Coal Mining Project Report
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Transcript of Coal Mining Project Report
PROJECT REPORT
ON
EXTENDED COAL HANDLING PLANT
PACKAGE FOR
PAKRI BARWADIH COAL MINING
BLOCK ,NTPC Ltd.
SUBMITTED BY :
SHIKHAR SINDHU
BRANCH-MANUFACTURING SCIENCE AND TECHNOLOGY
(2012-2017)
IIT KHARAGPUR
PROJECT GUIDANCE BY:
SANCHIT DUA (MANAGER)
------------
SIGNATURE
CONTENTS:
ACKNOWLEDGMENT
ABOUT NTPC
ABOUT LOCATION
BREIF DESCRIPTION OF PROJECT
SCOPE OF THE PROJECT
ELECTRICAL SYSTEM/EQUIPMENT
MECHANICAL SYSTEM
About NTPC –
NTPC Limited (formerly known as National Thermal Power
Corporation Limited) is a Central Public Sector Undertaking
(CPSU) under the Ministry of Power, Government of India,
engaged in the business of generation of electricity and allied
activities. It is a company incorporated under the Companies Act
1956 and a “Government Company” within the meaning of the act.
The headquarters of the company is situated at New Delhi.
NTPC’s core business is generation and sale of electricity to state-
owned power distribution companies and State Electricity Boards
in India. The company also undertakes consultancy and turnkey
project contracts that comprise of engineering, project
management, construction management and operation and
management of power plants. The company has also ventured into
oil and gas exploration and coal mining activities. It is the largest
power company in India with an electric power generating capacity
of 42,964 MW. Although the company has llotte. 18% of the total
national capacity it contributes to over 27% of total power
generation due to its focus on operating its power plants at higher
efficiency levels (llotte. 83% against the national PLF rate of
78%).
It was founded by Government of India in 1975, which held 75%
of its equity shares on 31 March 2013 (after divestment of its stake
in 2004, 2010 and 2013).
In May 2010, NTPC was conferred Maharatna status by the Union
Government of India. It is listed in Forbes Global 2000 for 2014 at
424th rank in the world.
Vision & Mission-
“ to be the world’s largest and best power producer, powering
india’s growth”
OVERVIEW
India’s largest power company , NTPC was set up in 1975 to
accelerate power development
Board of Directors
Shri Arup Roy Chaudhary believes in Project Implementation
through Proactive approach and his dictum is “Sankalp Suddah hi
Siddah”
Human Resources
People before PLF (Plant Load Factor) is the guiding philosophy
behind the entire gamut of HR policies at NTPC
Diversified Growth
NTPC’s quest for the diversification started about a decade back
with foray into hydro power
Future Goals
The National Thermal Power Corporation Ltd is on an expansion spree to meet the power requirements of the country – it has targeted to add 14058 MW in 12th Plan (From FY13 to FY 17) of which it had already added 4170 MW in the year 2012-13 and 1780 MW from April to 26 March 2014. Dr. Arup Roy Choudhury, Chairman and managing director, NTPC, said that capacity addition through Greenfield projects, expansion of existing stations, joint ventures and takeover of SEB stations were on the cards.
NTPC also plans to go global. The public sector company has signed a memorandum of agreement with the Government of Sri Lanka and Ceylon Electricity Board for setting up a 500-MW (2x250 MW) coal-based thermal power plant in the island nation. AnMoU has also been signed with Kyushu Electric Power Co. Inc., Japan, for establishing an alliance for exchange of information and experts from different areas of the business. The company is also in the process of finalisingan MoU with Nigeria for setting up power plants against allocation of LNG on long-term basis for NTPC plants in India. NTPC has also been allotted coal blocks namely, PakriBarwadih, ChattiBariatu, kerandari, Talipalli and Dulanga. Besides these recently Ministry of Coal has vide its press release dated 3 July 2013 has allotted 4 more blocks namely, Banai, Bhalmuda, Chandrabila and KudanliLaburi. All these mines are The National Thermal Power Corporation Ltd is on an expansion spree to
meet the power requirements of the country – it has targeted to add 14058 MW in 12th Plan (From FY13 to FY 17) of which it had already added 4170 MW in the year 2012-13 and 1780 MW from April to 26 March 2014. Dr. Arup Roy Choudhury, Chairman and managing director, NTPC, said that capacity addition through Greenfield projects, expansion of existing stations, joint ventures and takeover of SEB stations were on the cards.
NTPC also plans to go global. The public sector company has signed a memorandum of agreement with the Government of Sri Lanka and Ceylon Electricity Board for setting up a 500-Mw (2x250 Mw) coal-based thermal power plant in the island nation. AnMoU has also been signed with Kyushu Electric Power Co. Inc., Japan, for establishing an alliance for exchange of information and experts from different areas of the business. The company is also in the process of finalisinganMoU with Nigeria for setting up power plants against allocation of LNG on long-term basis for NTPC plants in India. NTPC has also been allotted coal blocks namely, PakriBarwadih, ChattiBariatu, kerandari, Talipalli and Dulanga. Besides these recently Ministry of Coal has vide its press release dated 3 July 2013 has llotted 4 more blocks namely, Banai, Bhalmuda, Chandrabila and KudanliLaburi. All these mines are having estimated Geological Reserves of 5.7 Billion Tones. The Company has also incurred a cumulative expenditure of Rs. 18360 million on these mines till December 2013. As per the MOU dated 22 February 2014, signed between NTPC, BSPGCL (Bihar State Power Generation Company Limited) and LBCPL (LakhisaraiBijlee Company Private Limited) NTPC will develop a 1320 MW (2 X 660 MW) Thermal Power Project at Kajra (Lakhisarai district), Bihar
e having estimated Geological Reserves of 5.7 Billion Tones. The Company has also incurred a cumulative expenditure of Rs. 18360 million on these mines till December 2013. As per the MOU dated 22 February 2014, signed between NTPC, BSPGCL (Bihar State Power Generation Company Limited) and LBCPL (LakhisaraiBijlee Company
Private Limited) NTPC will develop a 1320 MW (2 X 660 MW) Thermal Power Project at Kajra (Lakhisarai district), Bihar
Subsidiaries NESCL The company was formed on August 21,2002. It is a wholly owned subsidiary company of NTPC with the objective to construction
Business developmentNTPC has identifiesd Joint Ventures, strategic alliances as well as acquisitions and diversifications for business development
History1975 to 1994
The company was founded in November 1975 as “National Thermal Power Corporation Private Limited”. It started work on its first thermal power project in 1976 at Singrauli in Uttar Pradesh .In the same year, its name was changed to “National Thermal Power Corporation Limited”. In 1983, NTPC began commercial operations (of selling power) and earned profits of INR 4.5 crores in FY 1982-83. By the end of 1985, it had achieved power generation capacity of 2000 MW.In 1986, it completed synchronization of its first 500 MW unit at Singrauli. In 1988, it commissioned two 500 MW units, one each in Rihand and Ramagundam. In 1989, it started a consultancy division. In 1992, it acquired Feroze Gandhi Unchahar Thermal Power Station (with 2 units of 210MW capacity each) from Uttar Pradesh RajyaVidyutUtpadan Nigam of Uttar Pradesh. By the end of 1994, its installed capacity crossed 15,000 MW
1995 to 2004
In 1995, it took over the Talchar Thermal Power Station from Orissa State Electricity Board. In the year 1997, Government of India conferred it with “Navratna” status. In the same year it achieved a milestone of generation of 100 billion units of electricity in a year. In 1998, it commissioned its first naptha-based plant at Kayamkulam with a capacity of 350 MW. In 1999, its plant in Dadri, which had the highest plant load factor (PLF) in India of 96%, was certified with ISO-14001. During 2000, it commenced construction of its first hydro-electric power project, with 800 MW capacity, in Himanchal Pradesh.In 2002, it incorporated 3 subsidiary companies: “NTPC Electric Supply Company Limited” for forward integration by entering into the business of distribution and trading of power; “NTPC VidyutVyapar Nigam Limited” for meeting the expected rise in energy trading; “NTPC Hydro Limited” to carry out the business of implementing and operating small and medium hydro-power projects. In the same year its installed capacity crossed 20,000 MW.Listing: NTPC got listed on BSE and NSE on 5 November 2004. Against the issue price of INR 62 per share, it closed the first day of listing with INR 75.55 per share. On the day of listing, it becomes the third largest company in India in terms of market capitalization.
2005 to present
In October 2005, the company’s name was changed from “National Thermal Power Corporation Limited” to “NTPC Limited”. The primary reason for this change was the company’s foray into hydro and nuclear based power generation along with backward integration by coal mining. In 2006, it entered into an agreement with Government of Sri Lanka to set up two units of 250 MW each in Trincomalee in Sri Lanka. During 2008 and 2011, NTPC entered into Joint Ventures with BHEL, Bharat Forge, NHPC, Coal India, SAIL, NMDC and NPCIL to expand its business of power generation. By the end of 2010, its installed capacity crossed 31,000 MW.
Operations-
NTPC operates from 55 locations in India, one location in Sri Lanka and 2 locations in Bangladesh.
Headquarters: In India, it has 8 headquarters (HQ):
NTPC Plants and their capacity-
The total installed capacity of the company is 41,794 MW (including JVs) with 17 coal-based and seven gas-based stations, located across the country. In addition under JVs (joint ventures), six stations are coal-based, and another station uses naphtha/LNG as fuel
Sr. No. Headquarters City1 NCRHQ Delhi2 ER-I HQ Patna3 ER-II HQ Bhubaneshwar4 NRHQ Lucknow5 SR HQ Secunderabad6 WR-I HQ Mumbai7 WR-II HQ Raipur8 Hydro HQ Delhi
Thermal-Coal based
Sr. No. Project State Capacity
1 Singrauli Super Thermal Power Station Uttar Pradesh 2,000
2 NTPC Korba Chhattisgarh 2,6003 NTPC Ramagundam Andhra Pradesh 2,600
4 Farakka Super Thermal Power Station West Bengal 2,100
5 NTPC Vindhyachal Madhya Pradesh 4,260
6 Rihand Thermal Power Station Uttar Pradesh 3,000
7 Kahalgaon Super Thermal Power Station Bihar 2,340
8 NTPC Dadri Uttar Pradesh 1,8209 NTPC Talcher Kaniha Orissa 3,000
10Feroze Gandhi Unchahar Thermal Power Plant
Uttar Pradesh 1,050
11 Talcher Thermal Power Station Orissa 460
12 Simhadri Super Thermal Power Plant Andhra Pradesh 2000
13 Tanda Thermal Power Plant Uttar Pradesh 440
14 Badarpur Thermal Power Station Delhi 705
15 Sipat Thermal Power Plant Chhattisgarh 2980
16 Mauda Super Thermal Power Station Maharashtra 1000
17 Barh Super Thermal Power Station Bihar 1980
18 Kudgi Super Thermal Power Project Karnataka 2400 MW
19 NTPC Bongaigaon Assam 750 MW
20 LARA Super Thermal Power Project Chhattisgarh 4000 MW
Coal Based (Owned through JVs)
Sr. No. Name of the JV Location State Inst.Capacity in Megawatt
1 NSPCL. Joint venture with SAIL. Durgapur West Bengal 120
2 NSPCL. Joint venture with SAIL. Rourkela Orissa 120
3 NSPCL. Joint venture with SAIL. Bhilai Chhattisgarh 574
4
Nabinagar Power Generating Co. Pvt. Ltd. NPGC. Joint venture with Bihar State Electricity Board.
Aurangabad Bihar 1980
5
Muzaffarpur Thermal Power Station (MTPS). Joint venture with Bihar State Electricity Board.
Kanti Bihar 110
6
Bhartiya Rail Bijlee Company Limited. Joint venture with Indian Railways.
Nabinagar Bihar 1000
7Aravali Power CPL JV with HPGCL & IPGCL
Jhajjar Haryana 1500
8 NTECL JV with NTPC & TNEB Chennai 1500
Total 6904
Gas based
Sr. No Project State Installed Capacity in Megawatt
1 NTPC Anta Rajasthan – Baran 4132 NTPC Auraiya Uttar Pradesh 6523 NTPC Kawas Gujarat 6564 NTPC Dadri Uttar Pradesh 8175 NTPC Jhanor Gujarat 6486 NTPC Kayamkulam Kerala 3507 NTPC Faridabad Haryana 430
8 RGPPL (JV) Maharashtra – Ratnagiri 1940
Total 5895
HydelThe company has also stepped up its hydroelectric power (hydel) projects implementation. Some of these projects are:
1. Loharinag Pala Hydro Power Project by NTPC Ltd: Loharinag Pala Hydro Power Project (600 MW i.e.150 MW x 4 Units) is located on river Bhagirathi (a tributary of the Ganges) in Uttarkashi district of Uttarakhand state. This is the first project downstream from the origin of the Ganges at Gangotri. Project was
at advance stage of construction when it was discontinued by Government of India in August 2010 .
2. TapovanVishnugad 520MW Hydro Power Project by NTPC Ltd: In Joshimath town. The project is under construction.
3. LataTapovan 130MW Hydro Power Project by NTPC Ltd: is further upstream to Joshimath. This project is under environmental revision.
4. Koldam Dam Hydro Power Project 800 MW in Himachal Pradesh (130 km from Chandigarh )This project is under advanced stage of construction.
5. RupasiyabagarKhasiabara HPP, 261 MW in Pithoragarh, Uttarakhand State, near China Border. This project is yet to be given investment approval.
Environment Policy and ManagementFor NTPC, the journey extends much beyond generating power right from inception, the company had a well defined environment
CenPEEP Toward reduction of Greenhouse Gas (GHG) Emission from Indian thermal power plant, NTPC has been promoting
Ash UtilizationAsh utilization is one of the key concerns at NTPC. The Ash Utilisation Division, set up in 1991, strives to derive maximum
AfforestationMaintenance of ecological balance and a perfect environment has been of utmost impoertance at NTPC
NTPC Ltd.
Pakri Barwadih Coal mining Project
Ujjwal complex, Pugmil Road
HazaribaghLOCATION Barkagaon and kerakar blocks, Hazaribagh district Jharkhand North eastern part of the karanpuru coal field
Longitude of 85°10’ to 85°13’ E Latitude of 23°51’30” to 23°55’30” N
ROAD 120 km from Ranchi
RAIL the nearest rail station Koderma railway station on Howrah-Delhi 90 km of the project site. The coal field is likely to be connected by a new railway network under initial phase of execution from Gomoh-Daltonganj railway line of SE railway and also from Howrah-Delhi railway line at Koderma of eastern railway
AIR The nearest airport at Ranchi is located at a distance of 130 kms of the project site
LAND REQUIREMENT
Non forest 4681.18 acre
Forest 2051.13 acre
Total 6733.31 acre
COAL RESERVE
Geological 1436 MT
Mine able 519.34 MT
PRODUCTION 15MTPA
TYPE OF MINE Open cast
LIFE OF MINE 39 years
The Project
The Pakri-Barwadih Coal Mining Project is going to acquire about 8787 acres of land of which about 6286 is private land including residential and agriculturalland and the rest is permanent land
BRIEF DESCRIPTION OF PROJECTThis description pertains to the work of installation of extended coal handling plant for handling and transportation of (~) 50mm size coal from transfer point TP-6 at a designated place to fast loading silo at loading and by cross country conveyer system. The brief description of the envisaged system is as follows :
1. Crushed coal of (~) 50 mm size shall be transported from mine by a cross country conveyer system upto TP-6 which is being constructed separately by the owner. From this transfer point , the scope of work of CHP under this package starts. The package shall have double stream conveyors of capacity 2500 TPH . It shall cater to 15 million tons per annum coal throughout of mines
The conveyor shall be routed at an elevation point of min 6.0 m above ground along the corridor. At locations of crossing of rail lines or where an existing road runs across the conveyor corridor the conveyor corridor the conveyor shall be routed at an elevated level with minimum head room clearance of 8 mtr from top to road/rail
From transfer point TP-6 double steam troughed belt conveyor shall convey (-) 50 mm coal through a series of conveyor points and transfer points to silos
Future provision of ground bunker has also been envisaged for which inter connection provision from TP-10, TP-11 & TP-12 has been kept
2. Coal received at TP-6 hsall be conveyed directly to fast loading silos through conveyor 6A/B, 7A/B, 8A/B, 9A/B, 10A/B, 11A, 11B, 12B passing through transfer points TP7,8,9,10,11 & 12 conveyor 11A will feed silo A & conveyor 12B will feed silo B. Future provision for conveying the coal from TP-10 to silo through series of conveyors and transfer points passing through ground bunker , TP-
11 & TP-12 has been envisaged . For the necessary provision at TP- 10 & TP-12 to be kept.
3. Two nos. of fast loading silos shall be of 4000T capacity suitable for flood loading of Indian railways rakes. The silos shall be of RCC construction with two nos. per weigh bins of 149 m³ nominal flush capacities. The fast loading system shall comprise 8 nos. of silo discharge gates and 8 nos. maintenance/isolation gates. Two nos. flow flow control gates shall be provided in silo along with telescopic swing chutes for loading of Indian railways rakes.
4. Air cannon system for arch breaking along with air compressor,piping and automation shall be provided for silo. Continuous level indication for silo maintenance shall be provided of ultrasonic type single climbing scaffold for silo maintenance shall be provided . R&P type elevator shall be provided to acess various floors of silo
5. Service road shall be provided along with cross country conveyor corridor along with lighting and realted works. The conveyor corridor shall be adequately compacted of each conveyor for ease of movement of light vehicles
6. The rated capacity of each conveyor in scope of this package is 2500 TPH
7. Belt scales (BS-1;2) shall be mounted on conveyor 11A & 12B to meet coal received at TP-6 and conveyed for further transmission
8. At each transfer point i.e. TP-6,7,8,9,10 and 11 feeding chutes of dischanging conveyors shall have provision of feeding any of downstream conveyor s by means of motorized flap gates
9. At TP-13 & TP-14 automatic coal sampling section(CSU) is provided for sampling of coal
10. Coal of size (~) 50mm shall be fed to fast loading silo continuously. Before starting the loading process silo shall be kept filled up at least 65% of silo level coal from the loading hopper is drawn to pre weigh hoppers of 72 tones capacity through hydrauclically operated slide gates. Coal from these pre weigh hoppers is discharges into moving railway wagons/MGR wagon slider it through the swing chute arrangement
11. Two nos. in motion weigh bridge (WB-1,2) one each at approach each & exit side of each silo shall be installed to measure the load of empty rake received at the silo & loaded rakes leaving the silo
12. In entire coal handling plant all conveyors shall be controlled & monitored by PLC control system for which CHP control room is being constructed by the owner separately in TP-6,For fast loading silo, PLC based batching system complete with various sensors shall the silo, Fast loading silo shall have its own control room and shall be provided by the bidder
13. For control of fugitive dust, plain water dust separation is envisaged for potential dust generating points. Auxiliary service like service water system, ventilation system, cooling water system and portable water system is proposed for entire coal handling plant to be provided by the bidder
14. Fire detection, fire alarm and protecting/fighting system is also envisaged for the entire scope of the package
SCOPE OF THE PROJECT
Conveyor 6A/B of each of 2500 TPH rated capacity receive
ing coal from owner’s conveyor at TP-6 complete with
conveyor supporting structures short supports
Troughed belt conveyors. Belt cables 6 A/B; 7 A/B; 8 A/B; 9
A/B ;10 A/B; 11 A/B ;12 B each of 2500 tph rated capacity
TP-7,8,9,10,11,12,13,14 complete with all
mechanical ;electrical equipments to be housed
Two no. of belt scales; one no. of coal sampling unit
One no. rack & pinion type elevators at each silo for acess to
various operating floors of silo
Two no. of coal loading silos each of 4000 tones capacity
Two no. of electronic in-motion weigh bridge
Presssurized ventilation systems for all switch gear rooms;
MCC rooms & hydropak rooms
Air conditioning of control room; office room; remote i/o
panel room in each mcc/switchgear room
Two nos. belt vulcanization machine of adequate size
complete with all ccessories
ELECTRICAL SYSTEM/EQUIPMENT
MOTORS - All HT and LT motor with lugs and glands
415V MCCs/SWITCHGEAR/DISTRIBUTION
BOARDS-415V motor control centres, AC & DC
distribution boards/fuse boards, local push button
stations for all dries and local motor starters as required
by system and equipment
Outgoing feeder shall be segregated stream wise and
equally distributed on each bus section of MCC
Two nos. of 125A switch fuse feeders (total load
50KVA) shall be provided in each of the bus of above
indicated MCC
CABLES -All power cables (19/33kv, 6.6/6.6kv and
1.1kv grade), control cables,instrumentation cables, fiber
optics cables, signal cables and any special cables for
completeness of system
ILLUMINATION SYSTEM -Illumination system for
complete internal and external lightning of associated
plant and equipment like TPs, Conveyors, Switchyard,
Switchgear & control buildings, workshop, pump house
etc and roads
CABLING; EARTHING AND LIGHTNING
PROTECTION- Cabling viz. cable laying along with
cable accessories , cable trays with supporting structures,
termination & joining kits ,trenches ,duct banks etc
required for cables to be supplied by contractor ,cable
trays laid along conveyor galleries shall be of perforated
types and shall provide cable tray covers
Earthing/grounding and lightning protection for plant
and equipment
TRANSFORMERS -33/6.9 KV; ONAN transformers
and
6.6/433 KV ,ONAN transformers
6.6 KV SWITCHGEAR -6.6 KV switchgear is used,
spare feeders shall be provided as per electrical single
line diagram
6.6KV CAPACITOR BANK -6.6 KV capacitor bank
shall be provided at each 6.6KV switchgear location so
that overall power factor shall remain 0.95
BATTERY -Two sets of 110 V DC, 100 AH(min) lead
acid plante type/60 AH(min.) Ni-Cd battery. Each set
consists of two nos. battery chargers
BATTERY CHARGERS -Two sets of 110 volt, 50
A(MIN) float cum boost chargers are used. Each set
consist of two nos. of battery chargers
PLC AND CONTROL PANELS -Main control desk
with HMI ,video screens; PLC panels; remote i/o
stations; UPS; 24V DC battery and battery chargers for
control of entire coal handling equipment including silo
equipment and HT and LT switchgear
Local control panels for belt weighers; coal sampling
units ;fast loading silo ;sump pumps ;DS/DE ventilation
etc as required for system, CHP control desk with HMIs
shall be provided in silos as per PLC configuration
drawing
CLOSED CIRCUIT (CCTV) SYSTEM;
TELEPHONE & PUBLIC ADDRESS SYSTEM-
CCTV system with 32 nos, cameras ; public address and
telephone system for coal handling plant
33KV SYSTEM -33kv outdoor off-load isolator with
earth switches on pole structure & 33KV indoor circuit
breaker
MECHANICAL SYSTEM
BRAKES-Brakes shall be providing for
decelerating of driven equipment/conveyors as
per requirement .They are mandatory for H.T
drives involving scoop type coupling
BELT CONVEYOR SYSTEM- All belt
conveyors shall be furnished and erected along
with necessary supporting structures;
platforms and on ground or overhead
galleries ;trestle structures with foundation
footings; carrying and return idlers; automatic
take-ups; pulleys; drive motors with suitable
reduction units and couplings; belting; feeder
hoppers; transfer chutes; flap gates; hydraulic
couplings and other necessary accessories
DRIVE EQUIPMENTS-Drive equipments
like electric motors; gearboxes; fluid
couplings; flexible couplings and other
accessories shall be provided for belt conveyor
system; paddle feeders; mobile trippers;
various pumps of dust suppression/extraction
system; fans for ventilation system and other
equipments
BELT SCALES- Belt weigh scales for
measurement of coal flow rate and quantity
shall be provided at specified loactions system
shall be complete with flow rate indicator;
totalizer; control panel etc. It should be
designed for continuous automatic
weighing ;metering and printing of coal flow.
It is provided with self diagnostic feature for
troubleshooting of entire belt scale system
CHP BUILDINGS- Various buildings in coal
handling plant like transfer houses; crusher
house; control rooms and MCC rooms are
completed . All CHP buildings shall have
sufficient space to accommodate the entire
equipment like head end; drive unit and tail
unit of various conveyors; crushers; hoppers;
chutes; control equipment etc.
COAL SAMPLING UNIT- Coal sampling
unit shall be complete with necessary
samplers; crushers; flap values; chutes;
hoppers; belt feeders and sample collectors etc
to give samples from any of two streams
running at guaranteed capacity
IN-MOTION WEIGH BRIDGE- Two
weighbridges shall tentatively be located on
railway track before after silo. The system
shall indicate and print tare, gross and net
weight for each wagon in train. It shall also
indicate and print and of all the trains receives
in a day to know quantity of total coal being
received daily.
COMPLETE PICS OF CHP (Taken from
wiki)
Crushers