Modification jobs at CHP for enhancing its output

Shaon Maji
Asst. Manager CHP (M/M) STPS WBPDCL

Introduction
Having had the opportunity to work at The Coal Handling Plant of STPS right
from the stage of its commissioning, I have witnessed the mammoth leap that
CHP STPS has made both in terms of capacity utilization as well as reliability.
What shall follow next is a brief account of the various major modification jobs
that were carried out to enhance the output of CHP. Please feel free to contact
me/us for detailed explanations.
1.Removal of Track Hopper Fencing.
Previously the rail track at Track Hopper had fencing which ran all along the
track. This fencing also supported the Dust Suppression System Pipe Line for
the hoppers. The fencing became a major headache since stone and boulders
(coming with coal) could not be pulled out of the tracks. While pulling with
Hydra and slings these got stuck on the fence. Thus the fence had to be
removed. Then only it was possible to remove the stones without hindrance.
But what about the Dust suppression lines? It was using the fence as its
support. The D.S line would be gone if the fence was removed and Track
Hopper would become a living hell without proper dust suppression.
And thus the Dust Suppression lines were removed from the fencing . The
entire main header with nozzles was laid underneath the track hopper gratings
with support from Track hopper boundary walls. The individual supply headers
were also made to pass below the Track Hopper Floor. The fencing was then
removed.
Final result: Track Hopper at STPS does not have any fencing thus facilitating
free movement of Hydra Cranes on Track Hopper Floor and easy removal of
stones and boulders from rail track.
2. Openings for JCB entry on Crusher House walls.

The ground floor of the Crusher House used to be the most hazardous zone at
CHP due huge amount of coal dust accumulation. The dust came from all the
upper floors of Crusher House. Needless to say that conventional manual
cleaning was not feasible and mechanized cleaning with the help of tractortrailers and JCB had to be introduced. However there were no such access
points for the tractor- trailers. Thus huge openings were made on both sides of
crusher house for trailers to enter, collect dust and then leave. Though the
modification was a bit destructive in nature the step went a long way in
establishing mechanized cleaning at quite a critical zone.
Final result: Mechanized cleaning of Crusher House Ground floor.

3.Pre-Wetting System
Previously dust suppression of incoming coal was only restricted to the
Hoppers. There was no facility for wetting the coal while in loaded condition in
BOBR wagons. The D.S spray system along Track Hopper was not adequate
enough to suppress the huge dust that would come out every time the wagons
were unloaded. Thus pre-wetting systems were erected before the Track
Hoppers entry points.
Final result: Enhancement of dust suppression capability upon the incoming
coal
4.Coal Disposal Bypass line
The dust accumulating on the various floors of the Crusher House were
carelessly thrown away by the cleaning labors from the windows of Crusher
house floors. This coal dust caused tremendous nuisance while coming down.
Hence 06 nos. coal disposal lines were erected from the Belt Feeder floors.
Their function was to properly streamline coal disposal by not allowing it to
contaminate with atmosphere.
Final Result: Cleanliness enhanced in areas adjoining Crusher House
5.Introduction of Power Hammer for coal boulder breaking
Previously coal boulders were broken manually with hammers. This caused
considerable wastage of human labour and time. Hence mechanization was
introduced in the form of Power Hammers. These power hammers were used

for coal boulder breaking. Application of the same has reduced time for boulder
breaking and has enhanced productivity.
Final result: Enhanced productivity during stone/coal boulder breaking and
removal.

6.Installation of Buffer Plates at the striking portion of chutes

The first impact zones of the chutes were the most damage prone and
conveyers had to be shut down so that these striking portions could be
repaired. The problem was addressed by installing Buffer plates at these
striking zones. Hence the coal hit the buffer plate first instead of the chute
body .Thus the damage took place on the buffer plate instead of the chute
body. Upon damage the buffer plates are now replaced with newly fabricated
plates. This job is much easier compared to original chute body rectification.
Final result: Better chute availability.
7.Use of Fire Fighting spray nozzle instead of normal spray nozzle for
Dust Suppression.
The original nozzles that were used for dust suppression were not adequately
designed for atomization of water. Further these got choked time and again.
Since dust suppression effectiveness is a direct function of the amount of
atomization, these nozzles were not suitable for fighting excessive dust. Fire
fighting nozzles were found to be much more effective than normal nozzles,
since their inherent construction aids better atomization and their wider spread
ensures better wetting of coal. Though a bit messy if not operated in a
controlled manner, still these nozzles happen to be the most cost effective
alternative for dust suppression.
Final result: Effective dust suppression during enormous amount of coal dust
formation
8.Rail Track insertion in chutes

Owing to the frequent supply of stone and boulder laden coal, the chute plates
were subjected to a heavy impingement and consequent damage. Hence a
considerable amount of maintenance activity at CHP is directed towards up
keeping of chutes. In order to control the same, rail tracks were inserted inside
chutes to take the first blow of stones and hard materials. The residual impact
of the coal and stone mixture on the chute plates after hitting the rail pieces,
was thus reduced to benign standards and thus the original chute body was
saved.
Final result: Reduced chute damage

9.Use of forged hammer

Previously cast manganese steel hammers were used at CHP, STPS. Due to the
characteristic manufacturing drawback of centrifugally cast products-wherein
chance of blow hole and void formation is maximum, the life obtained from
these was dismal. Changeover from IS-276 GRADE-III material to Forged EN-19
has tripled the life of hammers. This life enhancement can be attributed to the
forging process wherein the presence of voids or blow holes in the metal body
are completely eliminated.
Final result: Four times the life of cast hammers at just double the cost
10.Installation of new Stacker Reclaimer and conveying system
The biggest and perhaps the most important modification at CHP, STPS was the
installation of a new Stacker Reclaimer and an entirely new conveying system.
The original scheme of CHP had a few critical draw backs. Since the scheme
had been prepared for catering coal to a single 250 MW unit and act as a
backup source for the existing 04 units of STPS, the coal stack-yard had been
kept small. As a result during 2X250 MW operation coal inflow was double than
the envisaged. Thus the yard filled up quickly and due to absence of any
further coal stacking area after bunkering, the BOBRs got detained. Further,
less yard capacity caused yard mismanagement and coal fires.
Installation of a new Stacker and a conveying system has tripled the yard
capacity and has introduced a new scope for better yard management. Further
with a backup Stacker, better stacker maintenance can be done.

Final result: Better coal stack management and enhancement of system

availability
Conclusion
Modification and betterment is a never ending process. With the power industry
becoming more competitive, sustainability in the long run completely depends
on our ability to usher in new technology and adapt to changes. Many other
modifications and betterment actions have been taken and a lot more in the
pipeline. We hope that these modifications insures us against any form of
decadence that may creep in during the long run.

1. D.S header below grating

Power Hammer

2. Opening for JCB movement

5. Use of

6. Buffer Plates

3. Pre-wetting system
fighting nozzle for D.S

4. Coal Disposal line

7. Fire