INDONESIA KIM 2150MW COAL FIRED POWER PLANT

2150MW

DESCRIPTION OF COAL HANDLING

SYSTEM

PDF "pdfFactory Pro" www.fineprint.cn

 CONTENTS

1 Design Basis

2 Design Input and Design Work Scope

2.1 Design Input

2.2 Design Work Scope

3 Scheme of Coal Handling Part

3.1 Jetty Unloading Equipment

3.2 Coal Yard and Storage Facilities

3.3 Belt Conveyor System

3.4 Coal Screening and Crushing System

3.5 Control of Coal Handling Part

3.6 Auxiliary Facilities

3.7 Notes

3.8 Index of Volume / Book of Coal Handling System

PDF "pdfFactory Pro" www.fineprint.cn

 1. Design Basis
Detail design work is done on the basis of the PPA signed by
PT.MABAR ELEKTRINDO and PLN.
The EPC contract and accessory signed by EPC Contractor and
PT.MABAR ELEKTRINDO.
The Design contract Signed by SEPC and SWEPDI.
Basic design documents for this project.
Technical agreement and manufacturers documents.
2. Design Input and Design Work Scope
2.1 Design Input
2.1.1 Standards and Codes
The Chinese National Codes and Standards will be adopted in different
system, equipment, civil engineering respectively.
2.1.2 Capacity
The power plant consists of 2150 MW condensing turbine generator
units. The design and layout of the coal handling system will be
compliance with contracts requirement such that the system will be able
to be easily and economically adapted for future operation.
2.1.3 Project site
The project is located at Medan city of North Sumatra province
Indonesia, in the northern part of the island of Sumatra,, at about 25 Km
of northeast Medan City, about 3 Km of west Belawan Port, about 7 km
apart from the Malacca Straits in east. The administrative seat belongs to
the Belawan Sicanang village. The site is near by PLNs Belawan thermal
power plant in east, and between the Belawan River to the north and the
Pantan River to the south. At present, the site has growth of a whole piece
of mangrove.
2.1.4 Coal Property
No. Item Unit Design Coal Check Coal
1

PDF "pdfFactory Pro" www.fineprint.cn

 No. Item Unit Design Coal Check Coal
1 Ultimate Analysis
2 Car 44.89 41.35
3 Har 3.59 2.38
4 Oar 10.77 8.47
5 Nar 0.42 0.26
6 Sar 0.18 0.48
7 Aar 3.15 7.06
8 Mar 37 40
9 Mad 20 15
10 Vdaf 41 43
11 HGI 60 54
12 High Heating Value Kcal/kg 4500 3900
13 Low Heating Value Kcal/kg 4084 3532

2.1.5 Coal Consumption

The capacity of the coal handling plant is designed originally on the basis
of 2150MW.
The coal consumption shall be as follows:
daily yearly
Hourly
Unit Capacity consumption consumption
consumption(t/h)
(t/d) (104t/a)
Design Coal 181.02 3620.4 126.86
2150MW
Check Coal 209.12 4182.4 146.55
Note: The daily coal consumption is based on 20 hours per day.
The yearly coal consumption is based on ~7008 hours per year.
2.2 Design Work Scope
Coal handling system will be common to 2150MW Units. The design
scope of coal handling system is from the head hopper of No.2 belt
conveyor to the coal silos in the bunker bay. The design of No.1 and No.2
belt conveyors and coal unloading system of jetty belongs to the CCCC
Third Harbor Consultants Co., Ltd.
The main parts shall be as follows:
2

PDF "pdfFactory Pro" www.fineprint.cn

 Belt conveyor system
Stacking and reclaiming system, coal storage yard
Screening and crushing system
Weighing, sampling, iron etc.
Control of coal handling system
For the normal operation, auxiliary distributed control system (ADCS)
and local control mode will be adopted in the system.
3 Scheme of Coal Handling System
3.1 Coal unloading system
The unloading jetty will be designed to handle 10,000 DWT class barge,
and total berth length will be around 98m. The capacity of unloading
system will be 150104t/a.
The unloading system will mainly consist of two grab ship unloaders of
fixed type and one belt conveyor. The capacity of one ship unloader will
be 450 ton/hr(totaling 900 ton/hr), and the belt conveyor will be 900
ton/hr (QMAX=1080t/h).
The design of No.1 and No.2 belt conveyors and coal unloading system
of jetty belongs to the CCCC Third Harbor Consultants Co., Ltd.
3.2 Coal storage system
Coal will be delivered by conveyors from jetty to the closed circular coal
storage yard.
A closed circular coal storage yard with diameter of 110m will be
provided, and the minimum capacity of thirty (30) days coal consumption
for two (2) units will be approximately 11104 ton. The machinery of
coal storage system will mainly consist of one (1) stacker-reclaimer with
stacking capacity of 900 ton/hour (QMAX=1080t/h) and reclaiming
capacity of 300 ton/hour. This equipment will be used for stacking the
coal in the coal yard or reclaiming the coal from the coal yard into the
plant.
3

PDF "pdfFactory Pro" www.fineprint.cn

 The safety monitoring system will mainly consist of 3D dynamic real
time monitoring System, temperature Monitoring System, and open fire
monitoring system of belt conveyor.
One bulldozer and one wheel type loader will be furnished for auxiliary
working.
3.3 Belt conveying system
Belt conveyors between unloading jetty and the coal yard belt conveyor
will be designed as single with B=1200mm, v=2.5m/s, Q=900t/h and
QMAX=1080t/h.
Belt conveyors after coal yard will be designed as double with B=800mm,
v=1.6m/s, Q=300t/h. In general, one of the double belt conveyors will be
in operation and the other will be in standby. However, the double belt
conveyors will be able to operate simultaneously for a short time.
Along the direction of belt conveyors going, left side belt conveyors are
called c-* A and right side belt conveyors are called c-*B.
Fire-resistance belt will be used for all conveyors.
Coal conveying system will be put into operation based on three turns per
day, about 4 hours for each turn.
Electric driving two-side ploughs will be installed on the belt conveyors
in coal bunker bay for unloading coal to coal silos.
High bin level signal, lower bin level signal and ultrasonic level signal for
determining the height of the coal in the coal bunker will be installed.
Belt conveyor gallery will be semi-outdoor with ceiling.
3.4 Coal screening and crushing system
There will be a coal screening and crushing house after the coal yard.
Two screens will be installed in the crusher house. The capacity of each
screen is 300t/h. Max inlet-size will be 300mm, out-size will be less than
30mm.
Two hammer crushers with capacity of 200t/h will be installed under the
4

PDF "pdfFactory Pro" www.fineprint.cn

 screens. Each hammer crusher include safety monitor for temperature,
vibration, hydraulic uncap device. The max inlet size of the crusher is 300
mm. The size of crushed coal will be within 30 mm.
3.5 Control of coal handling system
Auxiliary distributed control system (ADCS) and local control mode will
be adopted in the coal handling system.
The control of the coal handling system will be performed in the coal
handling control room, which located in the middle of the conveying
system.
Operating mode for the coal handling system will be selected and
automatically changed-over in the coal handling control room. Local
push-button will be used for emergency stopping and the system will
have interlock and protection devices.
The conveying control system will have sensors for zero speed switch of
belt, belt sway switch, pull-chord type emergency switch of belt,
blockage test device and stick ability trembler for chute, trip switch, bin
high level signal, radar level signal, etc. A sound alarm will be
automatically actuated by the switching-on of any equipment.
Main operation methods shall be as follows:

3.6 Auxiliary facilities

3.6.1 Auxiliary facilities
One belt-type magnetic separator is installed above the head of c-1 belt
conveyor in no.1 transfer tower.
5

PDF "pdfFactory Pro" www.fineprint.cn

 Two disc-type magnetic separators are installed above the middle of
C-05AB and C-06AB belt conveyor.
Two belt-type magnetic separators are installed above the head of
C-04AB belt conveyor in no.2 transfer tower.
These will have the function of extracting pieces of scrap iron and
depositing them in the iron collect box.
Three as-fired samplers are installed in the middle of C-05AB belt
conveyors and C-02 belt conveyor. The coal sampling equipment will be
able to take samples, crush the samples to the required size and select
(sieve principle) all specimens below a certain size for analysis.
Three electron belt scales with chain-weight-checking device are installed
in the middle of C-05AB belt conveyor and C-02 belt conveyor. The belt
scale will be equipped with a remote-controlled automatic zeroing
adjustment so that the rate of coal transfer from any chosen point in time
can be determined. The belt width and idler groove angle will be the same
as those for the main conveyor. The current and accumulated rate of coal
transfer will be displayed on a monitor in the main control room of the
coal handling system. Local displays will be installed to indicate the
hourly rate of coal transfer.
3.6.2 Bulldozer garage
The garage will be designed with 2 parking spaces, which includes
maintenance area, rest room and spare parts room, etc. One electric
single-beam bridge crane with 5t lifting weight will be installed for
maintenance.
3.6.3 Coal deposit pond
One coal deposit pond will be arranged in the system. The coal after
depositing will be reclaimed to the coal yards by wheel type loader.
3.7 Notes
3.7.1 Requirement Of Main Equipment Installation
6

PDF "pdfFactory Pro" www.fineprint.cn

 Installing main equipment should meet technical requirement of
manufacture and notes of working drawing.

Installing belt conveyors should meet GB10595-2009 Technical

Requirement of Belt Conveyor.

Installation or adjustment of mechanical sampler and electron belt scale

etc. should be guided by experts of manufacture.

Construction working of coal crusher should be strictly checked before

acceptance.
3.7.2 Crusher house is designed as laying wall after equipment erected.
3.7.3 After belt conveyors have been installed, the head and tail frame,
motor frame, vertical take-up rail must be second grouted. Grouted area
is equal to the shaped steel of the bottom. Middle support legs must be
second grouted. Grouted height is 100 mm.
3.7.4 After coal chutes have been installed, crevice between the chutes
and mounting hole should be filled with steel flat which width is 4 mm.
3.8 Index of Volume / Book of Coal Handling System
Volu
No
me Name of Volume/Book Index No.
.
Book
GENERAL PART
GENERAL DRAWINGSPCEIFICATION
1 1 INDEX OF VOLUME/BOOK OF COAL 50-F05761S-M0101
HANDLING SYSTEM
LIST OF EPUIPMENTS & MAIN
2 2 50-F05761S-M0102
MATERIALS
3 3 ORDER DRAWING OF BELT CONVEYORS 50-F05761S-M0103
4 4 ORDER DRAWING OF CHUTE SYSTEM 50-F05761S-M0104
STORING PART
STACKER-RECLAIMER FOR CIRCULAR
5 1 50-F05761S-M0201
COAL YARD ARRANGEMENT DRAWING
6 2 SAFETY MONITORING SYSTEM FOR 50-F05761S-M0202

PDF "pdfFactory Pro" www.fineprint.cn

 Volu
No
me Name of Volume/Book Index No.
.
Book
CIRCULAR COAL YARD ARRANGEMENT
DRAWING
CRUSHING PART
CRUSHING HOUSE ARRANGEMENT
7 1 50-F05761S-M0301
DRAWING
BELT CONVEYOR PART
C-03 BELT CONVEYOR ARRANGEMENT
8 1 50-F05761S-M0401
DRAWING
C-04A/B BELT CONVEYOR
9 2 50-F05761S-M0402
ARRANGEMENT DRAWING
C-05A/B BELT CONVEYOR
10 3 50-F05761S-M0403
ARRANGEMENT DRAWING
C-06A/B BELT CONVEYOR
11 4 50-F05761S-M0404
ARRANGEMENT DRAWING
C-07 BELT CONVEYOR ARRANGEMENT
12 5 50-F05761S-M0405
DRAWING
NO.2 TRANSFER TOWER ARRANGEMENT
13 6 50-F05761S-M0406
DRAWING
COAL BUNKER BAY TRANSFER TOWER
14 7 50-F05761S-M0407
ARRANGEMENT DRAWING
CONTROL PART
PLC FLOW DIAGRAM OF COAL
15 1 50-F05761S-M0501
HANDLING SYSTEM
AUXILIARY PART
MECHANICAL SAMPLER HOUSE
16 1 50-F05761S-M0601
ARRANGEMENT DRAWING
17 2 SUMP ARRANGEMENT DRAWING 50-F05761S-M0602
COAL DEPOSIT POND ARRANGEMENT
18 3 50-F05761S-M0603
DRAWING
MAGNETIC SEPARATOR INSTALLATION
19 4 50-F05761S-M0604
DRAWING
ELECTRON BELT SCALE AND
20 5 CHAIN-WEIGHT-CHECKING DEVICE 50-F05761S-M0605
INSTALLATION DRAWING

PDF "pdfFactory Pro" www.fineprint.cn

 Volu
No
me Name of Volume/Book Index No.
.
Book
ELECTRIC-DRIVING PLOUGH
21 6 50-F05761S-M0606
INSTALLATION DRAWING

PDF "pdfFactory Pro" www.fineprint.cn


1
2
2.1
2.2
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8

10

PDF "pdfFactory Pro" www.fineprint.cn

 1.
PT.MABAR ELEKTRINDO
PLN PPA
EPC





2.
2.1
2.1.1

2.1.2
2150 MW


2.1.3
2150MW
25km
Belawan 5km
9.2km Belawan
2.1.4

1
2 Car % 44.89 41.35

11

PDF "pdfFactory Pro" www.fineprint.cn

 3 Har % 3.59 2.38
4 Oar % 10.77 8.47
5 Nar % 0.42 0.26
6 Sar % 0.18 0.48
7 Aar % 3.15 7.06
8 Mar % 37 40
9 Mad % 20 15
10 Vdaf % 41 43
11 HGI 60 54
12 Kcal/kg 4500 3900
13 Kcal/kg 4084 3532

2.1.5
2150MW

(t/h)
(t/d) (104t/a)
181.02 3620.4 126.86
2150MW
209.12 4182.4 146.55
20h 7008h

2.2
2 167MW ( 2150MW
2


12


l
l

12

PDF "pdfFactory Pro" www.fineprint.cn

 l
l
l

3
3.1
150 1 1

2 Q=450t/h
2

2
B=1200mm V=2.5m/s
Q =900t/h Qmax=1080t/h

3.2

1 110m
12.5m 11104t 2150MW
30
900t/h
350t/h

300t/h

13

PDF "pdfFactory Pro" www.fineprint.cn



3.3
B=1200mmV2.5m/s
Q900t/h
B800mmV=1.6m/s
Q300t/h


4h





A B
3.4


300t/h 200t/h

10t

3.5
ADCS

14

PDF "pdfFactory Pro" www.fineprint.cn



KKS

3.6
3.6.1

4 AB
5 AB
6 AB

1

6 AB 2

15

PDF "pdfFactory Pro" www.fineprint.cn


1


6 AB 2

3.6.2
2 1
5t

3.6.3


3.7
3.7.1

GB105952009



3.7.2
3.7.3

3.7.4
4mm

16

PDF "pdfFactory Pro" www.fineprint.cn

 3.8

1 1 50-F05761S-M0101
2 2 50-F05761S-M0102
3 3 50-F05761S-M0103
4 4 50-F05761S-M0104

5 1 50-F05761S-M0201
6 2 50-F05761S-M0202

7 1 50-F05761S-M0301

8 1 3 50-F05761S-M0401
9 2 4 AB 50-F05761S-M0402
10 3 5 AB 50-F05761S-M0403
11 4 6 AB 50-F05761S-M0404
12 5 7 AB 50-F05761S-M0405
13 6 2 50-F05761S-M0406
14 7 50-F05761S-M0407

15 1 50-F05761S-M0501

16 1 50-F05761S-M0601
17 2 50-F05761S-M0602
18 3 50-F05761S-M0603
19 4 50-F05761S-M0604
20 5 50-F05761S-M0605
21 6 50-F05761S-M0606

17

PDF "pdfFactory Pro" www.fineprint.cn