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