Efficiency in Fuel Handling System PDF

THE WEST BENGAL POWER DEVELOPMENT CORPORATION LTD.
(A Govt. of West Bengal Enterprise)
LA Block, Sector-III, Salt Lake City, Kolkata-700 098, W.B.
8 May 2014

EFFICIENCY IN FUEL HANDLING SYSTEM

&
COST OPTIMISATION
PRESENTATION HAVING TWO PART :
PART A :
Coal Handling Plant Performance Improvement
Best practices in Fuel Management.
PART B :
Cost Optimization.
8 May 2014

COAL HANDLING PLANT(CHP) LAYOUT

MAJOR CONSIDERATION:
v The design and layout of a CHP should be simple but robust.
v Should
have
well
designed
optimized
railway
network
and
marshalling yard (for both coal and fuel oil unloading).

v Optimize use of Space: A] Coal Stack yard for at least 15 Days for
crushed Coal & Yard for Uncrushed coal B]Minimizations of losses
in the system
v Functional requirement.
v Provision of future expansion.
v Provision of dedicated space with accessories
to carry out maintenance of various equipments.
8 May 2014

UNLOADING
UNITS
EQUIPMENTS
FOR FIRE &
SAFETY AND
FUGITIVE
EMISSION
FEEDING
UNITS
MAJOR
PLANTS/
EQUIPMENTS
IN CHP
CONVEYING
SYSTEM &
BUNKERS
CRUSHING &
SCREENING
UNITS
STACKING &
RECLAIMING
UNITS
8 May 2014

RAKE UNLOADING SYSTEM

MAJOR TARGET
v No demurrage and No penalty.
v Proper weighing through In Motion
Weigh Bridge.
To monitor this WBPDCL has implemented
a software based on line Monitoring system
To accomplish quicker unloading, it is preferred to have
i) Large Engine for haulage and shunting,
ii) Electrified Track for Track Hopper.
iii) MERRY GO ROUND SYSTEM
8 May 2014

UNLOADING SYSTEM
Provision of the following system:

1. Track Hopper for BOBRN Wagons
2. Wagon Tippler System for BOXN wagons
3. Manual unloading system (with Proclaimer crane).
4. Secondary Fuel (LDO,HFO,LVFO) Unloading system
Besides, Provision of Unloading by Dumpers and Rope way( for
Pithead stations).
8 May 2014


BOBRN(Bottom Open Bogie on Rails) It is Rapid Bottom

Discharge (Pneumatic) Hopper Wagon
TRACK HOPPER:
Holding capacity of Track Hopper
should be sufficient enough [1 to 1
times the rake load of 3850 MT] so
that unloading can be conveniently
completed within the free time[2
hrs].
8 May 2014


WAGONS UNLOADING SYSTEM
WAGON TIPPLER BOXN Unloading :
Stipulated Rake Unloading Time 7 hours.
Wagon Tippler are used to unload BOXN wagon.
Wagon Tippler is of Two Types :

1) Rotary & 2) Rota side.
8 May 2014

RAKE UNLOADING
WAGONS
UNLOADINGSYSTEM
SYSTEM
NEW WAGON TIPLER-- RDSO RECOMMENDED(G33) Rev-1:
With creation of Dedicated Freight Corridor linking major

ports and a no of Feeder routes, the newest challenge to Indian
railways is the RDSO's G33 Rev 1 "Requirements." The "G33"
represents rules that are specific to Wagon Tipplers, and as a
whole, they are a mix of new and existing criteria. These
requirements dictate the dimensions (width, height, length) of
the rail wagons to be handled, that weigh bridges must be
integrated into the rail lines and that any auxiliary equipment
should not damage the rail wagons in any way. The acceptable
styles of Wagon Tipplers are the C-Frame Rotary Tippler
8 May 2014


Wagon Tippler [C-Frame
Capacity :140
tones
Total Axle load
Tare Weight
32.5T and 25T axial

Load
for DFC & feeder routes
No. of tips/hr
25 Tips / Hr
Angle of tipping: 160 Deg
Rotary Tippler]
Movable articulated
side wall design
The side wall moves through hydraulic cylinders and

touches the wagon standing on the platen without
applying pressure.
Positioning of Wagon
by Side Arm Charger
Entire Haulage from pulling loaded wagons, segregating &

Placing loaded wagon sequentially, pushing unloaded
wagon in empty buffer line
Mandatory Wheel
gripper
Two sets of hydraulically operated wheel grippers on the

rails are fitted to the platform to grip the wagon wheels
and prevent any derailing during the tippling operation.


Hydraulically operated wheel chocks on the inhaul
and outhaul side of the platen prevent the wagon
wheels from rolling back on the platen.
Mandatory retractable
wheel chocks on out haul
side
Wagon Bogies spring
release mechanism
Force exerted on Top
Clamp cylinder should not
be more than 1.5T per
clamp
pad;
Clamping
arrangement: By Hydraulic
Cylinder
Six Hydraulically-operated Steel Clamping Arms

Moving Through The Hydraulic Cylinder
The purpose is that any auxiliary equipment should
not damage the rail wagons in any way.
Time cycle
Tipping :30 Sec

Gross & Tare
Weighing:10 Sec.
Pause :05 Sec
Return :25 Sec.
Total time cycle 70 Sec.

Major Impediments for smooth Uninterrupted &

Reliable Operation of Unloading Units are:
Presence of Stones/Boulders/ Shale and Lumpy
Coal
It should be tackled by Effective use of Mechanical
Handling Equipments like:
vRock Grab Crane with Trailer
vRock Breaker or Hilti
vMobile Rock Grabber Equipment [Bob Cat]
vJCB Crane and Hydra Crane etc etc

Various type of Feeders used in CHP are:

Apron Feeder
Belt Feeder
Rotary Feeder
Screw Feeder
Vibrating Feeder
Unbalanced Motor drive feeder
Electro Magnetic Feeder
8 May 2014
13

STACKER CUM RECLAIMER

In older plants of WBPDCL, MAMC, Durgapur(oldest supplier
in India) make S & R are in use where the drives for Luffing,
Slewing, Bucket and Carriage Movements are by DC/AC
motor-Gearbox with Relay based operation & Control..
Modern Reversible Stacker cum Reclaimer Unit have both
Hydraulic as well as Motor-G/Box with Hydraulic coupling
drive with Microprocessor based control logic.
Main purpose :
a] Combine function of making stockpile on either side of
the rail track and also reclaim them when needed.
b] Proper blending of coal to ensure supply of design coal
to Boiler and minimize generation cost.
8 May 2014
14

CRUSHING & SCREENING UNITS

There are two types of Crushers:
A.
PRIMARY CRUSHERS :
The primary
crushers are either hammer type or single roll
crushers.
They are designed to crush the coal from
above300 mm to less than100 mm size. Coal
lumps bigger than 450 mm size causes
serious trouble in the crushers very often.
A.
SECONDARY CRUSHERS
: The secondary
crushers, which are either hammer type

or ring granulator type. These crushers
further crushes coal to the size of 25 mm
size.
8 May 2014
15

There are two types of Screens used in large Power Stations:

VIBRATING SCREEN: Vibrating screens are of gravity feed type, being
sloped downward from the feed to discharge end. A high frequency low
magnitude vibration (Elliptical or Rotary) is given to
the screen by Unbalanced Rotor shaft. The purpose of vibration is
to keep the meshes clear of wedged particles and stratify the coal so that
fine particles come down in contact with the screen. Double deck Screen
with Perforated Pate (100mm sq) at Top and Wire mesh (25mm sq) screen
below are preferred.
ROLLER SCREEN:
The coal is feed on the rollers, which are continuously rotating. While
rotating these shaft, transfers the coal from feeding end to crushing process
end. The required size of coal is passed through gap of roller shafts. The
remaining coal is passed through rollers to crusher.

PROTECTIONS IN CONVEYOR SYSTEM

For efficiency and reliability-all these protections must be always in
service.
v Numerical relay based Motor Protection with memory [E/F,
O/C, Thermal, Stalled Rotor, Hi Starting Time etc]
v Sector wise Pull cord switch
v Zero Speed Switch
v Belt Sway
v Chute Lock switch
Operation of these switches trip the conveyor along with all down stream
conveyors through PLC Logic.
In addition Hold Back device protection in Gear Boxes for major conveyors.
8 May 2014
17

MAJOR EQUIPMENT ASSOCIATED WITH CONVEYOR SYSTEM

MECHANICAL
q Conveyor Belt :Presently Nylon Belts are used ; Belt type,
plies, Strength & other properties as per IS 1891 and
ASTMD624.
q Idlers : Carrying Troughing Idlers : Return Idlers : Carrying
Self-Aligning Idlers : Return Self Aligning Idlers Impact Idlers
q Pulleys
q Gravity take Up system
q Spring loaded Belt scrapper
q Coffin Box

MAJOR EQUIPMENT ASSOCIATED WITH CONVEYOR SYSTEM

ELECTRICAL
q ILMS ( In Line Magnetic Separator)Along the Belt Before
Crusher
q Belt WeigherCalculates quantity of Coal at downstream belt
after Track Hopper/WT, Yard Conveyor/Intermediate Belt of
S & R and Bunker Conveyor
q
Metal Detector:
q Electro Magnet at downstream belt after Track Hopper/WT

TYPICAL PROBLEMS FACED IN CHP:

v
SEASONAL PROBLEMS ASSOCIATED WITH SUMMER AND

MONSOON
Management strategy is to have Action Plan at least 4 months in
advance with proper delegation of authority for execution:
Summer Preparedness
Major issue is Fire Hazards, Fugitive emission and stock build up
Monsoon Preparedness
Major issue is Water Logging and Screen ,Chute Jamming,

readiness of all sump pump
8 May 2014
20

KEY EFFICIENCY PARAMETERS FOR OPERATIONAL MANAGEMENT
v Specific Energy consumption per ton of Bunkering

v Belt Utilization Factor
v Blending Strategy
v Demurrages
8 May 2014
21

Development of Best practices on

Maintenance Management
Under
the
present
business
environment
&
cost
competitiveness, effective maintenance management has been
accepted as the key to corporate strategy for reduced cost.
The strategies are:
Identification of Critical Parameters
Dedicated department for Maintenance Planning
Institutionalized Process for Maintenance Planning and
scheduling
Documented procedures for individual equipments with
drawing and checklists.
8 May 2014
22

CONDITION BASED MAINTENANCE FOR CHP

Basic theory of condition monitoring is to know detoriating
condition of a machine, well in advance before a breakdown.
Working condition in CHP are dusty, dirty and often wet
conditions. There is a constant quest to improve uptime and
avoid unplanned maintenance.
Main objective of CBM for CHP:
Establish an alarm level based on variation of physical
parameters like vibration, power consumption, temperature
etc.
Prediction of impending failure of critical plant components
like crusher Rotors, Conveyor Pulley shafts, G/Boxes,, in real
time resulting in enhanced safety, operational reliability,
availability and maintainability.
8 May 2014
23

CONDITION MONITORING IMPLEMENTATIONS
The steps are:

Divide pant for ease of Maintenance
Detection of Physical Parameters.
In service examination by using NDT
Analysis of fault diagnosis
Correction.
8 May 2014
24

IMPORTANT PARAMETERS
That can be measured, trended and analyzed to
detect imminent failure or onset of problems
are:
Vibration
Temperature
Lube Oil analysis
Operational characteristics like Coal flow rate,
Conveyor speed, specific energy consumption
per MT coal conveying etc.
Prevention of Chute jamming and snapping of
belts-- Chute lock switch
8 May 2014
25

IN SERVICE EXAMINATION BY USING NDT

Ultra sonic thickness gauge measurement mainly
used at Transfer Chute liners, Crusher, conveyor
structures etc.
Infra
red
Non
measurement.
contact
type
temperature
Ultrasonic Flaw detector mainly used at shafts of

crusher, Stacker cum Reclaimer, WT etc
8 May 2014
26

BEST PRACTICES in FUEL MANAGEMENT
Fuel supply
from Coal
Companies
Coal
Quality,
Sampling &
Testing
Captive
Coal Block
Developme
nt
WBPDCL FUEL
MANAGEMENT
STRATEGY
Coal Import
Transportat
ion and In
Plant Fuel
Managemen
t

Fuel supply from Coal Companies
Selection of Colliery based on Minimum landed cost

per unit heat energy and review FSA.
Materialization of FSA Quantity a] with no additional
incentive to coal co ; & b] no short supply
compensation for as per FSA agreement
Claiming against a]Grade Slippage b] Boulders/
Lumpy Coal from Coal companies
Use of Beneficiated coal. Advantages are:
v Improve thermal efficiency, Lower Aux Power for Mill,
CHP and AHP & Spec Oil consumption
vReduce erosion & Maintenance cost
vCompliance of Env. Norms
vReduce coal transportation cost
8 May 2014


Fuel supply from Coal Companies

Adopt an effective monitoring and coordination system
through outsourced agencies (3rd Party) towards ensuring
adequate quality of coal from current coal supplier on timely
basis.
Performance of Service providers to be linked with short
supply, quality and quantity supplied with incorporation of
penalty clause.
Adopt an independent third party verification for coal quality
assessment (testing)
8 May 2014


CAPTIVE COAL BLOCK DEVELOPMENT
Reduce single coal supplier dependence by developing allocated
captive coal block
Development & Mining through engaging Mine Developer cum
Operator.
Selection of MDO through competitive bid process.
Target securing additional coal blocks towards ensuring fuel
security.
Major Advantages:
Most economic
Coal received at site is considered for payment for quality and
quantity and size.
8 May 2014


TRANSPORTATION AND IN PLANT FUEL MANAGEMENT
Railway Liasioning to be improved to avoid bunching of rakes.
No simultaneous placement of difficult rakes (having
stone/overburdens/ lumpy coal)at Track hopper and WT hopper
Agreement with railway to be negotiated on wagon on load basis
Engagement of Financial Transaction Adviser ( as done by NTPC,
Simhadri) for collection of RR and payment of Rail freight.
8 May 2014

COAL IMPORT
Scout for alternative coal sources supply
(indigenous or imported) and secure
additional suppliers of coal over & above
FSA quantity.
Coal import through Long term contract to
be entered on International competitive
bidding.
Penalty clause for Moisture, Ash and GCV
deviating a permissible band.
8 May 2014

COAL QUALITY, SAMPLING & TESTING

Proper Sampling (As per IS-436, part-1, Rev 1996)
a] At Loading Point
b] At Receiving Point i) Sampling at Wagons ii) At

Conveyor
c) At Bunker/Feeder (as fired)
v Proper Sample Preparation and Testing (As per IS1350, part-1, Rev 1986)

COST OPTIMISATION
Major area of concern for all stakeholders
including Govt.:
Energy security :The adequate availability of
energy at affordable price is one of the basic
requirements for faster economic and social
development of the vast majority of people.
Losses from coal based power generation
amounted to a significant % of total national
energy supply and should be major targets of
national energy conservation efforts.
8 May 2014
34

COST OPTIMISATION
Stiff Challenges in front of Coal based Power stations
Availability of
alternative power
from cheaper
sources
Lack of incentive to
private entrepreneur to
ensure capital flow in
this infrastructure
projects.
Tariff & Profit guided

by Regulatory Regime
Govt. mandate of
freezing of tariff even
though input prices
increases.
Area of Concern for Cost

Competitiveness
Volatility of prices
of Imported coal
Uncertainty of
fuel supply from
Indigenous
supplier
Inefficiency due to
old age and
obsolescence of
plants & equipments

OPTIMISATION of GENERATION COST
ROADMAP
Improve Efficiency
Augment capacity of older units thru
Energy Efficient R & M
Reduce cost of Generation particularly
Variable cost
Adopt automation and advanced technology

Accomplishment of Efficiency & Capacity

Improvement
Energy Efficient Renovation & Modernization of older
units
Increased availability of Primary Fuel by development
of own captive coal blocks.
Installation of new thermal power plant with Super
Critical Technology.
Minimize Coal conversation losses
8 May 2014
37

Conclusion.
Substantial capital investment is required to initiate capacity
augmentation of Coal Based Power generation. To make growth truly
inclusive, investment coupled with managerial and technical support
from Private Sector enterprise is essential. As power sector projects are
highly capital intensive, specific measures are needed to incentivize
private entrepreneur to ensure capital flow in this infrastructure
projects.
A paradigm shift is needed in our approach to energy policy. From a
supply-demand approach, we need to move to an integrated approach
incorporating a judicious mix of cost effective generation, investment in
capacity, efficiency improvement of the existing capacity through EE R &
M, reduction in T&D losses and improvement in end-use efficiency i.e.
promoting conservation

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THE WEST BENGAL POWER DEVELOPMENT CORPORATION LTD.

(A Govt. of West Bengal Enterprise)

LA Block, Sector-III, Salt Lake City, Kolkata-700 098, W.B.

THE WEST BENGAL POWER DEVELOPMENT CORPORATION LTD.

LA Block, Sector-III, Salt Lake City, Kolkata-700 098, W.B.