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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