Presented by:

P. K. Samantaray, Sr. Manager

&
M. Prasad, Manager

Under the Guidance of:

Sri R. Kumar, CEO
Sri A. K. Singh, GM (Maintenance)
 Bokaro Power Supply Company (P) Ltd. is a Joint Venture
Company of SAIL and DVC, each have 50% equity holding.

 Objective of BPSCL is to supply process steam to Bokaro

Steel Plant (SAIL) at 100 ata, 39 ata and 8-12 ata: 500-550
Tph and Power as per Annual target.

 BPSCL also supplies Sodium Cationated water: 300 Tph

 BPSCL has an aggregate installed capacity to generate

338 MW of Power and 2180 TPH of steam.

 Manpower strength in BPSCL is 247 (Executive-173, Non-

Executive-74) as on 01.07.2019
CAPACITY - Boiler
CAPACITY
 Profound dependence of TPP boilers on BF & CO gases from
BSL/SAIL.

 Incomplete Combustion due to inconsistent and inadequate

supply of BF & CO gases.

 Utilization of Fly ash.

 The poor health of only Wagon Tippler.

 Obsolete technology of TPP Boilers.

 Sever cracks were developed at various civil
structures.

 Frequency of breakdowns increased significantly

affecting the avg. detention time.

 Capital repair of the wagon tippler was long time due.

 Aging of the tippler structures.

 Risk of total collapse of tippler requiring very high

restoration time.
Make HEC, Ranchi

Year of Installation 1970

Type & Capacity Rotary, 1000 TPH

Angle of Rotation 170 °

RPM 14

Gearbox Reduction Rating 51.1

Motor Rating 30 KW, 415 V, Duty 40%

 Complete dependence of BSL for Power & process
steam requirement
 Threat of drawing power by BSL from DVC
exceeding the contract demand of 220 MVA.
 Coal unloading through manual means was not
adequate to cater daily coal feeding requirement
(5000 MT approx.).
 No prior experience/ expertise was available with
BPSCL in such renovation job.
 Identification and completion of all pre-shutdown jobs.

 To make all necessary contracts/work orders in place.

 Identification and arrangements of all required spares.

 To plan round the clock working during shutdown period

and maximizing the manpower engagement.

 To build healthy coal stock level

 Planning of various jobs.
 Execution of jobs before the actual shut-down.
 Activities were mainly in-house fabrication jobs.
 Dismantling of some of the supplied spares for easy
handling during erection.
 Pre-alignment and assembly of some of the spare
parts to save time during erection work.
 Transfer of required co-ordinates of wagon tippler.
 Resource and material mobilization at site.
 Duration: From 22/05/2018 to 05/06/2018 (15 days).
 Dismantling of complete wagon tippler.
 Removal of worn-out foundation frames by breaking RCC foundations.
 Erection & alignment of base/foundation frames by level re-transfer
followed by casting of base frame by CED.
 Erection of rotor (Inhaul side) followed by 1st bottom frame.
 Erection & alignment of middle rotor with 1st rotor along with erection
of pipe frames.
 Erection & alignment of 2nd bottom frame followed by last rotor (outhaul
side) along with erection of balance pipe frames.
 Erection and alignment of gearbox foundation frame followed by
casting of the foundation by CED
 Erection of both cradle assemblies after welding of bottom frames with
rotors.
 Erection of both tippler platforms followed by fixing of stay pipes and
arms.
 Erection of top beams and complete welding of different associated
structures.
 Removal of all locking structures, fixing and welding of checkered plate
and complete welding, painting followed by trial run of the tippler.
 Schedule of shutdown planned for 28 days
 Coal stock as on 22.05.2018 i.e. at start of the
shutdown: 68,201 MT
 Coal stock as on 05.06.2018 i.e. at end of the
shutdown: 34,313 MT
 Number of wagons unloaded manually during
shutdown period: 461 wagons
 Average generation level during shutdown period:
Steam: 1152 TPH (Min. – 1099 TPH, Max.– 1231
TPH)
Power: 139.7 MW (Min.– 127 MW, Max. – 159.64
MW)
 With better co-ordination among all involved agencies,
whole pre and post shutdown activities were completed
safely in 15 days.

 Use of high early strength and self-compacting concrete

mortar cum chemicals helped in reducing the overall
job time.

 Total cost involved: Rs. 34,39,429/-

* Mechanical jobs: Rs. 17,83,550/- (excluding cost of spares)
* For civil jobs: Rs. 16,55,879/- (including cost of materials)
Demurrage charges incurred: Rs. 11,83,350/-
Thank You