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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