LARA STPP (2 X 800 MW)

COAL HANDLING PLANT

BRIEF DESCRIPTION OF COAL HANDLING PLANT

1.00.00COAL TRANSPORTATION AND HANDLING SYSTEM

1.01.00

Coal Transportation

The daily coal requirement for 2 X 800 MW units shall be about 23885 tonnes based on average gross calorific value of 3500 Kcal/ kg (Design Coal), 100% plant load factor and 2176 kCal/kWhr unit heat rate.

The envisaged mode of coal transportation from the coal mines to the power plant is by Indian Railways rakes and NTPC owned railway rakes. The Indian Railway rakes shall be unloaded at wagon tippler terminal and NTPC owned railway rakes shall be unloaded at Track Hopper.

1.02.00

Coal Handling System

An independent coal handling plant is proposed to cater to the coal requirement of two (2) units of 800 MW. Coal handling plant consisting of 2400 TPH coal conveying system (with 100 % standby parallel stream) along with crusher house, trippers etc., Further, conveying of the crushed coal to boiler bunkers or stacking/ reclaiming of the coal to/from crushed coal stockyards is by means of one set of parallel double stream (one working and one standby) of belt conveyors.

Two numbers of unloading streams rated for 2400 TPH are proposed for unloading coal; one number for BOXN rakes and the other one is for BOBR rakes. Each is provided with parallel double stream (one working and one standby) of belt conveyors along with facilities for receiving & unloading. For unloading coal, two (2) number Wagon Tipplers shall be provided to unload coal from BOXN rakes and One (1) number track hopper is provided to unload coal from BOBR wagons. Two (2) nos. rails mounted, travelling Stacker-Reclaimers of bucket wheel type and One (1) no. rail mounted, travelling Reclaimer is proposed for coal stock yard management. Further One (1) number coal storage silo along with Belt feeders is provided at stock yard for blending of coal. The capacity of blending system is rated for 800 TPH.

The overall operating hours of the coal handling plant shall be 16 hours spread over two shifts per day leaving third shift exclusively for routine inspection and maintenance. The proposed CHP shall cater to the peak daily requirement of coal for both units in three bunker filling cycles in 12 hrs effective operation.

It is envisaged that ROM coal shall be supplied. Coal handling plant shall have crushers for ultimately sizing the coal to (-) 20mm.

From crusher house, the crushed coal can either be conveyed directly to the coal bunkers through a series of conveyors or stacked on to the crushed coal stockpiles by means of stacker reclaimers. Motorized travelling trippers shall be provided to feed crushed coal into the raw coal bunkers of the boilers.

Coal stockyards proposed shall have crushed coal storage capacity equivalent to 22 days coal consumption for 2 x 800 MW units

Dust suppression and service water system shall be provided throughout the coal handling plant. The receiving and unloading of BOXN rakes shall be controlled and monitored from the wagon tippler control rooms located adjacent to the wagon tipplers. The receiving and unloading of BOBR rakes shall be controlled and monitored from the track hopper control room located adjacent to the track hopper. A centralized main CHP control room (DDCMIS based) shall be provided to control and monitor the operations of the entire coal handling system.

1.03.0Salient feature of CHP :

a)

CHP Conveyor capacity :

2400

TPH

b)

Paddle Feeders:

1800

TPH

c)

Crushers & Vibrating screens :

1320

TPH

d)

Travelling trippers :

2400

TPH

e)

Stacker / reclaimer :

2400

TPH / 2400 TPH

f)

Wagon Tippler:

25 Tips/hr

g)

Apron Feeders:

2400

TPH

h)

Reclaimer:

800 TPH

2.00.0Brief scope of work :

2.01.0Mechanical :

Complete belt conveyor system having 1800mm wide belt conveyors of 2400 TPH rated capacity along with crushers, vibrating screen feeders, traveling trippers, stacker reclaimer, wagon tipplers, track hopper, technological structures, dust suppression, dust extraction, service water system, drinking water system etc.

2.02.0Electrical :

Complete electrical including controls for monitoring of CHP operation, cabling, power & control cables, switchgear, earthing, lighting etc. along with supporting structure and associated civil / structural works.

2.03.0Civil & Structural :

Complete civil / structural works for track hopper, wagon tipplers, crusher house, transfer points, conveyor footings, conveyor galleries, stacker reclaimer foundations, tunnels, wagon tippler control room, CHP control room, MCC buildings, water storage tanks for utilities and associated works.

SALIENT TECHNICAL FEATURES

Salient technical features of the equipment / systems / services covered in the IFB no. CS-9548-155(R)-2 are mentioned below. These Salient Technical Features are mentioned only to facilitate the prospective bidder to prima-facie understand the requirements under the tender and shall not in any way limit or alter the scope of work and technical features/specification of equipment/system/services covered in the bidding documents. Detailed provisions in regard of scope of work and technical features/specification of equipment/system/services covered in the bidding documents shall be final and binding.

The scope of coal Handling Plant package for LARA STPP – I (2 x 800 MW) shall cover system and detailed design, engineering, manufacture, shop fabrication, assembly, testing and inspection at manufacturer’s works, packing, dispatch, transportation, transit, insurance, custom clearance etc as applicable, delivery to site, insurance during storage, complete services of construction, including erection supervision, testing, inspection, commissioning and handling over to Employer and Guarantee testing including all associated electrical, civil, structural and architectural works.

The Coal Handling Plant has conveyors of 2400 MTPH capacity. Raw coal from Wagon Tipplers and Track Hopper will be conveyed to crusher house and crushed coal will be fed to bunkers through traveling trippers of bunker conveyors via series of transfer points. In case of excess supply, crushed coal will be stacked by stackers-reclaimer machines through stacking route from crusher house and similarly, coal will be reclaimed by stacker-reclaimer machines during shortage of coal supply. Additionally, a reclaimer is provided on a separate rail for blending of imported coal with indigenous coal.

The Coal Handling Plant package consists of Two (2) nos. Wagon Tipplers along with side arm chargers, one (1) no. Track Hopper along with Paddle Feeders, Conveyors and its accessories, Crusher House, Transfer points, Control rooms, MCC rooms, Pump Houses, Stacker Reclaimers, Reclaimers, Trippers, suspended magnets, metal detectors, ILMS, R&P and Rod gates, crushers, monorails, hoists, elevators, two (2) nos. coal sampling units, ventilation and air conditioning system, associated dust suppression systems, and other utilities, etc. along with Mechanical, Electrical, Civil, Structural & Architectural works.

OTHER SALIENT FEATURES:

The salient parameters of conveyor system and equipment are:

a)

Belt Conveyor :

 

 

∑

Rated Capacity (Guaranteed)

: 2400 TPH

 

∑

Belt Width

: 1800 mm

b)

Vibrating Screening Feeder :

 

 

∑

Nos. required

: Four (4)

 

∑

Rated Capacity (Guaranteed)

: 1320 MTPH

c)

Coal Crusher :

 

 

∑

Nos. required

: Four (4)

 

∑

Rated Capacity (Guaranteed)

: 1320 MTPH

d)

Stacker Reclaimer :

 

 

∑

Nos. required

: Two (2)

 

∑

Rated Capacity (Guaranteed)

: 2400 MTPH

 

 

(Stacking & Reclaiming)

 

e)

Reclaimer :

 

 

∑

Nos. required

: One (1)

 

∑

Rated Capacity (Guaranteed)

: 800 MTPH

 

 

(Reclaiming)

 

f)

Paddle Feeders

 

 

∑

Nos. required

: Four (4)

 

∑

Rated Capacity

: 1800 MTPH

g)

Apron Feeders

 

 

∑

Nos. required

: Two (2)

 

∑

Rated Capacity

: 2400 MTPH

h)

Wagon Tipplers

 

 

∑

Nos. required

: Two (2)

 

∑

Rated Capacity

: 25 tips/hr (min.) for wagons of type DFC 25

i)

Side Arm Charger

 

 

∑

Nos. required

: Two (2)

 

∑

Rated Haulage Capacity

: 58 wagons of DFC 25