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 1



PRESENTATION HAVING TWO PART :

PART – A :

EFFICIENCY IN FUEL HANDLING SYSTEM &

COST OPTIMISATION

8 May 2014 2

• Coal Handling Plant –Performance Improvement

• Best practices in Fuel Management.

PART – B :

• Cost Optimization.



MAJOR CONSIDERATION:

COAL HANDLING PLANT(CHP) LAYOUT

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).

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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.



MAJOR

UNLOADING UNITS

FEEDING UNITS

EQUIPMENTS FOR FIRE & SAFETY AND

FUGITIVE EMISSION

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MAJOR PLANTS/

EQUIPMENTS IN CHP

CRUSHING & SCREENING

UNITS

STACKING & RECLAIMING

UNITS

CONVEYING SYSTEM & BUNKERS



MAJOR TARGET

v No demurrage and No penalty.v Proper weighing through ‘In Motion

Weigh Bridge.

RAKE UNLOADING SYSTEM

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Weigh Bridge. To monitor this WBPDCL has implementeda 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




UNLOADING SYSTEM

Provision of the following system:

1. Track Hopper for BOBRN Wagons

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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).



BOBRN(Bottom Open Bogie on Rails) – It is Rapid Bottom Discharge (Pneumatic) Hopper Wagon


TRACK HOPPER:

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TRACK HOPPER:

Holding capacity of Track Hoppershould be sufficient enough [1¼ to 1½times the rake load of 3850 MT] sothat unloading can be convenientlycompleted within the free time[2½hrs].



WAGONS UNLOADING SYSTEM


WAGON TIPPLER BOXN Unloading : Stipulated Rake Unloading Time – 7 hours.

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v Wagon Tippler are used to unload BOXN wagon.

v Wagon Tippler is of Two Types :

1) Rotary & 2) Rota side.



WAGONS UNLOADING SYSTEMRAKE UNLOADING SYSTEM

NEW WAGON TIPLER-- RDSO RECOMMENDED(G33) Rev-1:With creation of ‘Dedicated Freight Corridor’ linking majorports and a no of Feeder routes, the newest challenge to Indianrailways is the RDSO's G33 Rev 1 "Requirements." The "G33"

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railways is the RDSO's G33 Rev 1 "Requirements." The "G33"represents rules that are specific to Wagon Tipplers, and as awhole, they are a mix of new and existing criteria. Theserequirements dictate the dimensions (width, height, length) ofthe rail wagons to be handled, that weigh bridges must beintegrated into the rail lines and that any auxiliary equipmentshould not damage the rail wagons in any way. The acceptablestyles of Wagon Tipplers are the C-Frame Rotary Tippler



Wagon Tippler [C-Frame Rotary Tippler]

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

The side wall moves through hydraulic cylinders and 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.



Mandatory retractable wheel chocks on out haul side

Hydraulically operated wheel chocks on the inhaul and outhaul side of the platen prevent the wagon wheels from rolling back on the platen.

Wagon Bogies spring release mechanism

Force exerted on TopClamp cylinder should not

Six Hydraulically-operated Steel Clamping Arms Moving Through The Hydraulic Cylinder

be more than 1.5T perclamp pad; Clampingarrangement: By HydraulicCylinder

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 Pause :05 Sec Return :25 Sec.

Gross & Tare Weighing:10 Sec. Total time cycle 70 Sec.



Major Impediments for smooth Uninterrupted & Reliable Operation of Unloading Units are:

Presence of Stones/Boulders/ Shale and Lumpy CoalIt should be tackled by Effective use of Mechanical 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

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• Belt Feeder• Rotary Feeder• Screw Feeder• Vibrating Feeder• Unbalanced Motor drive feeder• Electro Magnetic Feeder



• In older plants of WBPDCL, MAMC, Durgapur(oldest supplierin India) make S & R are in use where the drives for Luffing,Slewing, Bucket and Carriage Movements are by DC/ACmotor-Gearbox with Relay based operation & Control..

STACKER CUM RECLAIMER

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• Modern Reversible Stacker cum Reclaimer Unit have bothHydraulic as well as Motor-G/Box with Hydraulic couplingdrive with Microprocessor based control logic.

• Main purpose :a] Combine function of making stockpile on either side ofthe rail track and also reclaim them when needed.b] Proper blending of coal to ensure supply of design coalto Boiler and minimize generation cost.



There are two types of Crushers:

A. PRIMARY CRUSHERS : The primarycrushers are either hammer type or single rollcrushers.

CRUSHING & SCREENING UNITS

8 May 2014 15

crushers.They are designed to crush the coal fromabove300 mm to less than100 mm size. Coallumps bigger than 450 mm size causesserious trouble in the crushers very often.

A. SECONDARY CRUSHERS : The secondarycrushers, which are either hammer typeor ring granulator type. These crushersfurther crushes coal to the size of 25 mmsize.



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 isto keep the meshes clear of wedged particles and stratify the coal so thatto keep the meshes clear of wedged particles and stratify the coal so thatfine 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.



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

PROTECTIONS IN CONVEYOR SYSTEM

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v Sector wise Pull cord switchv Zero Speed Switch v Belt Swayv 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.



MECHANICAL

q Conveyor Belt :Presently Nylon Belts are used ; Belt type,

plies, Strength & other properties as per IS 1891 and

ASTMD624.

MAJOR EQUIPMENT ASSOCIATED WITH CONVEYOR SYSTEM

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



ELECTRICAL

q ILMS ( In Line Magnetic Separator)—Along the Belt Before

Crusher

q Belt Weigher—Calculates quantity of Coal at downstream belt

MAJOR EQUIPMENT ASSOCIATED WITH CONVEYOR SYSTEM

q Belt Weigher—Calculates 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

8 May 2014 20

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



KEY EFFICIENCY PARAMETERS FOR OPERATIONAL MANAGEMENT

v Specific Energy consumption per ton of Bunkering

v Belt Utilization Factor

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v Belt Utilization Factor

v Blending Strategy

v Demurrages



Development of Best practices on Maintenance Management

Under the present business environment & costcompetitiveness, effective maintenance management has beenaccepted as the key to corporate strategy for reduced cost.

8 May 2014 22

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.



CONDITION BASED MAINTENANCE FOR CHP

Basic theory of condition monitoring is to know detoriatingcondition of a machine, well in advance before a breakdown.Working condition in CHP are dusty, dirty and often wetconditions. There is a constant quest to improve uptime andavoid unplanned maintenance.

8 May 2014 23

avoid unplanned maintenance.

Main objective of CBM for CHP:• Establish an alarm level based on variation of physical

parameters like vibration, power consumption, temperatureetc.

• Prediction of impending failure of critical plant componentslike crusher Rotors, Conveyor Pulley shafts, G/Boxes,, in realtime resulting in enhanced safety, operational reliability,availability and maintainability.



CONDITION MONITORING IMPLEMENTATIONS

The steps are:• Divide pant for ease of Maintenance

8 May 2014 24

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



IMPORTANT PARAMETERS

That can be measured, trended and analyzed todetect imminent failure or onset of problemsare:

• Vibration

8 May 2014 25

• Vibration• Temperature• Lube Oil analysis• Operational characteristics like Coal flow rate,

Conveyor speed, specific energy consumptionper MT coal conveying etc.

• Prevention of Chute jamming and snapping ofbelts-- Chute lock switch



IN SERVICE EXAMINATION BY USING NDT

• Ultra sonic thickness gauge measurement mainlyused at Transfer Chute liners, Crusher, conveyorstructures etc.

8 May 2014 26

• Infra red Non contact type temperaturemeasurement.

• Ultrasonic Flaw detector mainly used at shafts ofcrusher, Stacker cum Reclaimer, WT etc



BEST PRACTICES in FUEL MANAGEMENT

Captive Coal Block Developme

Fuel supply from Coal Companies

Coal Quality,

Sampling & Testing

WBPDCL FUEL MANAGEMENT

STRATEGY

Development

Companies

Coal Import

Transportation and In Plant Fuel

Management




ü Selection of Colliery based on Minimum landed costper unit heat energy and review FSA.

ü Materialization of FSA Quantity a] with no additionalincentive to coal co ; & b] no short supplycompensation for as per FSA agreement


8 May 2014

compensation for as per FSA agreementü Claiming against a]Grade Slippage b] Boulders/

Lumpy Coal from Coal companiesü Use of Beneficiated coal. Advantages are:v Improve thermal efficiency, Lower Aux Power for Mill,CHP and AHP & Spec Oil consumptionvReduce erosion & Maintenance costvCompliance of Env. NormsvReduce coal transportation cost




ü Adopt an effective monitoring and coordination systemthrough outsourced agencies (3rd Party) towards ensuringadequate quality of coal from current coal supplier on timelybasis.


8 May 2014

basis.

ü Performance of Service providers to be linked with shortsupply, quality and quantity supplied with incorporation ofpenalty clause.

ü Adopt an independent third party verification for coal qualityassessment (testing)




CAPTIVE COAL BLOCK DEVELOPMENT

• Reduce single coal supplier dependence by developing allocatedcaptive coal block

• Development & Mining through engaging Mine Developer cumOperator.

• Selection of MDO through competitive bid process.

8 May 2014

• 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.




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

8 May 2014

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.




COAL IMPORT• Scout for alternative coal sources supply

(indigenous or imported) and secure additional suppliers of coal over & above

8 May 2014

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.



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 • 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 IS-

1350, part-1, Rev 1986)



COST OPTIMISATION

Major area of concern for all stakeholdersincluding Govt.:

• Energy security :The adequate availability ofenergy at affordable price is one of the basicrequirements for faster economic and social

8 May 2014 34

requirements for faster economic and socialdevelopment of the vast majority of people.

• Losses from coal based power generationamounted to a significant % of total nationalenergy supply and should be major targets ofnational energy conservation efforts.



Availability of alternative power

from cheaper sources

Govt. mandate of freezing of tariff even though input prices

increases.

Tariff & Profit guided by Regulatory Regime

Stiff Challenges in front of Coal based Power stations

COST OPTIMISATION

Area of Concern for Cost Area of Concern for Cost CompetitivenessCompetitiveness

sources increases.

Volatility of prices of Imported coal

Lack of incentive to private entrepreneur to

ensure capital flow in this infrastructure

projects.

Inefficiency due to old age and

obsolescence of plants & equipments

Uncertainty of fuel supply from

Indigenous supplier



OPTIMISATION of GENERATION COST

ROADMAP• Improve Efficiency• Augment capacity of older units thru’ • 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

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• 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



Conclusion.

Substantial capital investment is required to initiate capacityaugmentation of Coal Based Power generation. To make growth trulyinclusive, investment coupled with managerial and technical supportfrom Private Sector enterprise is essential. As power sector projects arehighly capital intensive, specific measures are needed to incentivizeprivate entrepreneur to ensure capital flow in this infrastructureprojects.projects.A paradigm shift is needed in our approach to energy policy. From asupply-demand approach, we need to move to an integrated approachincorporating a judicious mix of cost effective generation, investment incapacity, 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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