WELCOME

TO
THE
PRESENTATION ON

AUGMENTATION OF LIGNITE
HANDLING SYSTEM
THERMAL POWER
STATION - II

THERMAL STATION II AN OVERVIEW

INSTALLED
CAPACITY

1470MW (7X210)
MARCH 1986-JUNE1993

COMMISSIONING

Unit 3-1986
Unit 2-1987
Unit 1-1988

Unit 4-1991
Unit 5-1991
Unit 6-1992
Unit 7-1993

AREA

207 HECTARES

FUEL

LIGNITE STORED IN OPEN

STACKYARD & PARTIALLY IN
COVER SHED.

ANNUAL LIGNITE
USAGE

~ 10.5 MT

LIGNITE HANDLING SYSTEM TPSII

AN OVERVIEW
The pithead TPS-II is fed from an integrated
Mine II of 10.5 million tons capacity.
Ground storage capacity (approx.) :
Mine-II - 3.0 lakhs tons
TPS-II - 1.5 lakhs tons
Daily Requirement of lignite transfer to
TPS-II thro Corridor Conveyor system-I
(CC1 & CC2) (approx.) : 35,000 Tons.

Lignite is fed by RC1 and RC2

or direct loading from the lignite
bench
Lignite is received
from Mine-II through Corridor
Conveyor System- CC-1 and CC-2
at the rate of 2500 tons per hour
Working averagely 18 Hours a day

Lignite is transferred through

Junction Tower 2 & conveyor 2 to stock
yard on either side of conveyor 2
Another junction tower by the side of
JT2 named JT 3 to receive lignite is
presently not in use
JT3 has a facility to feed lignite to
conveyor 2
& stacker through an
interconnecting conveyor 3.1

Conveyor C1
from Mine-II
Bunker toTPSII Expn

Conveyor
from JT 5
to TPS-II
Expn

Existing Corridor Conveyor System-1

Diversion/sharing
arrangement in JT 5
Conveyor CC 1
from Mine-II
Bunker to TPS-II
JT 2
Conveyor No 3

JT 3

CONVEYOR CC 2

Conveyor No.2
Cover shed

Lignite Stock pile

STACKER

Lignite Stock pile

Junction Tower 2
Transfer Tower 1
Junction Tower 3

Reclaimer A
Corridor
conveyor 2

With the implementation &

Completion of Mine II expansion
the capacity of Mine increases
from 10.5 million tons to
15 million tons / Annum.
TPS II Expansion stockyard will
receive Lignite through C1
conveyor, (which is under
implementation) JNT 5, feeders
and stacker cum Reclaimers

PRESENT PROPOSAL
CORRIDOR CONVEYOR SYSTEM-II
The proposed project, CORRIDOR
CONVEYOR SYSTEM-II, envisages a
link between JNT-5 of TPS-II Expn. and
JT-3 of TPS-II, through a new conveyor
C-2, in succession to C1 conveyor
The Conveyors C1 and C2 will be in
parallel alignment to existing Conveyors
CC1 and CC-2.

Conveyor C1
from Mine-II
Bunker toTPS-II
Expn

Conveyor
from JT 5 to
TPS-II Expn

Primary
Crusher
TPS II Expn

Diversion/sharing
arrangement in JT 5

Conveyor CC 1
from Mine-II
Bunker to TPS-II

Propo
s
Conv ed
eyor C
2

JT 2
Con
veyo
rN

JT 3

o3

CONVEYOR CC 2

Conveyor No.2

Cover shed

Proposed Corridor Conveyor System-2

STACKER
Lignite Stock
pile
Lignite Stock
pile

FACILITY AVAILABLE AT TPS II EXPN.

Feeder conveyor SFD-1 located at 3.5 mtr. Level at
JNT 5 could feed either to TPSII Expn. And
proposed conveyor C 2 or both partially
A provision given in primary crusher house could
feed TPS-II from TS-II Expn. @ 1500 tonnes per
hour through RSFD 5B
Provision is available at TPS-II to receive lignite
from Mine-II alternately at Junction Tower 3 (JT3)
situated near JT2.

PROJECT JUSTIFICATION
CC1 & CC2 is in operation for more than 20 years in
a corrosive environment.
Break down probability of CC1 or CC2 is rare But
possibility can not be ignored
In such exigencies single source of supply of lignite to
TPS-II, and feeding of lignite to TPS II would come
to halt
On depletion of the available stock at TS-II will lead
to Generation loss
Requirement of additional facility to receive lignite
to TPS II helps TPSII s generation programme
unhindered

Conveyor C2
The Conveyor-C2 is fed with lignite either fully
(3000 T/Hr.) or partially (1500 T/Hr.) from
Conveyor-C1 via JNT-5 discharge hopper /
stationary feeder SFD-1 located at 3.5 mtr.
Level in TPS-II Expn..
The belt conveyor-C2 straight from JNT 5 of
TPS II Expn. up to JT-3, conveys lignite
through Con-3.1, Con-3.2 in JT3 to the storage
yard via Con-2 or directly to the boiler bunkers
via Con-7A.

Details of Conveyor C2
Belt Length

850 mtrs.

Belt Capacity

3000 T/Hr. Lignite

Belt speed
Belt width
Lift
Power

4.2 m/sec.
1800 mm
12 mtrs. approx.
2 x 350 KW at head end.

Belting
Conveyor design

Steel cord - St 2250

DIN 22101 in par with C1

Angle of conveying

Max. 5

CAPITAL COST
Basis of Estimation :
Estimate for Conveyor-C2 (Mechanical portion)
has been made based on Project cost for
2000mm conveyor for Mine-II Expn. Project .
From the above, Cost/Ton for the mechanical
portion was Rs. 1.18 lakhs/ton.
The escalation for 3 years is worked out
@ 40%, Cost/Ton for the mechanical portion is
arrived @ 1.7 lakhs/Ton.

ESTIMATE ABSTRACT
Mechanical portion

Rs. 692.00 lakhs

Electrical portion

Rs. 265.60 lakhs

Civil portion

Rs. 240.00 lakhs

Cost for Belt and belt joints

Rs. 343.00 lakhs

Magnetic detector and Separator

Erection charges @ 10% of Mech. & Elec. estimate
Testing & Commng. @ 1% of Mech. & Elec. estimate
Initial spares @ 10% of Mech. & Elec. estimate

Rs. 50.00 lakhs

Rs. 105.00 lakhs
Rs. 10.50 lakhs
Rs. 105.00 lakhs

TOTAL ESTIMATE FOR CONVEYOR- C-2

Rs.1811.10 lakhs

Tentative Estimate for CONVEYOR- C-2

Rs.1900.00 lakhs

Impact on Tariff
( Rupees in Lakhs

Estimated cost of installation

1900.00

Depreciation @ 3.6%

68.40

ROI @ 14 % on PAT67% (Assuming the entire 397.01

investment is from internal resources)
Maintenance Expenditure @ 2.5 %

47.50

Additional charges due to the above investment

512.91

Generation @ 75% (MU)

9657.90

Auxiliary consumption @10% (MU)

965.79

Generation at the bus (MU)

8692.11

Increased tariff due to installation of above

project Ps/ Kw Hr

0.59 0.6

IMPLEMENTATION
The project is proposed to be executed on turnkey basis.
The scope includes Design, Manufacture &
Supply, Erection, Civil works, Commissioning
and performance test of the system.
Time period for completion of the project must be
within 20 months from the date of LOA.

COMMITTEE

The feasibility and project report is prepared the

committee consisting of following
Shri. C. Ramachandran, GM (Mech.)/TS-II
Shri. Georgy Markose, DGM/Turb. Mtce.
Shri. S. Sathianarayanan, DGM/LHS O&M
Shri. A. Anbazhagan, CM/LHS Mtce.
Shri. V. Manoharan, CM/Services.

 Design and Engineering:

The specification of the system requirement
such as speed of conveyor, capacity, etc will be
made available in the tender documents.
The contractor has to do the detailed design
and engineering to suit the system.
Budget Provision has been made for Rs. 85
Lakhs under Budget No. 9102088021 in BE
2009-10 out of the Total cost of Rs.19.00 crores
for CONVEYOR - C2 - INSTALLATION WORK.

 Possible Transfer difference when TPS-II Expn. is in

operation:
Mine-II Expn. is designed to produce 4.5 MT of
lignite per year.
On TPS-II Expn. Commissioning, the lignite
requirement at 85% PLF would be 4.0 MT and
Transfer difference would be 0.5 MT.
On TPS-II Expn. Commissioning, the lignite
requirement at 80% PLF would be 3.76 MT and
Transfer difference would be 0.74 MT.

THANK YOU.

Possible Hinderances along the

single line alignment
considered for study
Location of the run off water collecting pond
east of the lignite storage yard of TS-II Expn.
Inspection road (BT road) scheduled to be
laid adjacent to and east of run off water
collecting pond.

Survey of the area between

JNT-5 and JT-3
It was physically measured and found that the
proposed alignment is comfortably away the
location of the run off water collecting pond
Considering the relative usage of the
inspection road, very close to the dead end,
the slight disturbances supposed to be caused
by the inspection road are not taken into
account.