CONSTROMECHTMEngineering Solution

Thermal Power Plant Services

Power Plant Services

  • Retrofit
  • Capacity Enhancement
  • Conversion
  • Troubleshooting
  • Installation & Commissioning

CONSTROMECH is a specialized mechanical service provider for material handling systems in thermal and captive power plants. Our offerings are built for high-load, high-temperature environments involving coal, ash, and alternative fuels. We support full project lifecycle services across CHP (Coal Handling Plants), AHP (Ash Handling Plants), and ESP/BOP zones with a focus on: System upgrades, Chain retrofits, Capacity increases, Belt conversions, Site commissioning, Lifecycle extension

Power Plant Services
Plant zones
6
Equipment types
16
Service types
5

What we do in each plant zone

Equipment we handle, the services we deliver and the results you can expect — zone by zone.

Wagon Tippler & Track Hopper System

Zone 01

Wagon Tippler & Track Hopper System

Related productsApron Feeder Chain

Equipment Handled

  • Rotary Wagon Tippler
  • Apron Feeders (Under Track Hoppers)
  • Belt & Chain Conveyors to Crusher House

Services Offered

  • Forged chain and apron replacement (from 250 mm to 315 mm pitch)
  • Drive system upgrade with higher torque gearboxes
  • Conversion of old cast apron pans to modular hardened plate pans
  • Hopper realignment & vibration dampening for impact zones

Technical Insights

  • Throughput upscaling e.g. 800 TPH → 1500 TPH
  • Chain service life enhancement
  • Extended Warranty
Crusher House & Coal Transfer

Zone 02

Crusher House & Coal Transfer

Equipment Handled

  • Drag Chain Feeders
  • Belt Conveyors
  • Pan Conveyors to Bunker

Services Offered

  • Retrofitting of drop-forged drag chains with hardened scraper flights
  • Sprocket ring upgrades with tooth hardness > 55 HRC
  • Belt-to-pan conveyor conversion for damp/abrasive ROM
  • Commissioning of zero-spillage feed chutes and gate valves

Technical Insights

  • Speed range enhancement
  • Chain pitch modifications
  • Service Life increment
  • Extended Warranty
Bunker Feeding & Pulverizer Feed System

Zone 03

Bunker Feeding & Pulverizer Feed System

Equipment Handled

  • Bucket Elevators
  • Drag Chain Conveyors
  • Volumetric Feeders

Services Offered

  • Chain pitch upgrade (e.g. from 26 mm → 30/34 mm) to increase lift capacity
  • Re-alignment of elevator casing, sprockets, and drive shaft assemblies
  • Addition of belt tensioning & snub pulley for converted belt elevators
  • Sealing retrofits to avoid dust leakage and product loss

Technical Insights

  • Bucket elevators capable of 60–75 m lift
  • Capacity enhancement: e.g. 150 TPH→ 300 TPH
  • Extended Warranty
ESP & Fly Ash Collection System

Zone 04

ESP & Fly Ash Collection System

Equipment Handled

  • Flow Conveyors
  • Drag Chain Conveyors
  • ESP Hopper Discharge Chutes

Services Offered

  • Full chain loop replacement using drop-forged scraper chain (e.g. pitch 142/160 mm)
  • High-temperature bushings (Ni-hard, for applications more than 250°C)
  • Enclosed trough redesign for fine ash flow
  • Liner replacement using ceramic/UHMWPE plates

Technical Insights

  • Designed for continuous operation (24×7)
  • Chain & scraper life enhancement
  • Extended Warranty
Bottom Ash Handling (Wet or Dry)

Zone 05

Bottom Ash Handling (Wet or Dry)

Equipment Handled

  • Submerged Scraper Chain Conveyor (SSCC)
  • Wet Ash Sluice Conveyors
  • Water Seal Trough Systems

Services Offered

  • SSC chain retrofit (twin-strand case hardened chain with bolted scraper blades)
  • Liner protection upgrade for water troughs
  • Shaft, sprocket & tensioning mechanism redesign
  • Commissioning of SS scrapers for high-corrosion zones

Technical Insights

  • Chain pitch modifications
  • Expected life: Chain increment
  • Extended Warranty
Fly Ash Elevation & Silo Handling

Zone 06

Fly Ash Elevation & Silo Handling

Equipment Handled

  • Bucket Elevators
  • Air-Slide Assisted Chain Conveyors
  • Screw + Drag Hybrid Conveyors

Services Offered

  • Steel cord belt bucket elevator conversion (for dust-free vertical lifts)
  • Bucket retrofits with sealed fasteners
  • Dust baffle and skirt seal retrofitting
  • Gravity-fed flow chain commissioning into truck loading or bulker bay

Technical Insights

  • Elevation height upgradation
  • Capacity enhancement: 50–250 TPH
  • Steel cord belt splice life increment
  • Extended Warranty

CONSTROMECH Technical Standards & Enhancements

ParameterSpecification / Performance Range
Chain HardnessSurface: 58–62 HRC
Forged Scraper Material25MnCr or Ni-hard coated (for fly ash)
Bucket Elevator Belt GradeST800 – ST2500
Typical System Uptime>95% post-retrofit with correct alignment & tensioning
Installation SupportFull on-site support including tensioning, alignment, trial runs
Warranty12–18 months standard

CMECH Technical Services

How we support thermal power plants on site

Every engagement is carried out by our own field engineers — from the first inspection to commissioning and hand-over.

How we work
  • Site Inspections & Equipment Audits

    Bucket elevators, conveyors, ash systems, reclaimers

  • Installation & Commissioning Supervision

    Chains, buckets, bearings, drive units, structural supports

  • Corrective & Preventive Maintenance

    Hot/cold chain replacement, sprocket rebuilds, belt tracking

  • Retrofit & System Upgradation Projects

    Chain-to-belt elevator conversions, scraper design mods, capacity enhancements

  • Operational Optimization Support

    Root cause analysis, performance tuning, load balancing

Thermal Power Plants: chain systems & spares

The chains, sprockets, buckets and conveyor components we manufacture for thermal power plants.

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Services for other industries

Planning a shutdown, retrofit or capacity upgrade?

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