MGR SYSTEM AN OVERVIEW

A CHATTERJEE , SS/MGR

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INTRODUCTION --Coal is the prime input for a thermal

power plant & hence adequate emphasis needs to be given for its proper handling and storage. -- It is equally important to have a sustained flow of this fuel to maintain uninterrupted power generation. - Coal contributes almost two third of the power generation cost in a Thermal plant.
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COAL AVAILABILITY FROM MINES Daily an average of 30,000 MT Coal is required for a typical 2000 MW Station & for 3260 Station like VSTPP , it is around 52,000 MT/day with 0.66 Sp Coal. Each super Thermal Power Project is linked with a particular coal mine to meet its coal requirement. This particular Mine is called Linked Mine. i) For VSTPP, The Linked Mine is Nigahi Mine of NCL. ii) The present capacity is 11milion Ton/year till date going to be 15 Million Ton by 2012) The required coal for any power station is allotted through SLC (Short Term Linkage Committee) allocation on quarterly basis i.e for 3 months . This allocation is decided in periodic Quarterly meeting held at Delhi in consultation with NTPC,COAL INDIA, CEA ,RAILWAYS, OTHER POWER SECTORSPMI Revision 00 etc. 24 May 2012

Grades of Coal
Grade Useful Heat Value (UHV) (Kcal/Kg) Corresponding Ash% Gross Calorific Value + Moisture % at GCV (Kcal/ Kg) (at 5% (60% RH & 40O C) moisture level)
Not exceeding 19.5 19.6 to 23.8 Exceeding 6454 Exceeding 6049 but not exceeding 6454

A B

Exceeding 6200 Exceeding 5600 but not exceeding 6200

C
D E F G
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Exceeding 4940 but not exceeding 5600

Exceeding 4200 but not exceeding 4940 Exceeding 3360 but not exceeding 4200 Exceeding 2400 but not exceeding 3360 Exceeding 1300 but not exceeding 2400

23.9 to 28.6
28.7 to 34.0 34.1 to 40.0 40.1 to 47.0 47.1 to 55.0
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Exceeding 5597 but not exceeding. 6049

Exceeding 5089 but not Exceeding 5597 Exceeding 4324 but not exceeding 5089 Exceeding 3865 but not exceeding. 4324 Exceeding 3113 but not exceeding 3865
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MGR SYSTEM PHILOSOPHY

Merry Go Round (MGR) system is a NTPC owned, full fledged Railway system used for hauling Coal from Min end to Thermal power station. For transportation of coal from Mine end, Coal Rakes are moved in the dedicated MGR Circuit of NTPC. Each coal rake consists of Bottom open Broad Gauge wagons (BOBR) hauled by one/two locomotive. The Rake Size is different for different project --for VSTPP the Rake Size is 50 Wagons. MGR circuit consists of Broad Gauge Track ( i.e 1676 mm gauge) MGR Track is laid on PRC (Pre reinforced Concrete) Sleepers. For changing of Rake movement , from one Track to another, Motor operated Point machine are provided which are operated from different Control stations of MGR Circuit. Multi Aspect Colour Light Signalling (MACLS) system , with panel Interlocking is provided for the safety of the rake movement from one station to other. 24 May 2012 Railway retired Loco drivers PMI Revision 00 are engaged on Contract basis to 5 operate MGR Rakes for coal transportation purpose,

MGR SYSTEM
MGR SYSTEM CONSISTS OF MAINLY 1) MGR OPERATING SYSTEM. 2) MAINTENANCE OF MGR ROLLING STOCK. 3) MAINTENCE OF TRACK & SIGNALLING SYSTEM. 4) COAL CORDINATION & COAL BILLING ACTIVITY.
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MGR OPERATING SYSTEM

Rake loading & Sampling

Loading system consists of a high-speed load- out station at the mine end called SILO. The capacity of the silos for the NTPC project varies between 3000 -- 4000 MT. The loading operation of the coal Rake takes place while it is moving under the silo at a speed of 0.8 - 1 k.m. per hr. It takes appx 1 Min/wagon for loading. The silos are cylindrical and fed by twin belt conveyors from Mine end through a Coal Handling System. For accurate weighing of coal to each wagon, Pre weigh Hoppers are provided which weighs coal of individual wagons before it is discharged to wagon. After loading sampling is carried out , through random samples collected from couple of loaded wagons for quality analysis.
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Loading

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COAL UN LOADING
After loading & Sampling is over Loaded Rake comes to T/H for unloading at power house end. Track Hopper is normally of 200-250 m length . Total Number of Track Hopper varies as per coal handling quantity (For VSTPP, it is 3 nos). In each placement appx 14-15 wagons are placed for simultaneous unloading at T/H. Wagons are provided with bottom discharge hoppers fitted with pneumatically operated automatic door actuating mechanism. After placing the wagons on the hopper, electrical pulse is given to the pneumatic device for opening the bottom doors. Coal rushes down due to its own weight. When the track hopper is empty, it takes only 20 seconds for unloading one wagon i.e. 60 Tons. After unloading operation, individual wagon doors are closed, checked for Proper setting of wagon doors & sent for subsequent loading. 24 May 2012 PMI This coal falls on a T table, Revision 00 over which a paddle feeder runs 10

TRACK HOPPER

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MGR OPERATION PRACTICES

1) TOTAL MGR CIRCUIT IS DIVIDED IN 3 CONTROL STATIONS. 2) MOVEMENT OF RAKE/LOCOMOTIVE , FROM ONE STATION TO ANOTHER , AFTER GETTING LINE CLEARANCE THROUGH PRIVATE NUMBER EXCHANGE & RECEIVING SLOT. 3) ALL MOVEMENTS DONE WITH SIGNALS ONLY WHEREEVER PROVIDED. 4) STATION WORKING RULE FRAMMED & DISPALYED AT ALL CONTROL STATIONS. 5) ABSOLUTE BLOCK WORKING FOLLOWED DURING RAILWAY MOVEMENT THROUGH DUDHICHUA CIRCUIT ,WHERE ONLY ONE PARTY OPERATES AT A TIME
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1) STRICT ADHERENCE OF STAION WORKING RULE & MOVEMENT THROUGH SIGNALS . 2) REGULAR BRAKE POWER TESTING OF RUNNING RAKES , AT LEAST ONCE IN A WEEK. 3) SIGNAL OVERSHOOT PROTECTION SYSTEM PERIODICALLY TESTED. 4) MONTHLY SAFETY AUDIT THROUGH VSTPP SFAETY TEAM & TECHICAL AUDIT THROUGH CORPORATE CENTRE TEAM. 5) YEARLY SAFETY AUDIT IS PLANNED THROUGH RAILWAY EXPERTS. 6) REGULAR FOOT PLATE INSPECTION BY DEPARTMENTAL HEAD & OTHER SENIOR OFFICIALS
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SAFETY ASPECTS IN MGR OPERATING SYSTEM

WDM2A Number 2 HP 2400 Speed 120 Tank Cap 5000 Lt Weight 120 MT Cost 7Cr
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WDS6

WDG-3A

4 4 1200 3100 60 100 4000 6000 126 MT 112MT 6 Cr 8 Cr

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ROLLING STOCK(WAGON)
Type of Wagon BSCL CIMMCO TEXMACO No of Wagons 43 67 39 +119 Total = 268 Nos Year of Comg 88-89 90-91 00-01 & 05-06 DOM System Single Link Single Link Double link Axle Load (Ton) 22.9 22.9 22.9 Length (M) 13.41 13.41 13.41 Carrying Capacity 60 MT 60 MT 60 MT Cost/Wagon Appx 25 Lacs

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LOCO MAINTENANCE
Light Schedule: T1,T2,M1,M2 including trouble shooting in MGR Work Shop. Heavy Schedule: M4 &M6 including Breakdown Maintenance in MGR Work Shop. Major Schedule: M 24 & M 48 in Railway Diesel Shed( like Patratu , E.C.Rly) POH:M 96 at Railway Workshops Golden Rock(Trichy)
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 Monthly Maintenance of 4 Rakes (50 Wagons) Maintenance of DOM Systems including overhauling of Spool Valves. Maintenance of Brake Systems including overhauling Distriubutor Valves. Wheel Changing. Overhauling/Reclamation of Axle Bearings. Reclamation of Wagon Doors.
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DETAILS OF WAGON MAINTENANCE

SIGNAL & TELECOM SYSTEM OF MGR

Vulnerable areas of the track are electrically circuited which are activated by the passage of trains for ensuring maximum safety in train operation Inter slotting system between the Cabins ensures involvement of two Cabins for receiving & dispatching of trains Apart from the Signals, communication channel between the Control Rooms & Loco Driver is established thro Wireless & Walkie Talkie sets. Signaling system with wireless communication is fully operational for safe train movement. Multi-aspect Color light signaling with motorized operation of Points System is operable from a interlocked Control Panel with mimic diagrams located in Cabins. 24 May 2012 time movement of trains are monitored thro Panel. Real PMI Revision 00 18

ROUTINE S&T MNTCE

Maintenance of Secondary cells numbering 300 Nos Checking & adjustment of Point machines 33 Nos for correct setting in Normal & Reverse positions Maintenance of 50 Nos Track Circuits Adjustment of Voltage & correct focusing of Signals Checking of interlocking circuits for proper correspondence between Panel & Site, Visual inspection of Relays Maintenance of Wireless and Walkie Talkie sets Maintenance of 2 Nos DG sets (for Standby Power supply)
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SALIENT FEATURES OF MGR TRACK

Length of main MGR coal circuit 19.6 Km. Total 52 Track Kilometer (including DCH & Non-coal track) is maintained by MGR/VSTPP

Almost 40% i.e.7.8 Km of main MGR are in curvature

Steepest Gradient 1 in 125 Down in DCH Circuit. 52 Kg rail, short welded rail panel, T-12 rails for main line and T-18 for yard lines in use. No of Points & Crossings : 1 in 8 48 nos 1 in 12 03 nos Sleeper density M+7 in main line and M+4 in yard lines. PRC sleepers laid throughout main MGR track Total number of bridges & culverts - 34 Longest being 78 M steel girder bridge at DCH Track.
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VSTPP MGR TRACK

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ROUTINE TRACK MNTCE

Daily patrolling of the entire track on foot by Key man. Packing of track at locations where slackness found. Through packing of entire track once in a year. Lifting of track at required locations. Overhauling of track. Replacement of worn out rails and sleepers. Maintenance of Hand lever operated points . Re-alignment of curvature where distorted. Lubrication of fish-plated joints yearly. Greasing of gauge face of curvature track. Removing spillage coal from track in W/Shop areas . 24 MayDrain cleaning & de-weeding00 2012 PMI Revision along the track. 22

MGR VSTPP AT A GLANCE

1) TOTAL TRACK LENGTH MAINTAINED(INCLUDING BASKET MINE) =45 Km. 2) MAJOR BRIDGES IN CIRCUIT 2 STEEL GARDER(13 M)- NGH CIRCUIT -- 1 STEEL GARDER(26 M) DCH CIRCUIT -- 1 STEEL GARDER(72 M) DCH CIRCUIT - 1 RCC GARDER BRIDGE(15 M) NGH CIRCUIT 3) STEEPEST GRADIENT 1 IN 125 (IN DCH CIRCUIT) 4) LOCOMOTIVES-WDS6 =4 Nos. WDM2 =2 Nos WDG 3A= 04 NOS(1 ON LOAN BASIS FROM SIPAT) TOTAL LOCO = 10 5) WAGONS BURN STANDARD =43 Nos CIMMCO =67 Nos. TEXMACO =158

TOTALWAGONS =268
6) TOTAL NUMBER OF MOTORISED POINTS IN CIRCUIT = 33 NOS 7) TOTAL NUMBER OF SIGNALS IN CIRCUIT = 21 NOS 8) RAKE SIZE 50 WAGONS
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VSTPP MGR CIRCUIT

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MGR PERFORMANCE(07-08) AT A GLANCE

MAXIMUM COAL TRANSPORTED 1) IN A DAY = 70,138.94 MT (31/03/08) 2) IN A MONTH = 17.21 Lac MT (Mar- 08) 3) IN A YEAR = 173.91 Lac MT (2007-08)

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COAL SUPPLY TO VSTPP DURING THE YEAR 2007-08

Total Linkage 176.58 Lac MT Total Receipt 173.91 Lac MT Total Consumption 171.43 Lac MT

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COAL-HANDLING SYSTEM:
Coal handling system is the arrangement for transferring of coal from coal-wagons to coal-bunker or coal stock yard. It also provide arrangement for separation of material impurities, crushing of coals, Coal sampling etc. In the coal handling system of NTPC stations, three coal paths are normally available Path A - direct conveying of coal from track hopper to boiler bunkers. Path B - from track hopper to stockyard Path C - from stockyard to boiler bunkers. The storage facilities at the stockyards have been provided only for crushed coal.
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COAL HANDLING PLANT LAYOUT

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Coal Handling
The coal handling system is designed to provide 100% standby for all the equipment and conveyors. The capacity of the coal handling system for super thermal stations varies from 1200 to 2000 t/h, normally, for a stage of 1000 MW,

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Coal Handling system equipment

plough feeder/ paddle feeder vibrating screen crushers, Conveyor belt, Idlers, Pulleys, Drive Unit, Take-ups, Skirt board, Scrapper, Stacker-cum-reclaimer, Magnetic separators, Motorized tripper. 24 May 2012 PMI Revision 00

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Track hopper to crusher house

Below track hopper paddle feeder arrangement is provided to unload coal to coal conveyors. The 200mm coal as received at the track hopper is fed to the crusher house through 1A & 1B conveyors.

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In the Crusher House

Vibrating Screen :The function of the vibrating screen is: To send the coal having size of less than 20mm to belt feeder through the bypass chute bypassing the crusher and To send the coal of more than 20mm size to the crusher.

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CRUSHERS
To crush the coal from 200mmto 20mm size received from vibrating screen Crusher hammer are made of MAGNEESE STEEL . Hammer row -4(stage 1) (a)Row-1 & 2 =18 hammer each (b)Row-3&4=20 hammers each

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No of hammer in each Crusherstage-1 = 76 hammers stage-2 = 92 hammers Weight of each hammer=18.5kg Crushing motor rating -740kw/3.3kv Life of hammer =4 lac MT of coal PMI Revision 00 Normal capacity=600 tons/hr

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Normally these crushers have a capacity of around 600 tons per hour. 24 May 2012 PMI Revision 00

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CONVEYOR BELTS
Made of diff. Layers or piles of fabric duck with rubber protected by a rubber cover on both sides & edges. Fabric duck are designed to withstand tension created in carrying the load . Nylon rubber cover protect the fabric duck. Material =fire resistant grade. Belt Width=1600 mm. Strength= 1000/1250 kN. Belt speed=3.2-3 m/s. Belt length=20km.

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IDLERS Idlers consists essentially of rolls made out of seamless steel tubes enclosed fully at each end fitted with stationary shaft, antifriction bearing and laybrith sealing. TYPES
TROUGHING IDLERS- shape the belt to support a moving load without spillage or damage to the belt.

IMPACT IDLERS - absorb the shock of falling material at loading and transfer points to protect belt from damage.
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POSITIVE ACTION TROUGHING TRAINERS automatically maintain troughing side alignment in one-way conveyors. A center pivot frame and offset neutral guide rolls provide the troughing action. RETURN IDLERS support the empty belt during the return run.

POSITIVE ACTION RETURN TRAINERS automatically maintain return belt alignment on one-way conveyors.
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PULLEYS

Made of mild steel.

Rubber coating is used to increase friction factor between belt & pulley (rubber lagging

Shell dia-500mm. Shaft dia-1400mm. Pulley length-1800mm. Shaft length-2350mm(bearing centre to centre)
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DRIVE UNIT
Motors coupled to reduction gear with the help of flexible/fluid coupling on the high speed shaft of the Gear box Flexible coupling on the input side

TAKE UPS
Take up pulley to facilitates

Necessary tension for the drive to operate the belt

Sag at a point where requires horse power will be at a minimum and load will move with least disturbance over idlers
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SKIRT BOARD
Used with chutes at trail end. Guides material centrally on the belt while loading until it has settle down on the belt

SCRAPPERS
Placed at discharge pulley in order to clean the carrying side of belt. It avoids the wear of return idlers due to build up material.
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Belt Protection Equipment

Pull Chord Belt Sway Zero Speed Chute block

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Stacker cum -reclaimer

This is used for stacking and reclaiming the coal from stock yard. Generally two stacker claimers have been provided at each of the NTPC's projects. Their normal capacity is 200 tons per hour and maximum design capacity is 450 tons per hour. The stacker reclaimer generally consists of (a) bucket wheel or digging wheel (b) boom conveyor. While the belt conveyor carrying the coal for the stock yard is in the same direction but the direction of the boom conveyor with respect to stacking and reclaiming is opposite. Digging Wheel The digging wheel is use for cutting and lifting the coal from the stock yard to the belt used for transfering coal from the yard. The above transfer takes place in case of reclaiming the 00 coal only. 24 May 2012 PMI Revision 43

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Stacker cum -reclaimer

During stocking operation, the coal from the crusher house is diverted towards the stockyard conveyor at a transfer point TP2/ TP3. The above conveyor discharges coal to the boom conveyor through a discharge chute. The boom conveyor, running in the forward direction, creates coal stacks. During reclaiming, coal from the stock yard falls on the boom conveyor with the help of the bucket wheel and the boom conveyor, during this period, rotates in backward direction. The coal from central chute falls on the conveyor belts used for transferring the coal from the stock yard. By this way, the coal moves on the underground conveyor belts connected to the main belts. A 6.6 KV motor is used for running the stacker-cumreclaimer and has a cable reeling drum on which flexible cable is wrapped. 24 May 2012 PMI Revision 00 45

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STACKER-CUM- RECLAIMER
Coal to/from stock yard Generally 2nos

Capacity ---200T/hr
Maximum---400T/hr
Bucket wheel Boom conveyor
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STACKER RECLAIMER
RECLAIMER IN OPERATION STACKER IN OPERATION
Bucket wheel

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SEPARATING FOREIGN MATERIAL FROM CONVEYOR

MAGNETIC SEPARATOR Any ferrous material on the conveyor will be lifted from the moving conveyor. No Tripping involved. MS is interlocked with Conveyor start up. When ferrous Metal is picked up, the MS is moved from the Conveyor, de-magnatised and the metal piece is removed.
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METAL DETECTOR
Any Metal with an area of 100 Sq Cm will be detected. Conveyor is tripped after detection. MD is not having interlock with start up. A sandbag is dropped near the Metal piece for easy location
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TRIPPERS
To stack material at desired bunker Provided with wheels which moves on rails parallel to conveyor.
Three types motorized tripper Belt propelled manually operated tripper
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Winch driven tripper

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WEATHERING OF COAL
WHEN COAL IS EXPOSED TO ATMOSPHERE - IT REACTS WITH OXYGEN - PRODUCTION OF HEAT - RISE IN TEMPERATURE - OXIDATION REACTION IS ACCELERATED - NUMBER OF CHANGES IN PHYSICAL AND CHEMICAL PROPERTIES OF COAL TAKE PLACE - IT IS CALLED WEATHERING OF COAL.

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IMPORTANT FACTORS FOR STORAGE OF COAL

RANK OF COAL

SURFACE AREA
SI ZE OF COAL ( MM ) 50 75 12 03 0. 3 0. 2 % LOSS I N CV 1 YEAR 2 YEAR O 11 . 0. 24 0. 5 1. 0 1. 0 2. 1

VENTILLATION COMPACTION AGE OF COAL

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SIZE AND HEIGHT OF STOCK PILES

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PREDICTION OF SPONTANEOUS COMBUSTION

B-M LIABILITY INDEX:
= 21.48M+ 0.98A- 0.62M2-0.58MA+ 0.08A2+ 10.2

WHERE, M=% MOISTURE(AIR DRIED BASIS)

A=% ASH(AIR BASIS) COALS HAVING B-M INDEX > 80 ARE HIGHLY PRONE TO AUTO-OXIDATION.
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MANAGEMENT OF COAL STOCKYARD

Proper coal-air interaction to avoid autospontaneous combustion. oxidation and

Close monitoring during march-june.

Design should ensure that for maximum duration of the year, air strikes the width of the stockpile and not the length.

Freshly mined coals should be stacked and old coal should be used.
Freshly mined coals should not be stacked over old coal. Stacking of coal layer by layer, with compaction of each layer.

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MANAGEMENT OF COAL STOCKYARD (CONTD.)

Stacking in trapezoidal shape, not in conical shape. Height of stockpile not more than 9-10m (indian coal). Lumps and fines should be stacked together and compacted. Before stacking coal should be visibly wet.

Segregation of stockpiles into various segments and relevent records of period of stacking, quality of coal (cv) should be maintained.
Compaction of finer particles over the bigger particles.

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THANK YOU

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