Wireless Communication system for Stacker Reclaimer Application.

Korba Super Thermal Power StationNTPC, Korba

at

By

Sheetal Wireless Technologies Pvt Ltd.Pune

General Description of Project

Project:

Stacker Reclaimer to CCR IO Communication using Wireless

Customer Information:

NTPC Korba, Dist. Bilaspur.

Solution for Wireless Communication by:

Sheetal Wireless Technologies Pvt. Ltd., Pune.

PO No:

4000043908-M55-1017 dated: 21/05/2010

Objective:

Wireless IO Communication over a distance of about 500ms,

for Moving Machines to replace the CRD (Control Rolling

Drum) wired connections.

Project Completion : 07 December 2010

• KSTPS, NTPC Korba, : In Coal handling plant Stacker Reclaimer were using

control Reeling Drum (Flexible control Cable ), CRD motor, slip rings for

carrying field IO signals to CHP control room for monitoring and controlling of

the machines .

• To avoid frequent breakdown of machines due to break in control cables , to

increase the system reliability and to avoid routine maintenance cost , NTPC

has opted the wireless solution for establishing the communication link

between Stacker Reclaimer and Control centre .

General Description of Project

WHY WIRELESS:

• To reduce the Installation time

• To make use of the flexibility which only wireless can offer

• Ease & Speed of deployment

• Easy for expansion

• Cost reduction, compare to cabled solutions

• Negligible maintenance cost

• Ease of implementation and installation

• Real-time Alarm Annunciation

14 13151012

91167 45 3

81612

CCRD sideTP 7 side

Slip ring No. Description

1 Common for S/R 24 V DC from PLC

3 Stacking On

4 Reclaiming On

7-8 11A Conv. Run status

11,5-6 NA

13-14 EPB ( Breaker )

13-11 WTI (Hi-Hi)-110 C

13-9 WTI (Hi)+ OTI (Hi) 19 C

13-10 63 IInd stage (No trip)

15-2 Telephone

Slip ring Description

No.

14 DC(-Ve)

13 DC(+ve)

11 DC (-Ve)

10 DC(-Ve)

9 DC(-Ve)

(Trip)

Signal Details for Stacker

Slip ring No.

System Selection Criteria & Consideration

For the above communication system, license free band is considered due to following reasons

• IEEE 802.11g is Open Standard: So License is not required .

• 54Mbps Signaling rate over 20MHz channel.

• AES Encryption technique is used for data security.

• 12 digital signals are transmitted from each stacker for status Indication & 4 Digital signals are transmitted from CHP CCR to each stacker to control multiple processes.

• The device provides flexibility to user to go online to access remote PLC, Edit Upload & download the PLC programs remotely.

• This system provides full duplex Voice communication between stacker PLC cabin & CHP CCR for communication between Operation team & machine operator, which was not provided by the previous system.

• This system can be terminated in Plant EAPBX as well.

• Huge bandwidth can be used for video surveillance of stacker machines as future expansion.

Equipments used

• Radio Modems : Prosoft – Technology : Model : RLX-IB-IHG

• Frequency Band : 2.4 GHz

• IO Transfer : Rockwell PLC

Network Architecture Diagram

CHP Control Room

Stacker1Stacker2Stacker3

RLX-IB-IHG

Micrologix 11008DI+4DO

VOIP MG3000

Telephone Unit Telephone Unit

VOIP MG3000 VOIP MG3000

Telephone Unit

Micrologix 110024 DO+ 12DI

Ethernet Switch

Ethernet Switch

Ethernet Switch

Ethernet Switch

VOIP MG3000

Telephone Unit

RLX-IB-IHG

RLX-IB-IHG

RLX-IB-IHG

Micrologix 11008DI+4DO

Micrologix 11008DI+4DO

CHP CONTROL ROOM

Crusher house

Stacker-1 rail track

Stacker-2 rail track

Stacker-3 rail track

Coal Yard

NTPC Power Generation unit buildings

NTPC CHP Area Satellite Image

Stacker-

1

Stacker-2Stacker-3

Photo taken from Crusher House -1

Building

Coal Yard

Antenna and

pole

installation Photo Taken from stacker

Antenna at

roof top of

crusher

house -1

building

Antenna

and Radio

modem

junction

box at

same pole

Installation Photos

Antenna InstallationRadio Installation

CONTACT

Maneesh Bopardikar

Sheetal Wireless Technologies Pvt. Ltd.

Pune-411038, Maharashtra, INDIA

Mob: 09730069940

Ph. 91-20-25422941 / 25467179 / 64007732

bopardikar@sheetalwireless.com

sales@sheetalwireless.com