Coal Handling Plant Stage # 3

An Introduction

Companies

Coal fields

Wagons

Box-N BOBRBottom Open Bottom Release

WT Control Room

Side Arm Charger

Wagon Tippler

Coal Discharge Direction

Dust Suppression System

Wagon Tippler

Suspended magnetsFor removing tramp iron piecesLocation - discharge of Conv. 42A/B, 31A/B Efficient cost-saving recovery of harmful tramp iron in free-flowing materialsThey are simple to install and have no maintenanceInstalled over conveyor

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Metal detectorsTo detect non-magnetic metallic materials presentLocation - 32A/B head, 38 A/B

ILMS

Removing left tramp iron pieces Location - discharge of 32A/B in crusher – to remove any

tramp iron piece present in coal before entering crusher

- TP 21 – to avoid entry of the same in bunker- TP 27 – to eliminate the same from the coal coming

from stockyardInstalled at discharge of conveyors near pulleyILMS includes belt, pulleys, magnet etc.

Inline Magnetic Separator

ILMS

Crusher HouseROD GATES (2+2)

RACK AND PINION GATES (2+2)

VIBRATING SCREEN FEEDERS, (2+2) 940 TPH

RING GRANUATOS (CRUSHERS ) (2+2)940 TPH

BELT FEEDER (2+2)

REVERSIBLE BELT FEEDERS (1+1)

BunkerCapacity – 800 MTHeight - 26.3 mNos. – 9 x 2

11.91 m

8.13 m

6.25 m 260 MT

200 MT

340 MT

0 m

2 m

4 m

6 m

8 m

10 m

12 m

14 m

16 m

18 m

20 m

15 m

22 m

26.3 m

26.3

m

800 MT

730 MT

650 MT

565 MT

480 MT

395 MT

310 MT

225 MT170 MT140 MT

85 MT

45 MT

18 MT

New Installations In CHP Stage # 3

Electro-Mechanical System Stage # 1

P L C ( Programmable Logic Control ) Stage # 2

D D C M I S ( Distributed Digital Control Monitoring and Information System) Stage # 3

Wear an tear of contacts because of heating High cost of installation, maintenance and modification processEasy to modify and implement

The control system for all the coal handling drives including conveyors, Dust Suppression System, etc. shall be DDCMISExcept for the Stacker Reclaimer and wagon tippler , which will be controlled by PLC

Control System

PLC Vs . DDCMIS

PLC focuses more on controlDDCMIS focuses more on Human Machine Interface

STATUS TABLE

PCS/BSS/ ZSS NOTIFICATION

TABLE

RESET

ACKNOWLEDGEMENT

PCS/BSS/ZSS

STATUS

PUMP HOUSE

ALARM TABLE

VENTILATION

BELT WEIGHER

BYPASS

Invensys System

EQUIPMENTS FUNCTIONS

DDCMISDistributed Digital Control Monitoring and Information System

Auto /manual operation of gates/ valves/ dampers, pumps, drives, Local / remote selection of operation, Status indication, annunciation, interlock and protection of pumps/drives

ConveyorsDust suppression system Paddle feedersMobile trippers over bunkersBelt weighersMetal DetectorsInline Magnetic separators Suspended Magnets Coal sampling Units Hydraulic scoop Coupling

Apron FeederIt consists of a series of overlapping Heavy Duty Pans (or Flights) that carry the material.Used for handling more abrasive, heavy and lumpy material. The material is carried on an overlapping metal plate called pans, which is mounted between strands of the conveyor chain. Apron feeders are placed under storage bin for regulating the feed material

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An Apron Feeder can regulate the flow of material based on volume.  The pan speed and the gate cut off height can be regulated to provide an even volumetric feed  down stream.

Belt FeederA short belt conveyor. The belt is flat and supported on closely spaced idlers or on a smooth slide plate. Belt feeders are used for handling fine / free flowing / abrasive materials. Even properly designed belt feeders are used for handling lumpy material.Increased redundancy and flexibility

Reversible Belt FeederUsed when only one outlet is used to feed two different belts2 in no. in stage 3Location - Crusher house

Reversible Belt FeederUsed when only one outlet is used to feed two different belts2 in no. in stage 3Location - Crusher house

Three Way ChutesMore flexibilityMore availability

Stone pickingLocation – PH 1 headManual Stone Picking arrangement at conveyor gallery before the crusher house shall be provided complete with stone picking accessoriesFour (4) nos. manual pickersTwo (2) nos. manual pickers shall be positioned on each belt Each manual picker shall cover 3 m long belt stretchDisposal chute from discharge hoods of length up to 2 meters from ground levelConveyor Gallery shall be 2 meters wide

DESCRIPTION STAGE I STAGE II STAGE III

BELT CAPACITY 1250 MT 1500 MT 1500 MT

BELT SPEED 3.2 m/s 3.2 m/s 3.2 m/s

BELT WIDTH 1400 mm 1400 mm 1400 mm

TOTAL NO OF BELTs 29 20 40

TOTAL BELT LENGTH 6.98 Km 6.14 Km 16.93 km

TRACK HOPPER CAPACITY 2700 MT 3400 MT 4562.16 MT

WAGON TRIPPLER CAPACITY NA NA 194.33 MT

PADDLE FEEDER CAPACITY 625 TPH 1125 TPH 1125 TPH

CRUSHER CAPACITY 625 TPH 940 TPH 825 TPH

TOTAL NO OF BUNKERs 16 20 18

BUNKER CAPACITY 800 MT 1140 MT 800 MT

YARD CAPACITY ----- 192500 MT 182900 MT

S a n t o s h K u m a r Ve r m aC H P- O P N ( G r o u p D )

Thankyou

Mentor :: Shri P N Prasad DGM ( CHP OPN & Commissioning)

Special Thanks :: Shri D P Tiwari Shri A Lakra