Analysis & Design of Junction Tower at Thermal Power Plant: Assistant Professor JIT, Davanagere, India
Analysis & Design of Junction Tower at Thermal Power Plant: Assistant Professor JIT, Davanagere, India
I. INTRODUCTION TO KPCL
The proposed site of Coal Based Thermal Power Plant
Karnataka Power Corporation Limited is located near
Kudatini village at about 22 km from Bellary town, on
Hospet-Bellary NH-6, Karnataka state.
Karnataka Power Corporation limited (KPCL) a 1) WAGON TIPPLER (WT)
fully owned undertaking of the Govt of Karnataka is a 2) BELT CONVEYOR (BCN)
premier power generating company, established in 1970. 3) JUNCTION TOWER (JNT)
KPCL is currently operating and maintaining power stations 4) PENT HOUSE (PH)
with an installed capacity of 6500MW in Karnataka state 5) PRIMARY CRUSHER HOUSE (PCH)
including thermal, hydel, solar and wind power project. 6) SECONDARY CRUSHER HOUSE (SCH)
Bellary Thermal Power 7) EMERGENCY RECLAIMING HOPPER (ERH)
Station (BTPS) This section covers general requirements for design,
Name of the Project
Unit-3, 700 MW construction fabrication and erection of various structures,
Coal fired Power Plant buildings and facilities for the coal handling system, covering
Latitude N 15°11’58” complete civil and structural works. Some of the important
Longitude E 76°43’23” areas of works are described below.
Elevation 475m above MSL
III. COMPONENTS OF COAL HANDLING SYSTEM
A. Wagon Tippler (WT)
It is the initial stage of the CHS. The raw coal from the ore is
carried by wagons and it is unloaded by tippling action and
then it is sent to next process through tunnel. The capacity of
the wagon tippler is about 100 tones.
1) Wagon Tippler Hoppers/ Emergency Reclaimer Hopper:
Hoppers shall be of RCC construction. The pit shall
accommodate the hoppers along with feeder and conveyors
below. Monorail for taking machinery into the pit shall be
provided in the access shaft projecting through to leaf steel
Here we made an attempt to learn the steps which sliding door. plinth level of the pit shall be kept at least
are involved in construction activity from the undertaken 500mm above graded level with RCC sloped paving all round
project. The project mainly deals with analysis and design of to enable bulldozer movement.
JUNCTION TOWER at BTPS Ballary. B. TUNNELS, PENT HOUSE
We are assigned by our guide for the job of
Tunnels are of underground RCC constructions. A PCC shall
analyzing and designing of a JNT. To meet this requirement,
be provided to direct the drainage on to one side of the tunnel.
we are suggested to consult Ninganna T R Cheif engineer
A small trench shall be provided on that side of the tunnel to
(civil) BTPS Ballary. And also we are suggested to consult
lead the drainage to the nearest sump. Tunnel shall be
Ananda D S Executive engineer (KPCL design office,
provided with RCC/ Brick work, for ventilation duct.
Bangalore).
Where the tunnel enters the ground level a pent
We selected a plan of JNT-16 (G+4) among various
house is provided of RCC construction. Pent house shall be
components of BTPS.
provided with lifting beam to lift equipment to the tunnel.
Tunnel shall provided with walk way on either side of the
II. COMPONENTS
conveyer. Single pipe handrail shall be fixed to the tunnel
The salient features of the proposed expansion unit-3 are wall.
furnished below.
C. CONVEYOR GALLERIES AND TRESTLES The entire coal storage area from drain to drain shall
Overhead conveyor shall be housed in a suitably enclosed be provided with properly sloped PCC paving over rubble
gallery of structural steel. Maximum span of gallery shall be soling with properly compacted subgrade. The PCC paving
limited to 24 m unless higher span is necessitated due to site shall be of nominal mix of grade M15, 150mm thick with
constraints. nominal temperature reinforcement laid over 230mm thick
1) Single and Double Conveyors: compacted sand and rubble filling. RCC drains with
For single conveyor walkways shall be provided on either removable precast RCC slotted cover shall be provided on
side. For double stream conveyor gallery one central and two either sides of each coal stack.
side walkways shall be provided. Walk ways shall have These drains shall be so designed to carry the
minimum width of 750mm, in case of space restriction drainage from coal yard to the decantation tank. After 30
minimum allowable clear width shall be 600mm. minutes storage settlement the decanted water shall be lead to
Both sides of the central and side walkways shall be coal pile run off pond and further pumped to ash pond.
provided with pipe handrails with kerb plates using pipe of
medium class as per IS:1169 having 32mm nominal size. IV. INTRODUCTION TO JUNCTION TOWER-16
Handrails shall not be connected to conveyor supporting
stringer. Floors of the conveyor gallery shall be provided with
seal plates and walk way shall be constructed with anti-skid
arrangement.
Conveyor gallery shall have permanently colour
coated metal sheet roof and side cladding shall be of
permanently colour coated non insulating metal. Roof
framing shall be given a slope of 1 vertical: 3 horizontal. A
continuous slot opening of 500mm height shall be provided
on both sides. Windows shall have grills of wire mesh.
D. Trestles
In between transfer points four legged trestles, two legged
trestles may be provided. Trestles shall generally provide
using rolled beams only. For the purpose of analysis one end
of the gallery shall be treated as hinged and other end as
Junction tower is important structure in Coal Handling
rollers.
System. Inspite of other Junction Towers we have chosen
E. Junction Tower Junction tower-16 for analysis and design because four belt
Junction towers are the major component of coal handling conveyors join at this point those are BCN 33A/B, BCN
system. These are supporting structures for the conveyor 36A/B, BCN 28A/B.
system to transfer materials from one location to other Junction tower or Transfer houses are one of the
location. All junction towers would be of structural steel with major component of CHP. Junction towers are provided for
chequered plate covered floors. coal handling conveyor system or any other material
conveyor system, to change direction of conveyor from one
F. Crusher House direction to other direction.
This is the structure where large lumps of coal are crushed The change of direction is achieved by way of
into small pieces. dropping the material from upper level to lower level of
Crusher house is of steel structure is of framed/ conveyor running in different direction. The junction towers
braced design. Floors and roofs shall be of RCC. Roofs shall also facilitates in transferring one belt conveyor to other belt
be given adequate slope for drainage. Adequate window shall conveyor going in two or more direction.
be provided with steel glazed side hung windows using wired The Junction tower also accommodates horizontal
glass. Wherever monorails are projecting outside for lifting and vertical gravity take up in order to maintain the belt
of equipment, steel sliding doors shall be provided. Crusher tension as per the design requirements. It also houses Dust
shall be mounted on the floor framing using vibration Extraction System, screw conveyors Inline Magnetic
isolation system. Handrail shall be provided around all big Separators, Cranes/ Monorails etc.
openings and kerb plates shall be provided around all small
openings. V. INTRODUCTION TO STAAD-PRO
G. Stacker Cum Reclaimers A. Analysis of Junction Tower
It is the place used to store excess coal and it is used whenever Analysis is carried out using STAAD-Pro software
necessary. Stacker cum reclaimer rail shall be supported on package.
RCC foundations giving continuous support to the rails. The Appropriate load and its combinations, for most
beams supporting the rails shall be given expansion joint unfavorable effects are chosen for design.
preferably every 30m. Stacker/ reclaimer conveyor support
shall also be provided connecting the above two beams.
FRONT ELEVATION
SUPPORT DIAGRAM
Bea
m 165 192 199 206 179 238 234 329
no.
Stre
ss 0.3 0.4 0.4 0.5 0.5 0.5 0.3 0.4
Rati 70 30 80 10 28 43 67 19
o
C. Design of Side Runner action effectively reduces to one way action in the direction
of the short span although the end beams to carry some slab
D. Design of Floor Slabs
loads. Two way slabs should have their longer span not
E. Design of Slabs exceeding two times the shorter span.
1) General Approach: All slabs are designed as two way slabs with different end
Slabs are plate elements forming floors and roofs of buildings conditions.
and carrying distributed loads primarily by flexure. A slab
may be simply supported or continuous over one or more
supports and is classified according to manner of support and
there are two types slabs.
One way slabs spanning in one way direction .
Two way slabs spanning in both the direction.
Slabs are designed by using the following theories of
bending and shear.
The following methods of analysis are available.
1) Yield line theory,
2) Elastic analysis - idealization into strips,
3) Finite element method.
E. DESIGN OF RAFT
X. CONCLUSION
The junction house is analyzed with the assumed
sectional properties of members and it is designed in
STAAD-Pro. All members have passed the design
checks in STAAD-Pro.
Transfer Tower, but steel is chosen for its durability and
easy fabrication. Moreover steel Transfer Tower can be
easily extended in future for its expansion.
For the concrete tower of the same level as that of steel
tower, the c/s of members is more and because of more
headroom the weight and the space of the structure is also
more and hence unfeasible.
The junction house is analyzed with the assumed
sectional properties of members and it is designed in
STAAD-Pro. All members have passed the design
checks in STAAD-Pro.
The construction of concrete junction house is time
consuming while steel junction house structure is faster
to fabricate.
Transfer Tower can be easily extended in future for its
expansion.
Steel is durable, recyclable.
REFERENCES
[1] DESIGN OF STEEL STRUCTURE BY Devdas menon
and Unni Krishnan
[2] STEEL STRUCTURES DESIGN AND PRACTICE BY
N Subramanian
[3] DESIGN OF REINFORCED CONCRETE (IS-
456:2000) BY N KRISHNARAJU
IS CODE BOOKS
[4] IS-456:2000 - Code of practice for plain and reinforced
concrete.
[5] SP-16 - Design aids for reinforced cocrete.
[6] SP 16 : 1980 Design Aids for Reinforced Concrete to IS
456 : 1978
[7] IS 800 : 1984 Code of practice for general construction
in steel
[8] IS 456 : 2000 Plain and Reinforced Concrete - Code of
Practice
[9] IS 875 : Part 1 : 1987 Code of practice for design loads
(except earthquake load)for buildings and structures Part
1 Dead load
[10] IS 875 : Part 2 : 1987 Code of practice for design loads
(except earthquake) for buildings and structures: Part 2
Imposed loads
[11] IS 875 : Part 3 : 1987 Code of Practice for Design Loads
(except Earthquake) for Buildings and Structures - Part 3
: Wind Loads
[12] IS 875 : Part 5 : 1987 Code of practice for design loads
(except earthquake) for buildings and structures Part 5
Special loads and load combinations
[13] IS 1893 : Part 1 : 2002 Criteria for Earthquake Resistant
Design of Structures - Part 1 : General Provisions and
Buildings.