Title: Coal Handling Plant (CHP)

Industry: Power, Cement, Steel

Business Challenge:
COAL HANDLING SYSTEM (CHS) is a Turnkey package for Stacking, Reclaiming and conveying coal to Bunker Unit (BU). The material to be handled by the system is Coal (Indian (Washed) & Imported coal). Coal is required to be conveyed to Bunkers. Coal would be received at the plant boundary by rail. In this turnkey project includes the various sub system i.e. Wagon Tippler, Stacker & Reclaimer, Conveyor (BCN) system & CSU (coal Sampling Unit).To increasing availability,increasing efficiency, and controlling emissions is a major requirement of the power industry today, and its importance will grow in the future. This causes industrial organizations to purchase control and instrumentation systems first on price, so that organization is able to control, monitor the complete plant remotely with ease access.

Solution:
We are committed to provide solutions to its customers as “start with, live with, and grow with”. In order to help operations in industry and realize a greater value, lower cost-of-ownership from their automation technology investments. This approach is applicable to end users in particular & developing regions, which are increasingly concerned about the long-term costs of maintaining their control systems assets. Compact Programmable Logic Controllers (PLCs) to meet the needs of customers with a wide range of industrial infrastructure projects.

The Master Logic solution provides the versatility and low cost commonly associated with PLCs and augments it with a global support network and the ability to integrate with the industry’s newest control systems-Experion-HS. A versatile line-up of I/O modules and networking options enables flexibility in how the controller fits into an entire automation scheme. The Master Logic (ML PLC) & EPKS Control system integration enables to read/write PLC data and monitor PLC alarms and events from Experion Station. Master Logic is designed to bring power and robustness to very high-speed logic, interlock and sequencing applications. Using the Experion-HS SCADA system we can generate the graphical (Standard/Customized) representation as per the application requirement.

Activities comes under the Engineering solution of each control system –

• Engineering Documentation (HDM,I/O Assignment, System Architecture)
• Software development (Control logic, Graphics, Database, Alarm management)
• FAT (Factory Acceptance Test)-Visual inspection & testing of hardware
• Site Commissioning
• SAT (Site Acceptance Test)-operation & maintenance Training, Handover etc.

Here is the detail of all above-mentioned packages that are controlled & operated from ML PLC & Experion-HS SCADA

Application: Coal Handling System
CHP Packages is split in to two parts for two units (U-5 & U-6) and each unit having separate sub system so that the system operated for both units independently. Wagon Tippler of 200T capacity is provided for unloading the coals from wagons.

Stacking & Reclaimer -
A separate stacker cum Reclaimer and Reclaimer-2 are mounted on BCN. This independent stacking and reclaiming machine on Yard conveyor BCN facilitates simultaneous stacking and reclaiming. During stacking BCN conveys / stacks coal in the stock yard by stacker cum Reclaimer and during reclaiming BCN conveys coal to JNT by Stacker cum Reclaimer or by Reclaimer or by both stacker cum Reclaimer and by Reclaimer.

The Conveyor System (BCN with design capacity) in which the coal is fed from hopper below the WT to BCN through AFD (Apron Feeder). Using this conveyor system, coal is conveyed from various BCN to Coalbunker through various FG (Flap gate) position, FD (Flow Divider),MD (Metal Detector),MS (Magnetic Separator).

CSU (Coal Sampling Unit) is provided in JNT over BCN with three primary cutters, Belt Feeder, Crusher, Secondary Sampler, Screw Conveyor and Sample Collector with all its accessories to collect the required amount of sample from the running conveyor occasionally.

Benefits of Automation /Control system for various applications -

• Monitor & Control the entire system from control room.
• Live status from the field.
• Interface option to communicate with third-party devices using user-defined protocol.
• Enhanced redundancy features including fast switchover time, high-speed synchronization and dual ring topology option.
• Flexibility of network options (Fast Ethernet, Modbus ASCII/RTU/TCP)
• Variety of I/O modules including channel-to-channel isolation
• Robust diagnostics (system/error logs, system monitoring, network monitoring, ping test, frame monitor)
• Tight integration with Experian HS via dedicated protocol
• Integrated programming and engineering environment with Soft Master.