WELCOME

to

a presentation on

O&M Conference IPS-2012

REDUCTION IN COAL UNLOADING TIME IN CHP – OUR SUCCESSFUL ENDEAVOUR

REDUCTION IN COAL UNLOADING TIME IN CHP -

OUR SUCCESSFUL ENDEAVOUR

BHILAI

By:

BK Mukhopadhyay (DGM/CHP&WS)

AK Sahoo (SS/ CHP)

BRIEF ABOUT OUR CHP

• NSPCL, Bhilai expansion project has

2 X 250 MW capacity.

• Its coal handling plant is designed

by TRF with Track-Hopper and one

no. wagon Tippler

• Track hopper was designed for

BOBRN wagons

• It is having Radial Stacker &

Reclaimer-one of its own kind..

BHILAI

0

100

200

300

400

500

600

700

800

900

2009 2010 2011

Total received rake(in nos)

353

830

672

THE TURNAROUND….

BHILAI

0

5

10

15

20

25

30

35

40

45

50

2009 2010 2011

Unloading in free time(in nos)

5

461

141

THE TURNAROUND…. BHILAI

0

2

4

6

8

10

12

14

16

18

2009 2010 2011

Avg BOXN unloadingtime (in hrs)

16.61

10.73

5.7

THE TURNAROUND….

BHILAI

0

1

2

3

4

5

6

7

8

9

10

2009 2010 2011

Avg BOBRNunloading time (inhrs)

9.35

4.22

1.94

THE TURNAROUND….

BHILAI

Big size coal boulders in Track

Hopper…

Condition of wagon tippler cradle

pit after wagon unloading…

The boulders could be removed

with the help of hydra…

The scene of track hopper covered

with big sized boulders…

Some Glimpses of initial days ..

BHILAI

Putting diverting plates on the

Bolster Beam of wagon tippler

• Gap between sector gear and

hopper wall used to get blocked by big size coal lumps

• obstructing the free movement of wagon tippler leading to extra time for unloading. Obstruction got removed

MODIFICATIONS IN WAGON TIPPLER

BHILAI

Before modification After modification

MODIFICATIONS IN WAGON TIPPLER

BHILAI

Before modification After modification

MODIFICATIONS IN WAGON TIPPLER

BHILAI

Passage for JCB movement • Before modification-

After unloading of coal the area used to be covered with boulders and lumps,

No provision of any space at entry/exit of wagon tippler area for movement of JCB or skid steer loader.

• After modification-

A passage for movement JCB or skid steer loader from both sides.

Enables speedy evacuation of big size coal lumps and boulders, etc.

MODIFICATIONS IN WAGON TIPPLER

BHILAI

MODIFICATIONS IN WAGON TIPPLER

BHILAI

Modification in Side-Arm charger

• Adding safety interlocks

• Installing new limit switches

• Change in mechanical structures

• The supporting structure modified to avoid striking with wagon tippler

• Annunciations and horns made in auto

BHILAI

Modification in Side-Arm charger

BHILAI

Modification in Side-Arm charger

The Impact…

• Reduction in cycle time from 4 minute to 3 minutes.

• Rise in no. of wagons getting unloaded from 12 to 18 per hour.

BHILAI

MODIFICATIONS IN TRACK HOPPER

Repositioning of water spray line for dust suppression

BHILAI

Putting Demolition Hammers

MODIFICATIONS IN TRACK HOPPER

BHILAI

Putting JCB in regular operation through contract

MODIFICATIONS IN TRACK HOPPER

BHILAI

CO-ORDINATION AT MINES-END

• Deployment of agency helped in controlling the coal size

• Immediate reporting about oversized coal with video and still photographs to the coal-companies

• Preparedness at our end became adequate with fast communication by agency

• Suitable financial penalty in case of large big-sized boulders

BHILAI

• Special contract for breaking & removing big

size boulders.

• Electrical demolition hammers put to operation

• Liasoning with agency at mines end.

SOME MORE STEPS FOR…

LOCOMOTIVE-

• Maintenance contract outsourced to RITES.

• Arranging additional LOCO WDS-6 which

could pass through the cradle of wagon tippler.

BIG SIZE BOULDERS-

BHILAI

SOME MORE STEPS…

Deployment of Skid Steer Loader that contributes to

quick boulder clearing

BHILAI

BHILAI

ADDITIONAL INTERVENTIONS…

• Providing Unique jackets having glowing appearance.

• Introduction of Signal Lights and Flags

• Placing of movable Barricades in W/Tippler

• Monitoring of Wagon Tippler thru cc camera

• Motivation of contract people through special award during Vishwakarma Puja etc.

• Conducting training programs thru RITES and other agencies for contract people

BHILAI

SUSTAINING SUCCESS…

Month wise trend of unloading rate (in hours)

BHILAI

TASKS AHEAD

• Removal of structure to have simultaneous movement of two JCBs from two sides in wagon tippler area.

• Provision for pre-wetting in track hopper area.

• Providing two more weight-scales in conveyer 6 & 7 to have proper blending.

BHILAI

THE JOURNEY WE CHERISHED…

From unloading time of 71 hours per rake on

28-01-09 to a unloading time of 2.25 hours on

08-02-2012…

BHILAI

This Journey Greatly ATTRIBUTES to…

Special Guidance

Active Support &

Constant Encouragement

Of

Our Respected

GM & BUH

BHILAI

One of our Proud moments…

Three consecutives rakes got unloaded within

three hours on 04-02-2012

A National record.

BHILAI

FINAL THOUGHT...

Our target

Zero Detention../ Zero Demurrage …

We trust

the spirit

Of

Innovation and Team-work

Will

triumph…

BHILAI

BHILAI