
KORADI
KHAPARKHEDA
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
1/31/2012
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
1/31/2012 1/31/2012
Concept of MGR Railway Concept of MGR Railway
Coal mines near to the power Coal mines near to the power
station. station.
MSEB Property MSEB Property
Most economical mode. Most economical mode.
Low maint. Low maint.
Existing at CSTPS Existing at CSTPS
1/31/2012
MGR
POWERSTATION
COAL MINES
Railway
wagon
Rails
1/31/2012
GENERAL LAYOUT OF CHP
Wagon tippler
Crusher House
Bunkers
Tripper Trolley
Conv. Belts
Vibrating
Screens
Crushers
Feeders
Surge
Hopper
1/31/2012
STACKING / RECLAIMING
CYCLE
Bunkers
Stacking Belts
Reclaiming
Belts
Crushed
Yard
Non-
Crushed
Yard
From 3 Rs
Crusher House
Bunkering
Belts
By-Passed Coal
1/31/2012
Conveyor System
Wagon Tipplers
Coal feeders
Crushers
Coal trippers
Stacker-Reclaimers
Protection System.
Interlocks
Operating Cycle
1/31/2012
Conveyor System
Conveyor Belts
Idlers
Pulleys
1/31/2012
Conveyor Belt
System
HEAD PULLEY
TAIL PULLY
CONV. BELT
1/31/2012
Conveyor Belt
System
HEAD PULLEY
TAIL PULLY
IDLERS
CENTRE AXIS
1/31/2012
Conveyor Belt
System
HEAD PULLEY
TAIL PULLY CONV. BELT
IDLERS
RETURN SIDE
1/31/2012
DIFFERENT LAYOUTS
OF THE CONV. BELTS
Moves along the centre of its axis.
PLAN VIEW
1/31/2012
DIFFERENT LAYOUTS
OF THE CONV. BELTS
Moves along the centre of its axis.
1/31/2012
DIFFERENT LAYOUTS
OF THE CONV. BELTS
Moves along the centre of its axis.
1/31/2012
CONVEYOR BELTS
Construction:
Rubber+ Cotton Threads.
Rubber + Fiber Threads
Rubber + Steel Wires
Ply Rating :
4 Ply
5 Ply
6 Ply
1/31/2012
BELTS : Ply Rating
1ply
2 ply
3 ply
FIBRE
1/31/2012
Belts : Quality
Long Life
Strength
Toughness
Light
Elastic
Pliability
1/31/2012
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
1/31/2012
BEELTS : Tensioning
3 TYPES
1.Screw Operated
2.Winch Operated
3. Gravity Take-ups
1/31/2012
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.
1/31/2012
BELTS : Automatic Gravity Take-ups
Bend Pulley
Counter
Weights
Tensioning
Pulley
Guides
Conv. Belt
Head
Pulley
1/31/2012
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
1/31/2012
IDERS : Diagram
Roller
Conv.Belt
Brackets
Return Idler
1/31/2012
DETACHABLE IDLERS
SUPPORTING
BRACKETS
IDLER
ROLLER
SHAFT
END
1/31/2012
IDLERS : Types
Carrying Troughing Idlers
Carrying Troughing self aligning Idlers
Return Plain Idlers
Return self aligning Idlers
Impact Idlers.
1/31/2012
IDERS : Diagram
CARRYING TROUGHING IDLER
Roller
Conv.Belt
Coal
Brackets
Return Idler
1/31/2012
RUNNING OUT OF THE BELT
UN-EVEN LOADING OF COAL ON THE BELT
MISALLINGNMENT BETWEEN HEAD & TAIL PULLEY
MISALLINGNMENT OF THE IDLERS
LOCKING OF TRAINING IDLER
IMPROPER VALCANIZING JOINT
DEFLECTION IN SUPPORT TOWERS
CHOKING OF CHUTES
1/31/2012
SELF ALLIGNINING IDLERS
1/31/2012
IMPACT IDLERS
Why do U need Impact
Idlers?
BELT
Coal falling from
heighted chute
Marks
1/31/2012
IMPACT IDLERS
Rubber Rings
IDLER
Falling
Coal
Vertical Chute
1/31/2012
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.
1/31/2012
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
Driving
Pulley
1/31/2012
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
1/31/2012
BELT SAFETY
Removal of Ferrous Materials.
Magnetic separators are provided
Fixed Overhead Magnets
Rotating Magnets
1/31/2012
ROTATING MAGNETS
Magnet Rotating Belt
Conv.
Belt
Ferrous Mat.
1/31/2012
BELT SAFETY BELT SAFETY
Removal of Non-Ferrous Materials.
Stone lifting Manual contract
1/31/2012
PROTECTIONS PROTECTIONS
FOR BELT CONV. FOR BELT CONV.
PULL CHORD
BELT SWAY SWICH
ZERO SPEED SWICH
MOTOR PROTECTION
1/31/2012
COAL FEEDERS
Vibrating Feeders
Vibrating Screens
1/31/2012
VIBRATING FEEDERS
Provided at Coal input points
Electro-magnetic type
Coal feeding rate can be monitored as per
requirement
1/31/2012
VIBRATING SCREENS
Mechanical
Fixed rate of feeding
In Crusher House
Eccentricity
Vibrating Screen
Driving Unit
Coal
Bypass
To
Crusher
1/31/2012
COAL CRUSHERS
Primary Crushers : up to 600 mm
Secondary Crusher : 600 to 100 mm
Final Crushers : Up to 25 mm
1/31/2012
1/31/2012
COAL TRIPPERS
Traveling Type
Traveling Trolley
BUNKERS
Rails
A
B
C D E F
Conv.Belt
1/31/2012
OPERATING SEQUENCE OF
CHP
DIRECT TO BUNKER
DIRECT TO STACK
STACK TO BUNKER ( RECLAIMING)
1/31/2012
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.
1/31/2012
QUESTION & ANSWER
SESSION
QUE 1 : Consumption of COAL per day for 210
MW set is
1000 MT
2000 MT
3000 MT
1/31/2012
QUESTION & ANSWER
SESSION
QUE 2 :Which is the popular mode of COAL
transport to the power station
ROPEWAY
RAILWAY
ROADWAYS
SHIP
1/31/2012
QUESTION & ANSWER
SESSION
QUE 3 : Size of the COAL after final
crusher is
50 mm
30 mm
25 mm
1/31/2012
QUESTION & ANSWER
SESSION
QUE 4 : Demurrage charges start
after
10 hrs
11 hrs
1 day
1 week
1 month
1/31/2012
QUESTION & ANSWER
SESSION
QUE 5 : For ropeway ,coal mines
should be at least
5-10 km
10-20 km
100 km
from power station.
1/31/2012
QUESTION & ANSWER
SESSION
QUE 6 :The rated capacity of RING
type wagon tippler is
10 wg/hr
20 wg/hr
25 wg/hr
30 wg/hr
1/31/2012
QUESTION & ANSWER
SESSION
QUE 7 :The rated capacity of
side wagon tippler is
11 wg/hr
12 wg/hr
13 wg/hr
15 wg/hr
1/31/2012
QUESTION & ANSWER
SESSION
QUE 8 :Conv. Belts are used
for transmission of
COAL OR POWER
1/31/2012
QUESTION & ANSWER
SESSION
QUE 9 :Conv. belts are made
out of rubber
TRUE OR FALSE
1/31/2012
QUESTION & ANSWER
SESSION
QUE 10 :
Snub pulley is provided for belt
tensioning:
TRUE OR FALSE
1/31/2012
QUESTION & ANSWER
SESSION
QUE 11 :
Vibrating Screens are provided
at coal input points:
TRUE OR FALSE
1/31/2012
QUESTION & ANSWER
SESSION
QUE 12 :
Pullchord protection is for
1. Man
2. Machine
3. Both
1/31/2012
QUESTION & ANSWER
SESSION
QUE 13 :
Impact idlers are provided for
gripping of the belt
TRUE FALSE
1/31/2012
QUESTION & ANSWER
SESSION
QUE 14 : Coal Trippers are for
Unloading wagons
Feeding Conv. Belts
Bunkering
1/31/2012
QUESTION & ANSWER
SESSION
QUE 15 : Fluid couplings are provided for
1. Belt tensioning
2. Belt loading
3. Belt alignment
4. Belt smooth running
1/31/2012
QUESTION & ANSWER
SESSION
QUE 16 : Conv. Belts can take a
turn of
1. 30
o
2. 45
o
3. 90
o
4. None of the above
1/31/2012
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
I
1/31/2012
PULL CHORD SWITCH
1/31/2012
BELT SWAY SWICH