UNIT #1 500 MW UNIT #2 500 MW UNIT #3 500 MW

C 9A C 9B C 10A C 10B C 11A C 11B

MCC TP 5 TP 6 TP 7 TP 8 TP 9 TP TP
1C 10 11
C 6 A/B (144)
C 6 A/B
C5 C 7 A/B (107) C 8 A/B (118)
A/B P HOUSE
( 520) C ERA SCOPE

4A
TP 14 TP 3 (283) TP 4
4B
P/H
A
TP 13 TP 2 STACKER RECLAIMER 2 TP 16
CONVEYOR 12B
13 A13 B 3A 3 B
CONVEYOR 12A STACKER RECLAIMER 1
TP 12 TP 1 TP 15
(720)

2B
CTRL ROOM WORK IN PROGRESS
2A
(415)
PUMP
`
MCC 1B
MCC 1A` HOUSE B
PENT
IN OPERATION

HOUSE
CRUSHER 1A
1B
TP 19
HOUSE
(283)
W
WT 3 16 B
15 A/B
(103)
WT 3 & 4 TP 20 TP 21
T 16 A
(157)
22
WT
14 A STATUS OF
TP 17 TP 18
WT 1 14 B COAL HANDALING
(157)
PLANT
MAJOR MILESTONE
1st Coal rack arrived: 15.08.2010

1st Stacking Stream Trial: 16.08.2010

1st Rack unloading time : +200 Hrs

Conv-5A- Belt trial run done: 21.09.2010.

Conv-9A Belt trial done 20.09.2010

Conv- 6ABelt trial done 26.09.2010

1st Bunkering stream Trial: 26.09.2010

U#1 Synchronisation on coal: 28.09.2010 (1st time in NTPC)
1st Reclaiming stream Trial: 17.10.2010
U#1Bunkering in LHS bunker done: 18.01.2011 with 1st stream
DFDS compressor trial done: 15.02.2011
Yard 1 RHS sprinkler charged with Fire Water 25.02.2011
U#2 LHS coal feeding 30.10.11
U#2 RHS coal Feeding 17.03.12
 Name of the agency: M/s TRF
Cost of Package : 306.57 Crore
Paid till date : 278.00 Cr (90.09%)
Package awarded : 29th Jan’2008, Completion time: 36 M ie 29.01.2011
4th Provisional time extension valid upto : 31.05.2012
Part-1 Installation & commisioning  Awarded (Crore) Executed (Crore) %
  Civil Engg.Works 106.51 91.17 85.60
  Structural work (fab. + erection) 32.40 28.64 88.39
Part-2 Supply  
  Main Equipment - WPT 52.23
  Main Equipment - BOUGHT OUT 57.97 148.20 98.22
  Main Equipment - Electricals 40.68
  mandatory spares 6.78 3.66 53.98
  Type Test Charges 0.05 NIL
Part-3 Installation works (mech.ern.) 7.47 4.74 63.45
Part-4 Local transportation main supplies 1.17 1.11 95
Part-5 local transportation - mandatory spares 0.06 NIL
Part-6 CST on Works products 0.77 .77 100
  Total 306.15 278.29 90.9
 Major Highlights of CHP
• Total no of Conveyor : 30 Nos
• Total Length of Belting 2000/4 : 3.4 Km
• Total Length of Belting 1000/4 : 10 Km
• No of TPs : 21 no ( 6 Era Scope)
• Bunker Sealing 315/2 : 300 M
• Wagon Tippler : 4 No : 1200TPH
• Stacker reclaimer: 2 No : 2400TPH
• Crusher- 4 No : 1200TPH
• Flap Gates : 44 No
• DE system at Crusher house : 2 No
• Ventilation System Under ground : 5 No
• Ventilation system MCC’s : 3No
• Inline magnetic Seperator: : 6 No
• Package A/c : 14 No
 Major Site Issues Resolved
• 14A/B tail pulley uprooting issue
• Flap gates foundations uprooting issue
• Under ground tunnel leakage of water (Except 14A/B)
• Coal spillage to wagon tippler pit
• Heavy Coal dust puffing from Shuttle conv.
• LT movement of Shuttle drive (MBF)
• Take up / Tail pulley guards provided
• Bottom and Side seal plates provided(6A/B & 5A/B partly)
• S/R loading to 2400TPH in stacking (10 M height)
• Platform & approach TP-6 onwards
• Erratic readings of Belt weigher
• Suspended Magnet Erection at 14A/B and 16A/B
 Commissioned system
1. Bunkering Stream 1&2 (Unit1&2)
2. Stacking stream 1&2
3. Reclaiming Stream 1&2
4. Yard spray header 1 to 8
5. Drinking water system up to TP-5
6. Service water system up to TP-7
7. Belt weigher system
8. Air conditioning system of MCC (2 No)
9. Air conditioning of WT’s (3 No)
10. Exhaust fans at 14A/B and 16A/B
 Balance Erection works
1. WT#4 and associated stream : 15.07.12
2. Dust extraction system 1&2 : 25.06.12
3. Ventilation system MCC’s-3 no : 30.06.12
4. Ventilation sys. Tunnels-5 no : 31.08.12
5. Suspended magnet 4 no : 10.08.12
6. Monorails & Hoists-26/70 no: 30.06 to 31.08
7. Maint.Platform & Ladders-12 no : 15.09.12
8. DFDS system in auto mode : 10.08.12
 Major Engineering Issues
Issue
Issue of not tippling of wagons
Frequent Failure of SAC & Wagon Tippler
Hyd. Coupling
Spurious tripping of Metal Detectors
MBF heavy dust generation
C-12 A cable trays modification for
Maintenance Ease
Inadequate illumination leval in U/G tunnels &
TP’s
Potable water storage tank foundation TP-6
onwards
Supplier Action Plan
WT#3 tippling tested at 108.7 MT.
M/s TRF 45MT counterweight approval to be
submitted by TRF-15.06.12
M/s Rexorth to change the bell housing
M/s Rexorth
shaft and modified coupling by : 30.06.12
M/s Prayas
Deficiencies being attended by 30.06.12
Engg
Action shall be taken after DE system
M/s TRF
commissioning : 25.06.12
Electrical erection to start the work at Risk
M/s TRF
& cost of TRF
M/s TRF TRF to plan for further enhancement to design
Scope & Drg. To be to be cleared by Engg.
M/s ERA
Erection drg sent to Engg. On 31.05.12
 Contract Issues
1. Payment of service tax of 3.0 Cr to TRF
2. Supply of Damaged equipments by TRF.
3. Mandatory spares BBU amendment of works
products(35 Items) submitted in March'12- Joint meeting
with contracts & engg.to be organised at Jamshedpur to
resolve the issues expeditiously
 Items required from TRF
• PCRD & CCRD cable of stacker-1(Theft)
• Lifting of cable from TRF yard (loot)
• PC & computer from S/R-1(Theft)
• Silver contacts of feeders (Partly replenished)
• Idlers damaged during operation
• Belt damaged during operation
 Major Material Issue (TRF)
1. 32 Km cable (Non billable) various sizes yet to be received
2. WT#4 & SAC#4: Cannibalized items yet to be supplied
3. Items used by CHP from AF's & SAC's to be supplied by
TRF for completion of WT#4 stream
4. Unit #3 Balance Materials: for Stream B by 30.06.12
5. Mandatory spares 225/480 supplied, Balance supply plan
6. Flexible cables for Electric Hoists commissioning
7. Ventilation fans for Pump house & WT's hydraulic
enclosure area - C Doctor to supply (
8. Steels for support beams for maintenance platform,
approaches, ladders -230/300 MT supplied
 Water system
    Commissioning  

Items Total Installed Manual Auto operation

DFDS Total points 122 88 24 6 2
Potable water System          
No of Points 64 No 64 Taps provided (20 No)
No of overhead water Tanks 18 no 12 Cleaning & charging
No of pumps 4 no 4  Commissioned
Service water System 157 points   To be charged
2 No tested & charged
Pump for DE system 2 No  

Electrical Hoist & CP Blocks

• Electrical Hoist: 70 Nos. -26 erected
• Chain Pulley Block: 86 Nos.: 15.07.12
 Metal scanning system
• Metal Detector (6A/B, 15A/B)-In operation
• ILMS -5 No -In operation
• Stone Pickers 1A/B,6A/B -In operation
• Suspended Magnet- 4 no - Compl.by 10.08

Reject removal system

• Tramp iron chutes : 48 MT (Approx. 400 Mtr)
• Reject Chutes: 22 MT (Approx. 285 Mtr)