WELCOME

TO

PRESENTATION
ON
COAL HANDLING PLANT
 Layout for Coal Handling Plant
C #6AB
U#4 U#5 U#6 LEGEND
TH-I to 200
TP #4 C #7A/B
BUNKER
To 3X 200 MW TH-II to 500
C # 5A/B BUNKER

M TP #3 MD
S TP #19
MS
C # 4A/B C #21A/B
C #14A/B MS
TP #18

TP # 2
C #24A/B C #13A/B TP #10

C #3 A/B C #11 A C #12A/B

TP #6
M C #20 A/B
D C# 9 A/B TP #8
TP #5 SR # 1 Ground
CRH # 1 Hopper
C #10 A/B
C#8A/B C #11 B
TP #7 TP # 9
C #23
M
SR # 2
D C #22 A
CRH #2 C #22 B
C #2 A/B TP # 21
M
SR # 3
D
TH # 2
TP # 17 C # 18 A/B
MS
PH
TH # 1
TP # 1
C # 1 A/B
MS M
D
 BLOCK DIAGRAM OF COAL MOVEMENT

Coal Crushed
Coal From COAL to
to -20 mm
Mines Unloaded Bunkers
Size in
at TH Through Crushers
MGR

COAL TO YARD
( Supply >
Consumption)
COAL FROM YARD
( Supply <
Consumption)
CHP SYSTEM OF STAGE-1&2
The coal handling plant is divided into four groups. They
are-
Stage#1
Area – Track Hopper # 1 to 200 bunker including S/R#1
Stream and reclaiming cycle .
Capacity – 2000 tph
Bunkers - 18 nos (3 x 6) , Maximum Capacity- 390 MT ,
- size 7 m dia x 9.2 m ht.
Track Hopper – 200 m length & Capacity – 3200 MT.
Commisioned on – 1982/ 83

Stage# 2 (500 MW side)

Track Hopper Capacity – 2000 TPH , Bunker Capacity-890
MT (9x3)
Area -Conv#7 A/B to 17 A/B of stage -2 bunker area.
Commisioned- 1987/88
Stage#2 extension
Capacity- 2000 TPH
Area- 10A/B, 11B, S/R#2, 12A/B (TP9, TP8)
Commisioned- June 1989
Augmentation
Capacity -2000 TPH
Area- Conv#18A/B to Conv#22A/B ,Conv#23 & S/R#3
Track Hopper- 160m length & 3200 MT capacity
Commisioned- 1991/92

TRACK HOPPER
There are two track hoppers in NTPC Korba each of 3200 MT.
Track Hopper#1 is 200m long and is covered with grill and is
used for receiving both indian and imported coal.
Track Hopper#2 is not covered with grills and is used only
for receiving domestic coal.
 Grades of Coal
Grad Useful Heat Value Corresponding Gross Calorific
e (UHV) (Kcal/Kg) Ash% + Moisture Value GCV (Kcal/
% at (60% RH & Kg) (at 5%
40O C) moisture level)
A Exceeding 6200 Not exceeding Exceeding 6454
19.5
B Exceeding 5600 but 19.6 to 23.8 Exceeding 6049 but
not exceeding 6200 not exceeding 6454
C Exceeding 4940 but 23.9 to 28.6 Exceeding 5597 but
not exceeding 5600 not exceeding. 6049
D Exceeding 4200 but 28.7 to 34.0 Exceeding 5089 but
not exceeding 4940 not Exceeding 5597
E Exceeding 3360 but 34.1 to 40.0 Exceeding 4324 but
not exceeding 4200 not exceeding 5089
F Exceeding 2400 but 40.1 to 47.0 Exceeding 3865 but
not exceeding 3360 not exceeding. 4324
G Exceeding 1300 but 47.1 to 55.0 Exceeding 3113 but
not exceeding 2400 not exceeding 3865
SILO
Loading
TRACK HOPPER
 PADDLE FEEDERS
TYPE – Rotary Rail Mounted(Length of Guage-
2257mm)
Population – 04 (for stage#1)& 04(stage#2)
Capacity- 1000TPH for stage#1 & 1250TPH for
stage#2
Travel length- 210m for stage#1 , and 160m
+(15m +13.8m)
Travel speed-3m/min for stage#1,1-2m/min
stage#2
Operation- Continuous to and fro
No. of blades or arms- 5 for stage#1, 6 for stage#2
 METAL DETECTOR
Location – Conv#1A/B, 3A/B, 13A/B, 19A/B, 20A/B.
Population- 10
Detecting material – ferrous and non ferrous metal. It only
detects the material ,it does not separate the metal from
the coal.

MAGNETIC SEPARATOR
Location- Conv#1A/B , 4A/B, 13 A/B, 20 A/B
And 19A/B (In Line Magnetic Separator)
Population- 10
Detecting material- only ferrous metal. It separates the
ferrous material from the coal particles.
 .

 .
 MAGNETIC
SEPARATOR METAL
 Any ferrous material DETECTOR
on the conveyor will Any Metal with
be lifted from the an area of 100 Sq
moving conveyor. Cm will be
 No Tripping detected.
involved. Conveyor is
MS is interlocked tripped after
with Conveyor start detection.
up. A marker is
When ferrous Metal dropped near the
is picked up, the MS Metal piece for
is moved from the easy location
Conveyor, de-
magnatised and the
metal piece is
removed.
 VIBRO FEEDER & GRIZZLY FEEDER
STAGE#1- VIBRO FEEDER
Population – 4
Capacity – 1000 TPH
Speed – 1000 rpm
Type of system- directly motor driven.

STAGE#2 – GRIZZLY FEEDERS

Population – 4
Capacity – 1250 TPH
Speed – 1000 rpm
Type of system- hydraulically driven.

The function of vibro feeder and grizzly feeder is to uniformly

feed the coal by using the vibrating mechanism .
 VIBRATING GRIZZLY FEEDER

- 20 MM 2000 TPH BELOW CRUSHERS

 RING GRANULATOR
(CRUSHER)
Manufacturer M/S L & T Ltd.

Population 04 Nos.

Capacity : 940 TPH

Input size (-) 250 mm

Output size (-) 20 mm, 98%

Motor Rating 500(KW), 600 RPM

 FLAP GATE

TYPE Motorized Actuator

Make M/S PrePEC

Population 32 Nos.

Stroke length 575 mm

Travel Speed 130 mm / Sec

 TRIPPER
Type Motorized Traveling Type

Make M/S L & T Ltd.

Population 04 Nos.

Capacity : 1500 TPH

Travel 33.625 M

Travel Speed 15 M / Min

 Stacker -Reclaimer

Make M/S L & T Ltd.

Capacity : 1500 MTPH

Slewing Angle - 900 to + 900

Slew Speed 35 m/min (Maxm)

Luffing Angle - 6.70 to +100

(w.r.t. Horizontal)

Luffing Speed 5 m/min

 RECLAIMER
It is a single equipment which allows 1.Stacking of
coal in Coal yard. 2. Reclaiming of coal from Coal
yard .

BOOM
CONVEYOR

BUCKET WHEEL YARD

CONVEYOR

BOOM
CCRD
COAL RAIL TRACK
YARD LONG TRAVEL
CABLE TRAY
 STACKER CUM
RECLAIMER
IN YARD COAL IS STACKED FROM YARD CONVEYOR
VIA BOOM CONVEYOR

BOOM
CONVEYOR

BUCKET WHEEL YARD

CONVEYOR
STACKER RECLAIMER

RECLAIMER IN OPERATION
STACKER IN OPERATION
Bucket wheel
CONVEYOR BELTS
Made of diff. Layers or piles of fabric duck with rubber
protected by a rubber cover on both sides & edges.
Fabric duck are designed to withstand tension created in
carrying the load .
Nylon rubber cover protect the fabric duck.

Material =fire resistant

grade.
Belt Width=1600 mm.
Strength= 1000/1250 kN.
Belt speed=3.2-3 m/s.
Belt length=20km.
 IDLERS

Idlers consists essentially of rolls made out of seamless

steel tubes enclosed fully at each end fitted with
stationary shaft, antifriction bearing and laybrith sealing.

TYPES

TROUGHING IDLERS- shape the belt to support a

moving load without spillage or damage to the belt.

IMPACT IDLERS - absorb the shock of falling material

at loading and transfer points to protect belt from
damage.
POSITIVE ACTION TROUGHING TRAINERS –
automatically maintain troughing side alignment in
one-way conveyors. A center pivot frame and offset
neutral guide rolls provide the troughing action.

RETURN IDLERS –
support the empty belt during the return run.

POSITIVE ACTION RETURN TRAINERS –

automatically maintain return belt alignment on one-
way
conveyors.
PULLEYS

Made of mild steel.

Rubber coating is used to increase

friction factor between belt & pulley
(rubber lagging)
 DRIVE UNIT
Motors coupled to reduction gear with the help
of flexible coupling on the high speed shaft of the
Gear box
Flexible coupling on the input side

TAKE UPS
Take up pulley to facilitates –

Necessary tension for the drive to operate the belt

Sag at a point where requires horse power will be

at a minimum and load will move with least
disturbance over idlers
SKIRT BOARD
Used with chutes at trail end.

Guides material centrally on the belt while loadi

until it has settle down on the belt

SCRAPPERS

Placed at discharge pulley in order to clean the

carrying side of belt.
It avoids the wear of return idlers due to build u
material.
 INTERLOCKS &
PROTECTION IN CHP
 PROTECTION SYSTEM IN
CONVEYOR BELTS
1. PULL CHORD SWITCH
2. BELT SWAY SWITCH
3. ZERO SPEED SWITCH
4. OVER FLOW SWITCH
5. EPB
 PULL CORD SWITCH


 Belt Sway Switch
 .
 LIMIT SWITCHES

 .
 VSTPP - COAL HANDLING
PLANT
 Interlock and Protection in
Tripper
01. PCRD over tension switch

02. EPB

03. End limit switch

04.Rail clamping
 VSTPP - COAL HANDLING PLANT
 Interlock and Protection in Plough
Feeder Over tension switch
Traverse Trip

Anti collision switch

Auto Reverse

End limit switch

Auto Reverse


Oil low level switch

Main motor trip

Oil temp. trip

 Main motor trip
SPECIAL FEATURES
 DOZER maintenance shed.

 CONSERVATION OF ENERGY :
CABLE GALLERY, TP, TH, CH are provided with
transparent sheets.

 FLEXIBILITY of coal feeding.

 CONTROL ROOM:
LVS : Large Video Screen.
FULLY PLC operation.

 ALL MCCs are at ground floor.

SPECIAL FEATURES
 PHONES and PA System in TRIPPER and PF.

 INSPECTION DOORS of improved design.

 TRIPPER-Cable Trolley in place of PCRD.

 PADDLE FEEDER traverse by Electric Motor.

 ELEVATOR is provided in TP-21and CR House

.
SPECIAL FEATURES
 ADJUSTABLE Skirt Pads to arrest dust at TPs.

 AUTO Dust Suppression System.

 S/R can be operated in AUTO or MANUAL mode.

In AUTO each operation is dictated by PLC.

 SEAL PLATE is of Convex shape to avoid water

accumulation.

 FLAP GATES have Internal Limit Switches.

SPECIAL FEATURES

 PF Spray System is provided.

 NO Underground Reclaim Conveyors.

DEFICIENCIES :

 BUNKER GRILL : No Cross Bar is provided.

 UNIVERSAL Acceptor.

 TRACK HOPPER : Spray Nozzles are located

behind unloading platform.

 LT Modules get opened in locked and OFF

condition.

 FALL ARRESTER for Take Up Pulley not

provided.
 FUTURE MAJOR MODIFICATIONS

 Clubbing of all three Control Rooms of

CHP.

 Provision for Coal Feeding to Stage-I and II

from Stage-III CHP.