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Preface This COAL HANDLING OPERATION SYSTEM MANUAL was made according to the instruction book of maintenance and relevant drawing offered by the coal handling equipment manufacturer of the 2×315M coal fired power plant project in PACITAN, Indonesia. It is only suitable for the operation of the coal handling system of the 2×315M coal fired power plant project in Pacitan, Indonesia. The manuals will be revised and improved with the project progress development. Page 2 of 160 Content 1 INTRODUCTION OF COAL HANDLING SYSTEM.....................................................5 1.1 COMPREHENSIVE INSTRUCTION OF COAL HANDLING SYSTEM................................................................5 1.1.1 Overview....................................................................................................................................................5 1.2 SUMMERY TABLE OF THE COAL HANDLING SYSTEM EQUIPMENTS DRAWING (SEE THE APPENDIX 1.2) ...................................................................................................................................................................... 5 1.2.1 Drawing of the Overall Arrangement and Installation of the Equipments (See the Appendix 1.2.1)...........................................................................................................................................................5 1.2.2 Drawing of Equipment Construction (See the appendix 1.2.2).........................................................5 2 COAL HANDLING SYSTEM OPERATION MANUAL.................................................6 2.1 INTRODUCTION TO COAL UNLOADING EQUIPMENT AND OTHER COAL SILO EQUIPMENTS....................6 2.1.1 Bridge Type Grab Ship Unloader...........................................................................................................6 2.1.2 Bucket Wheel Stacker & Reclaimer.....................................................................................................27 2.1.3 Water Wiper.............................................................................................................................................73 2.1.4 Bulldozer..................................................................................................................................................75 2.2 EQUIPMENT OF COAL HANDLING SYSTEM..............................................................................................79 2.2.1 Belt Conveyor..........................................................................................................................................79 2.2.2 Idler...........................................................................................................................................................83 2.2.3 Tension Device........................................................................................................................................84 2.2.4 Cleaning Device......................................................................................................................................86 2.2.5 Auxiliary Equipment................................................................................................................................86 2.2.6 Ring Hammer Type Coal Crusher........................................................................................................92 2.2.7 Inclination Variable Isochoric Roller Screen.......................................................................................95 2.2.8 Magnetic Separator................................................................................................................................99 2.2.9 As received Coal Sampling Device....................................................................................................104 2.2.10 Mechanical Sampler of As-Fired Coal...............................................................................................109 2.2.11 Electronic Belt Scale............................................................................................................................114 2.2.12 Non Magnetic Metal Detector.............................................................................................................117 2.2.13 Low Noise Anti-Blocking Mechanism................................................................................................119 2.2.14 Coal Feeding Equipments...................................................................................................................121 2.2.15 Coal Charging Equipment...................................................................................................................123 2.3 COAL HANDLING EQUIPMENT CONTROL...............................................................................................126 2.3.1 Function and Components of Centralized Control..........................................................................126 2.3.2 Centralized Control Mode....................................................................................................................126 2.3.3 Interlinking Criteria on Centralized Control Equipments:...............................................................127 2.3.4 The Main Coal Stack Mode for the Coal Handling System...........................................................127 2.3.5 Inspection and Preparation before Centralized Control Operation...............................................127 2.3.6 The Start/Stop Operation of Coal Handling Procedural Control...................................................128 2.4 PROTECTION DEVICES OF COAL HANDLING SYSTEM.............................................................................137 2.4.1 The Formation of Protection Devices of Coal Handling System...................................................137 Page 3 of 160 2.4.2 The Double-Pole Switch for Detecting Deviation State of Belt in Belt Conveyer.......................137 2.4.3 Two – Throw Pulling Switch................................................................................................................137 2.4.4 D H—Ⅲ Type Relative-Movement Detector....................................................................................138 2.4.5 DH—S Type Speed Detector..............................................................................................................138 2.4.6 Vertical Slitting Protective Equipments of ZL Series.......................................................................138 2.4.7 Supersonic Wave Material Level Instrument....................................................................................139 2.4.8 MW—Ⅱ Type High and Low Coal Level Control Instruments......................................................140 2.4.9 Materials Flow Detector of LL—ⅠSeries..........................................................................................140 2.4.10 Protective Epuipments for LDM Series Downspouting Blockage.................................................140 APPENDIX 142 1.2 COAL DELIVERY SYSTEM EQUIPMENT SUMMARY DRAWINGS TABLE..................................................142 1.2.1 Equipment General Arrangement and Installation Diagrams........................................................143 1.2.2 Equipment Constructional Drawings.................................................................................................146 Page 4 of 160 1 Introduction of Coal Handling System 1.1 Comprehensive Instruction of Coal Handling System 1.1.1 Overview The coal handling system of this power plant is designed by the capacity of 2 units of 315MW. The function of the coal handling system is to unload coals from the coal barge of coal unloading terminal and convey them to the coal yard. Then the coal will be processed into those with the particle size needed by boiler combustion, and finally delivered to the bin ahead of the boiler. The equipments of coal handling system includes: unloader, belt conveyor, coal crusher and other equipments, which are necessary to the procedure of coal unloading, conveying and crushing. The belt conveying system between stacker–reclaimer and main workshop is double. C-1、C2、c-3、c-7are all with single belt, which are installed in the coal yard and emergency coal bucket. The particle size of the incoming coal is below 300mm. That in the bin ahead of boiler is below 30mm. All the equipments in the coal handling system can meet the requirement of running continuously for 24 hours per day and 7 days per week. They can also adapt the climate environment where the equipments are located. The design service life is 30 years. 1.2 Summery Table of the Coal Handling System Equipments Drawing (See the Appendix 1.2) 1.2.1 Drawing of the Overall Arrangement and Installation of the Equipments (See the Appendix 1.2.1) 1.2.2 Drawing of Equipment Construction (See the appendix 1.2.2) Page 5 of 160 2. Coal Handling System Operation Manual 2.1 Introduction to Coal Unloading Equipment and Other Coal Silo Equipments 2.1.1 Bridge Type Grab Ship Unloader 2.1.1.1 Equipment overview The equipment is of bridge type grad ship unloader with four leading wound rolls. The representative unloading equipment is a bulk cargo crane with1.2-2 ton capacity. The structure and location of this machine refers to the Fig. 1. During operation, the grabber picks up material from the cabin of ship and then the grabber trolley moves towards the shore and unload the material into the hopper that is located at front door bridge interior. The crane moves along the jetty and takes material. ZQX1250 ship unloader consists of systems like the metallic structure, the operation mechanism with lifting parts, opening and closing parts, and trolley (three parts are on a complete set, which is called four rolling spool mechanism), lifting mechanism, crane operation mechanism, grabber and material collecting system, dust proof system, mobile cab, maintenance facilities and safety tools like anticreeper, anchoring, tie down device, safety hoop, and position limiting device, as well as electrical system. This equipment is of box girder structure. The front and rear crossbeams are connected by pin shaft. During non-working state or when the ship approaches the shore or leaves the shore, the front crossbeam lifts up for the ship to go. The front crossbeam is of dual-crossbeam structure. There are horizontal girders located at two sides to increase the side rigidity of the front crossbeam. The main building room and electrical room are located back of the rear crossbeam lower platform. The gravity center of the equipment is quite low and the stability is good. The lower outlet of the hopper is a kind of vibration material feeder. This mechanism uses the four-spool leading method. The gravity of buggy is quite light with ease rope connection. The applied force of steel rope is small and it is easy to replace. The guiding pulley is made of highly-reinforced nylon material, which can extend service life of the steel wire rope. The AC frequency converting speed adjustment system is used for the mechanisms like lifting, opening and closing, buggy operation mechanism, amplitude variable mechanism and crane operation mechanism. Material can be unloaded in semi-automatic mode or manual operation by PLC programmable controller. The material collecting system and other machinery equipment use the AC power supply and AC motor. The operation of each system and mechanism can be done on the panel in the mobile cab or operated locally. The mobile cab can move independently along the trail and can select the best view to operate. The material hopper system can reliably supply for the sealing-tape machine on the jetty. There are falling coal collecting board, coal hopper damper, dust collector and water spraying system equipped the dust prevention pollution points like hopper. Page 6 of 160 The wall board of main building and electrical house is made of high quality insulation material. Appearance is good and suitable. Insulation and sealing performance is good. This kind of setting improves the working environment of electrical equipment. The vertical air conditioner in the electrical house helps to guarantee the reliable and safe operation of electrical equipment. In addition, there are 5T crane for maintenance use. The stairs, platforms and passage ways are all made of galvanized boards that own the advantages like easy water discharge, hardly water accumulation and ice forming, corrosion resistant, good rigidity and nice appearance. There is a lifting suppose under the supporting leg in order to facilitate maintenance of crane. Various kinds of limiting protection systems, interlock limiting device, and communication systems are allocated for this machine to guarantee reliable and safe work of ship unloader. Power supply of this equipment is 6300V, 50Hz. It is supplied with cable rolling way. The length of rolling cable can support the ship unloader to walk on the 180m trail. There is another controlling cable rolling disc located there to communicate and contact with the personnel on ground and to serve a interlock protection for the belt on jetty. 2.1.1.1.1 Ship unloader material receiving characteristics and main technical parameters Ship unloader material receiving characteristics and main technical parameters Item Unit Value mm ≤50 % <8 t/m3 0.65~0.78 ° 35~50 t/h ≥1250 Coal Material size (Max) Moisture content Bulk density Angle of Repose Unloading capacity Main technical parameters: Rated production rate (of the ship unloader) 1250 t/h Track distance 18 m Base distance 16 m Rated lifting weight of grabber 32 t Gravity weight of grabber 13 t Grabber capacity 19 t Max outer distance 25 m Max inner distance 14 m Page 7 of 160 Lifting scope above the roller 23 m Lifting scope under the roller 10.5 m Cab outer distance 25 m Cab inner distance 14 m Ship unloader moving scope ~170 m  KN Lifting and closing speed 20/160 m/min Buggy moving speed 180 m/min Front crossbeam moving time Single journey -8min Crane moving speed 20 m/min Moving speed of the cab 20 m/min Hopper capacity 110 m3 Production capacity of the hopper 1250 t/h Designed ambient temperature -12~ 40 Max moisture 99 ℃ % Annual average relative moisture 80 % Power source 6300V, 50Hz, three   phase Control mode PLC semi-auto manual Complete equipment capacity ~1250 kw Complete equipment gravity weight ~830 t Max pressure of the roller 400 2.1.1.1.2 Introduction to main parts of the ship unloader 2.1.1.1.2.1 Metal structure or   The main metal structure of ship unloader is composed of the following parts: front and rear crossbeam, front and rear pulling rod, small front gate, sloped supporting rod, side girder, board, hopper and bracket. The most structures are constructed in term of thin wall enclosed box form. They are made of Q345-B steel. The main connecting joints are hinge joints or welded connection, which owns the advantages like simple structure, good rigidity, easy assembly and light gravity weight. The rotating hinge joints of front and rear crossbeam and front pulling rod uses the graphite sliding bearing with self lubrication. The wear resistant performance of this bearing is good and it is easy to maintain with easy rotation. There are upper and lower supporting bases located directly under the track with adjusting gaskets to ensure a precise position after the cross beam is lowered down. The track joints make a good difference in twist resistance at hinge ear. Structure of the front and rear Page 8 of 160 pulling rod is quite simple, which is made up with one or two transposition plates. The platform board in computer room uses rear arm suspending method. The gravity center of the whole equipment is then moved backwards. The balancing weight for inclination prevention is decreased in this way and the stability of the equipment is enhanced. Because it uses the leading system, the gravity weight of the buggy is light with simple structure, low mobile load and easy maintenance. There are two couples of horizontal guiding pulleys equipped at buggy bracket side (at two sides of the same track). In this way, it can prevent the friction between the wheel rim and track side that is caused by high speed operation of buggy, and also the vibration during buggy operation can be overcome. Fig. 1 2.1.1.1.2.2 Overview of ship unloader Mechanism of the four spools The four spool mechanism is the central part of this equipment, which is located in the main building. The operation of buggy and lifting and closing of the grabber is achieved by rotation from directions of the four spools. When the lifting motor is started up, two spools are driven by the gearbox to rotate in the same direction to achieve the lifting and lowering of the grabber. When the shutdown motor is activated, two spools are driven by the gearbox to rotate in the same direction to achieve the opening and closing of the grabber. When the operation motor is activated to drive two gearboxes, the four spools rotates in groups and in opposite direction to achieve the movement of the buggy. When the lifting motor, closing motor and buggy leading motor are activated at the same time, the grabber can work in a curvilinear motion. Page 9 of 160 Working principle of the four-roller mechanism (refer to Fig. 2): (1) Lift up and lower down, open and close the spool and make it rotate to the right side. Lift up the grabber. (2) Lift up and lower down, open and close the spool and make it rotate to the left side and lower down the grabber. (3) Lift up and lower down one couple of the spool and make it rotate to the inner side so that the grabber buggy moves towards the water side (this working condition is driven by buggy leading motor). (4) Lift up and lower down one couple of the spool and make it rotate to the outer side so that the grabber buggy moves towards the land side (this working condition is driven by buggy leading motor). (5) The lifting spool does not work. Open and close the spool so that it rotates towards the right side. The grabber can be closed at this point (only the closing and opening motor is started up under this working condition). (6) The lifting spool does not work. Open and close the spool so that it rotates towards the left side. The grabber can be opened at this point (only the closing and opening motor is started up under this working condition). Fig.2 Four-roller mechanism fig. Power of the lifting and opening/closing motors of this mechanism is 416KW. The high speed shaft breaker uses the disc type breaker of 800×30 with high breaker torque, reliable performance and safe and easy operation. Power of the buggy leading motor is 132KW. One disc type breaker is equipped on the high speed shaft. Bending fatigue and wear condition of the opening and closing section steel wire rope in the grabber is severer than that of other parts. In order to extend the service life of the steel wire rope and decrease the consumption of the rope, certain storage is left on the steel wire rope spool during the design. In this way, the severely worn parts in the grabber can be cut off. One section on the spool is left to satisfy the required length for normal lifting and opening/closing. Usually, one rope can be reused for at most three times. The mode of the steel wire rope for this equipment is 36NAT6x29Fi+Fc1770ZS and Page 10 of 160 36NAT6x29Fi+Fc1770SZ. The high quality steel rope with hemo core filling is of higher toughness, elasticity and certain lubricating grease. It has characteristics like higher bearing capacity, extrusion resistant capacity, non rotation and fatigue resistant ability. In order to effectively prevent rotation and properly use the steel rope. The lifting/lowering and opening/closing should be rotated in pairs from both the left side and right side. Use left rotating steel rope on the right spool and vice versa. A special sliding block like clutch mechanism is equipped in the gearbox to facilitate the assembly and disassembly of the steel wire rope. Single spool rotation is achieved through lifting and lowering motor and buggy operation motor (or opening/closing motor and buggy motor). In addition, steel wire rope going-through mechanism is set to decrease the going through (rope changing) intensity. 2.1.1.1.2.3 The amplitude variable mechanism The four spool mechanism is equipped at rear section of the amplitude variable mechanism. The gearbox is driven by one 55KW AC frequency-variable motor. The crossbeam moves upwards and downwards as the spools rotate in opposite direction, which drives the pulling back and throwing of the steel wire rope. Two rope ends of the steel wire rope are fixed on the end of the spool and on the balancing pulley. One balancing pulley is located on the upper section of the small gate in order to balance the force bearing of the two group ropes. The applied force of the two groups can be adjusted automatically. Fig.3 Frequency variable structure There is a kind of interlock relationship between this mechanism, buggy leading mechanism and mobile cab. Only when the buggy and cab are in the crossbeam scope, the lifting mechanism can work. The modes of the steel wire rope of the lifting mechanism is 28NAT6x29Fi+Fc1770ZS and 28NAT6x29Fi+Fc1770SZ, which are of left and right rotation structure. 2.1.1.1.2.4 Crane operation mechanism The crane operation mechanism of the ship unloader consists of four groups of eight wheel running trolleys. There are altogether 32 wheels. One set of driving mechanism Page 11 of 160 is used on the trolley. The driving mechanism is driven by one frequency variable motor to motive the crane to move. The structure of this mechanism is easily assembled, which is easy to disassembly and repair. There are interlocks between the crane operation mechanism and anticreeper and the anchoring device. Fig. 4 2.1.1.1.2.5 Trolley groups of the crane moving mechanism Coal conveying system The hopper of this equipment is located on the sea side track. There is a weighing sensor equipped on the hopper supporting beam. The system interlock is activated and deactivated by weighing sensor, feeder and grabber, by which way the working time of the hopper coal storage and out-conveying port is controlled. A frequency variable speed governing vibrating feeder is equipped at lower part of the hopper. The coal supplying amount has to be well-distributed and the amount can be adjusted. There is a wall type vibration motor equipped on the side wall of the hopper, which can remove the accumulated coal. A stainless steel lining plate is equipped on the hopper lower part inner wall. A dust prevention screen is equipped on the upper part of the hopper, which can separate the large block coal and also can prevent the dust or ash. A 3m high board is located on the sides of the hopper opening and another board behind the opening for dust suppression. A mobile chute board is located on the front part of the hopper opening to prevent the coal bock from falling into the sea, which pollutes the environment. Work of cut board is driven by a trigger gear. 2.1.1.1.2.6 Water spraying dust prevention system To meet the environment protection requirements, there are dust collector and dust prevention device located at each dust raising points of the coal collection system. Water for the mist spraying system is supplied from the jetty designated water supplying point, which is stored in the water tank of the equipment. Pressure is raised Page 12 of 160 by the water pump. Water becomes mist at the spraying nozzle. In this way, the dust prevention aim is achieved. The hopper upper part water spraying and unloading of grabber are in interlock. The water spraying at coal re-conveying points is in interlock with the coal flow way. Water spraying can be canceled manually. 2.1.1.1.2.7 Driver cab, main building and electrical building The cab is a kind of enclosed structure with good view. Doors and windows are sealed with aluminum alloy. There are decorating plates located on inner wall with insulation material in the middle and air conditioners equipped. Working environment in the cab is very nice and comfortable, and the appearance is also beautiful. The driver cab is a self moving one with the self-moving mechanism. The driver can move along it depending on requirement of the view. If emergency power-off occurs, the driver can go to the roof through the outdoor stairs and then go up to the walkway on the beam. Necessary facilities in the can are complete, such as inlet interlock platform, wind velocity indicator, loud-speaker and telephone. Communication is convenient. The main building is located on the upper platform that is under the crossbeam. The lifting, opening/closing and frequency variable rope enter the building through the water-proof holes on the roof. One 5T electric single beam crane is equipped in the building. This crane comprises the CD15-18D motor-driven hoister and other moving parts. Other large components in the building can be lifted to the ground of the jetty through lifting holes. Two transformers and a electrical panel are located in the electrical building. 2.1.1.1.2.8 Grabber The European type advanced four-rope and four-pole grabber is equipped for this equipment. The taking rate of the grabber is large with high production rate. The port edge is made of highly reinforced corrosion resistant material with good welding performance, intensity and rigidity. In addition, there are lifting ears for the bulldozer located on the grabber. In order to equalize the force bearing of the four ropes, the rope ends for opening and closing are fixed on the pulleys at two sides of the pulley group. The length of two closing rope can be automatically equalized within certain scope. The easy broken problem of the steel rope at fixing connection can be avoided by using this fixing method. The hinge joints of the pole inside the grabber use sliding bearings to decrease daily work. There are rope protective shield located on the grabber inner pulley group. A # type roller is located at head rope out-leading port to prevent the steel wire rope falling off and to decrease the wear condition. Working principle of the grabber: The opening and closing of the grabber completely depends on the relative moving Page 13 of 160 speed of the lifting up rope and the closing rope. When speed of these two is same, certain opening/closing, lifting or lowering can be maintained. When the speed of these two varies, hopper opening or closing are carried out at the same time during grabber lifting up or lowering down process. The specific work circulation is shown in the following: (1) The empty hopper opens and decreases. (2) At this point, the closing steel wire rope is loosened. (3) The total weight of the grabber is borne by the lifting steel wire rope. The lifting and opening/closing can be released with same speed. The grabber decreases down with a nature open state and to the material pile on the cabin. (4) Taking up of grabber. (5) After the grabber is lowered down to the coal pipe and opened. (6) Lift the steel wire rope and loosen it for a while to keep it in a slightly loose state. With gravity weight, the jaw plate inserts in the pile. At this time, the lifting rope does not work. Tighten the opening/closing rope, and the taking up of the grabber can be completed. (7) Full load lifting. (8) Start lifting the rope when the grabber is about to be closed. (9) As the rope lifts up, the grabber is lifted up in closing state. At initial stage when the grabber leaves the pile, the total weight of the grabber is borne by the opening/closing rope. In this way, the grabber is lifted up and the load of opening/closing rope is equalized. (10) Hopper opening and material unloading, when the full load grabber moves to the upper part of the hopper, release the opening/closing rope. At this point, the weight of the grabber is borne by the lifting rope. With the gravity weight, it is opened automatically. Unload the material from the hopper. Till now, one circulation process of the grabber unloading is finished. The working process is shown in the following: Grabber state Grabber Grabber opening and opening lowering down material taking Working state of Lower Loosen Stop lifting rope down with Page 14 of 160 Full load and Grabber opening and lifting and material unloading Slight Lift up Tighten Stop loosen with Take-up Working state of Lower same opening/closing down speed rope Lift up Take- Lift up same up speed Lower down Loosen The grabber working condition and grabber unloading are in interlock in electrical control. When the material storage amount of the grabber exceeds certain value, the grabber cannot open to unload, cannot even when the grabber moves to the direct top of the pile 2.1.1.1.2.9 Cable reel The dynamic power, control signal and communication facility of the ship unloader are lead in the equipment through the cable reel. The dynamic cable reel is mainly responsible for the reclaiming and releasing of the 6300V AC HV cable. It is driven by the hysteretic motor, which is similar to the constant tension driving function. This can work reliably with safety guarantee. The controlling cable reel is mainly responsible for the reclaiming and releasing of the LV communication cable. The driving device and working condition are similar to the previous mentioned one. In order to guarantee the normal work of the cable, there are cable leading bracket located under the reel. 2.1.1.1.2.10 Safety facilities 2.1.1.1.2.10.1 Anticreeper, anchoring and tie down equipment Four anticreepers, four manual anchoring devices and four removable tie down devices are equipped for this equipment. The anticreeper and anchoring device are set to prevent strong wind attacking, to be specific, prevent the crane sliding off that may cause severe damage. The ship unloader is stopped from moving along the track by inserting the anchoring block into the base on the jetty. The tie down equipment aims to prevent the unloader capsizing forwards and backwards when strong wind occurs. There is one tie down located on four supporting stems, which is firmly fixed on the anchoring base manually. Do not loosen the tie down unless the equipment is activated. The anticreeeper, anchoring device and crane are in interlock. If the rail clamping device is not loosened and anchoring block is not lifted up to its position, the motor cannot be supplied with power. Therefore, the crane cannot move. The anticreeper can withstand Level 10 gale. If the wind exceeds Level 10, the anchoring and tie down work have to be done. 2.1.1.1.2.10.2 Safe hook The safe hook is located at top of the ship unloader small frame in order to lock the lifted boom. The model is of hook type. When the boom lifts up to set position, the hook can be lifted up by hydraulic push pole. As the boom is lifted up to position, the hydraulic push pole is powered off and stops working. The hook lowers down to lock the boom. The hook sends out the signal when it reaches the position. The lifting mechanism stops working. Page 15 of 160 When the boom needs to be lowered down, first tighten the frequency variable steel wire rope. The hydraulic push pole is powered on and lifts up the hook. As the hook is pulled out, release the frequency variable steel wire rope. Lower down the boom to the horizontal level. The activation signal of the hook is provided by the position limiting switch. 2.1.1.1.2.10.3 Buffering device There is a polyurethane buffer located at two ends of the crane travel mechanism bogie frame. The buffering base is fixed at track on the jetty, at two ends of the trolley frame, and one polyurethane buffer is equipped at two ends of the trolley track. In addition, at two ends of the operator cab moving wheel, there is another buffer. The main function of the buffer is to absorb running equipment, eliminating the impact and decrease the impacting vibration. 2.1.1.1.2.10.4 Electrical position limiting device There are activation switches controlling position limiting, speed reducing, locating, and crash prevention that are in mechanical interlock with the electrical part of each mechanism. In addition, safety protection devices like cam position limiting switch, photoelectric encoder, overspeed protection are equipped for the four spool mechanism and lifting mechanism. Purpose of using various protection systems is to guarantee the reliable, safe and flexible operation of each mechanism on ship unloader, and to reduce the labor force intensity of the driver at the same time. 2.1.1.1.2.10.5 Others Apart from the above mentioned safety devices; there is wind velocity indicator equipped on the ship unloader, which is installed at the top position of the unloader. The signal that detects is transmitted to the display in operator’s cab. There is acoustic-optic alarm located there also. If the velocity of the wind exceeds Level 7, it is required to stop working. Do not work at all when the velocity exceeds Level 8 and the anchoring has to be done. Tie down device has to be equipped in the typhoon season. Aviation light markers in read color are equipped at top of ship unloader and at boom ends. Four speaker signal alarm slewing flash lights are equipped on bogies of the crane travel mechanism. Acoustic-optic alarm is produced during crane operation to alarm the operators on the jetty. Signals are sent to the display in the cab for better understanding of material conveying condition. The ship unloader has to be located at anchoring maintenance position when work is finished or when it is suspended. Anchoring is then carried out and the tie down device has to be equipped if necessary. The interconnection telephone and outside line for communication system has to be complete. 2.1.1.1.2.11 Electrical system 2.1.1.1.2.11.1 Overview Page 16 of 160 The electrical part of the ZQX1250 bridge type grab ship unloader includes the power distribution, control, illumination, ventilation and communication for the following systems: the lifting, opening/closing, trolley traveling, lifting, crane traveling, mobile operator cab, and internal coal conveying system. The power source for this equipment is HV 6.3KV, 3 phase, 50Hz, which is lead onto the ship unloader from the jetty HV connection box through the dynamic cable winch disc. The communication (including telephone and signal interlock) of this equipment with the ground personnel is achieved by flat cable CFR(24 X1.5), which is also lead onto the ship unloader from the jetty controlling connection box through the controlling cable winch disc. The total capacity of this electric equipment of the unloader is 1250KW. As one of the main equipment for power plant coal conveying system, the vital part of electrical control part is the product from international famous ABB Corporation, whose controlling performance is good and reliability is high. There are interlock control panel, CMS display, power distribution box for dynamic illumination, wind velocity indication, speaker, and air conditioners located in the Operator Cab. Main and auxiliary transformers are located in the Transformer Room. HV leading in panel, main transformer control panel, transmitting leading in panel, transmitting panel, vibrating feeder and trolley/lifting switching panel, PLC panel, CMS panel, power distribution box for auxiliary equipment, illumination box and air conditioner for the Electrical Room are equipped in the Electrical Room. One lifting operation box is located in the Lifting room. One computer room operation box is located in the computer’s room. Other electrical equipment is located in vicinity of the related mechanisms. Refer to the electrical related equipment locating sketch. 2.1.1.1.2.11.2 Power distribution system The power distribution system consists of the HV power distribution and LV power distribution systems 1) HV power distribution High voltage power distribution panel is manufactured by Wuhan Gangdi Electrical Co.,Ltd.. There are two panels in total, which are wire lead-in panel and main transformer panel. Also, there is vacuum circuit breaker in the main transformer panel. Refer to the Operation Instructions for the details of HV operation. 2) LV power distribution The LV power distribution includes the LV power distribution for both the main system and auxiliary systems. The main system LV power distribution supplies dynamic power for lifting panel, opening/closing panel, trolley/lifting panel and crane panel through the driving leading-in panel. The auxiliary power distribution panel supplies the dynamic and control power for the Page 17 of 160 auxiliary systems like coal feeding system. Double-pole and double-throw switch is used to provide the dynamic power and control power for the illumination box, operator cab illumination box, lifting control box, computer room illumination box and electrical panel. When the HV power has to be cut off for maintenance, the double-pole and doublethrow switch can be pulled downwards. At this time, the illumination and maintenance power is supplied from the ground. The make-and-break of the illumination power main contactor are controlled at four locations, which are respectively the operator cab, stair climbing position, electrical room illumination box and computer room illumination box. 2.1.1.1.2.12 Replacing method and adjustment of steel wire rope a Length of the lifting steel wire rope Length of left rotating steel wire rope is L=240m Length of right rotating steel wire rope is L=240m b Length of the lifting steel wire rope Length of seaside steel wire rope is L=150m Length of landside steel wire rope is L=200m c Length of the opening/closing steel wire rope Length of seaside steel wire rope is L=170m Length of landside steel wire rope is L=200m Opening/closing rope partial replacement method is shown in the following: 1) Drive the trolley to landside stop limiting position; 2) Place the grabber onto the jetty surface and maintain the rope tension. Disengage the nylon gears for lifting the main gearbox and opening/closing the limiter; 3) Place the grabber onto the jetty completely; 4) Get rid of the fixing device on the grabber on which the steel wire rope needs to be replaced; 5) Select the relevant drum whose rope needs to be replaced. Individual rotation of this drum is controlled in computer room. Lower sufficient section of the rope to the jetty; 6) Pull out the damaged section of the rope and cut it off; 7) Fix the rope that is in good condition onto the fixing device of the grabber again. 8) Replace one piece of rope IAW the step 4-6. Page 18 of 160 9) Tighten the rope and balance the grabber. 10) Restore the grabber to the state as step 2 and restore the nylon gear for gearbox lifting and closing/opening limiter. 11) Finish now. Whole piece rope replacement method includes the following: a) Drive the trolley to landside stop limiting position; b) Place the grabber almost on the jetty and maintain the rope tension. Disengage the nylon gears for lifting and opening/closing of the main gearbox limiter; c) Place the grabber onto the jetty completely; d) Get rid of the fixing device on the grabber on which the steel wire rope needs to be replaced; e) Select the relevant drum whose steel wire rope needs to be replaced. Get off the rope fixing device on the drum. Fix the thin steel wire rope of the going-through mechanism onto the rope that needs to be replace and place the ropes onto the jetty completely; f) Connect the new rope onto the thin rope of the going-through mechanism; g) Operate the going-through mechanism in the computer room and lead the new rope into the related drum; h) Fix one end of the new rope onto the drum; i) Fix the other end of the rope onto the fixing device in the grabber; j) Replace other ropes IAW the steps from 4 to 9. k) Tighten the rope and balance the grabber; l) Restore the grabber to the state mentioned in Step 2 and restore the nylon gear for the main gearbox lifting and closing/opening limiter; m) Finish now. 2.1.1.1.3 Operation 2.1.1.1.3.1 Dos and don’ts before operation Ship unloader should be operated by specially trained personnel, who are familiar with working principles and structures and know the functions and repairing methods. The operation should be stopped at the force 7 wind. The unloader should be in anchoring state off duty everyday and when the shutdown repairing occurs. The front crossbeam should be lifted during nonworking hours, hooked firmly with the safety hook. No one is allowed to stay where grab bucket passes when the equipments are working, such as dork or deck of the cabin. To crane and transport workers with grab Page 19 of 160 bucket is also forbidden. Workers should not repair or regulate the rotating parts when the equipment is still operating. The power supply should be cut off during checking and repairing. The driver should immediately haul all the control handles back and cut off the main switch during operation when power failure or dramatic pressure drop of the circuit occur. 2.1.1.1.3.2 Preparations before operation Know the power supply condition of the main switch. Check if there are obstacles and oil contaminations on the dray track. Lift the anchoring plug .Check the lubrication condition of every lubrication point of the unloader. Check if the oil level of oil tank and reducer meets the requirement. Check the attrition condition of steel rope and pulley and the reliability of the fastening of the steel rope end. Check if the fastening of the screw bolt is mobilized and if the steel structure is flawed or the paint is flaked off. Check if every operation handle and switch is at zero position and if communication facilities are in good condition. Switch on and observe if the numbers shown on the ampere meter and voltmeter are normal and if the contactor works well. Let each mechanism run without load for several minutes and check if its drive and braking are reliable and flexible. Check if the limit travel switch of hoisting, closing, circuit breaker and other facilities work and transmit signals normally and correctly. 2.1.1.1.3.3 Safe operations at work The driver should operate the handles correctly and nimbly. When switching the rotation direction of each generator, the driver should pull the handles to zero position and operate in a reversed direction after a pause. Directly switching the direction of operation handles is not allowed. The driver and other workers should pay attention at all times that if each mechanism or electrical equipment has abnormal sound or phenomenon and if the generator and bearing abnormally emit heat .The generator should be shut down if necessary. After unloading is finished, the driver’s cab should be stopped at the permitted place. Start the jib lubing mechanism to pull the rope back and hang the front crossbeam up to a specific place and hook it firmly with a safety hook. Anchor the truck when it operates to the anchoring port. If there’s a big wind, tie the mooring rope firmly to the dock ground anchor. Pull the handles and switches in the operation room to the zero position at the same time. Cut off the power supply successively. Tie the driver’s cab firmly to the sidewalk. 2.1.1.1.3.4 Energization Press the light indication button on the right ganged platform in the driver’s cab. If the indication light is bright, the operation of the driver’s cab is effective. If the operation is effective at other place formerly and wants to be transferred to the driver’s cab, then de-energize at the former place or press the button “tripping” first and then energize by pressing “switch on”.(Tripping and switch on here refer to the “dynamic power supply tripping and switch on. 2.1.1.1.3.5 Initialization Page 20 of 160 At the starting up point, hoisting, closing and breaker mechanism should be limited at low speed. After initialization, they can be operated at normal speed. Switch the transfer switch SA800 to hoist + close position, and then lift the grab bucket to the proper position (the operation of hoisting rotation limit switch. Hoisting and closing photoelectric encoder set the reference value(1000)automatically and operate the grab bucket at low speed to a proper aerial position. Switch the transfer switch SA800 to the closing position and close the grab bucket. Press the indication button SB806 and the grab bucket closing initialization is finished. The indication light will not shine, but it’s bright at the closing position of the grab bucket. Then open the grab bucket and press the indication button SB807 at the maximum opening position the operator thinks proper. The grab bucket opening initialization is finished. The indication light will not shine, but the light is bright here. Finally, drive the breaker to the side ground parking place and the photoelectric encoder of the breaker sets the reference value(1000)automatically. The whole process of Initialization is finished. 2.1.1.1.3.6 Manual unloading Switch the transfer switch SA800 to the grab bucket position and manual unloading can be operated after switching SA806 to manual. The operator controls the closing, hoisting speed and anti-rolling of the grab bucket and operating speed of the breaker. Due to using digital DC speed adjusting device and PLC control, the following controlling functions are still available to reduce the operators’ work load in the manual operation. 2.1.1.1.3.6.1 Cooperative control of hoisting and closing If the operators open the switch light to hoisting or descending, hoisting and closing generators will hoist or descend at the same time. If PLC calculates that the grab bucket is closed according to the numbers of hoisting and closing photoelectric encoder, it will balance the load automatically, making the current of hoisting and closing generator well-distributed. If the grab bucket is open, it will automatically balance the position, keeping the openness unchanged in the rising and descending process. 2.1.1.1.3.6.2 Open and Close Control of Grabber To increase production efficiency, operators only need to open or close the master switch to the maximum degree because there has been special designation for the thorough open and close of the grabber switch in its initialization. According to the data of photoelectric encoder, PLC automatically accelerates the speed of the open and close motor smoothly to the rated speed, and automatically decelerates the speed before the grabber opens or closes to the greatest extend, and shut the engine down automatically when the grabber reaches the open or close position without manual adjustment. 2.1.1.1.3.6.3 The Automatic Lift and Drop Control of the Grabber The lift and drop of the grabber is a potential load-bearing gear. For the reason that Page 21 of 160 the speed adjustment devices has the function which suits the potential load, so when the grabber is lifting or dropping, an electric torque should be built up to overcome the load torque. Then loosen the band-type brake to make sure that the grabber will not drop suddenly. Only when the working speed has reduced to about 10% of the rated speed, can the brake perform automatic brake to decrease abrasion and start/brake smoothly. However, in case of emergency shutdown or the action of terminal limit switch or faults of power ect., the brake immediately closes for the seek of safety. 2.1.1.1.3.6.4 Control of Material Grabber close and loaded draught When the grabber is closed in the air, set the master switch towards the close direction. At this time, the close motor works while the lifting motor does not and the band-type brake does not loosen. But when the grabber is grabbing materials the master switch SA802 should be fully switched to the close position and to the lifting position. These performances should be finished within two seconds Then, the close motor automatically accelerates to a steady speed, and decelerates speed when it is about to close realizing soft close. At the same time, the lifting motor loosens brake and enters current control adding the wire rope a lifting force to make sure the grabber will drop during closing process and the lifting wire rope will not loosen. Grabber being in the close position makes the switching motor transfer into personnel limit load control (the current of the motor is about 50% of the rated current). The time is about 0.5 second. Thus, the loads of the lifting and switching rope have been balanced before the grabber rises. Then, lifting and switching motor rises the grabber in a load-balanced way. 2.1.1.1.3.7 Semiautomatic Unloading Materials Screw the transfer switch SA800 to the grabber position. At the same time, screw SA806 to Auto position. Then the semiautomatic unloading is started. 2.1.1.1.3.7.1 Safe Height After initially selecting semiautomatic mode, the driver should suspend the grabber over the cabin at the predicted safe height and press the button SB808 with indicating light. Then the indicating lamp stops flashing. Set this position as light on and fix the safe height. After about four hours the indicating light will flash again alarming the driver to reset the safe height. Only when a new safe height is entered, can the semiautomatic circulation continue, and the safe operation of semiautomatic recycle is ensured. 2.1.1.1.3.7.2 Application for semi-auto In automatic circulation, operation is still performed manually within the safe height. To enter semi-auto, press the button at the top of the master switch on the right worktable and the beeper on the right worktable will produce a short alarm 2.1.1.1.3.7.3 Semiautomatic Operation Page 22 of 160 Before each semiautomatic circulation begins, the following condition should be achieved: 1. The breaker master switch is at zero position. 2. The grabber is closed and the master switch is rising. 3. The grabber is at the safe height. 4. Lifting, switching, breakers are faultless. 5. The semi-auto is applied for. 6. Unloading the material is permitted. (The interlocked conditions, such as open, are permitted when the grabber is above the bunker. After entering semi-auto, the master switch on the right should be at the zero position. The grabber automatically rises to the unloading height and at the same time moves towards the bunker on the land (safe curve track). If the transfer switch SA807 is at the static unloading position, the grabber automatically begins to stabilize itself and rest upon the center of the hopper, and then opens the grabber to unload To achieve good anti-rolling effect, before the grabber enters the semi-auto circulation, i.e. below the safe height, the breaker master switch on the left interlock table can be operated to do the manual anti-rolling. When the transfer switch SA807 is in the dynamic unloading state, the anti-rolling process of the grabber can be omitted before the hopper, instead, the grabber can use the shaking bucket to shake off the materials. The breaker does not suspend upon the hopper. When the grabber is at the greatest position angle on the landside, the breaker moves towards the opposite position. When the grabber automatically moves towards seaside and drop to the former grabbing position, the manual control is transferred into. And also, by operating breaker master switch in advance to transfer into manual control, the loading point is chosen to grab material. During semiautomatic circulation, as long as the breaker master switch is out of zero position, e.i. the semi-auto operation is stopped and the manual control is in charge. 2.1.1.1.3.7.4 Manual Operation in Semiautomatic Operation 2.1.1.1.3.7.5 Push frame When lifting the push frame, the transfer switch should be switched to the push frame position. The grabber should be limited to low speed operation. Only when the grabber and push frame are dropped to the lowest lifting position, can the motor for driving unit cross over the hopper. 2.1.1.1.3.8 Equipment Room Function The function of this room is to carry out steel rope penetrating and maintenance. When operating in this room, speed limit of each motor should be at low speed. 2.1.1.1.3.8.1 Energization Page 23 of 160 Press the button “Switch in”, with an indicating light on. The motor room operation is valid. 2.1.1.1.3.8.1.1 Roller Selection Threading or replacing steel wire rope should choose roller working mode. The two rollers near lifting motor are coiling block number 1 and number 2.The two near motor for start and stop and motor for driving unit are number 3 and number 4. The cooperated operation between lifting motor and motor for start and stop or between motor for driving unit and motor for start and stop can achieve roller isolated operation. Pressing lighted button “roller selection” makes roller working mode available. Each inverter controls roller number 1 and number 4 respectively. The direction of inverter rotation is identical to the direction of roller rotation. Attention: To make roller number 1 or number 2 in isolated operation separate the crane clutch on start and stop side firstly. To make roller number 3 or number 4 in isolated operation separate the carriage clutch on lifting side firstly. 2.1.1.1.3.8.1.2 Actuator Selection Pressing lighted button “actuator selection” makes actuator operation mode available. Each inverter controls low speed of lifting motor, motor for start and stop and motor for driving unit respectively. Inverter SA204 and button SB214 control operation and shutdown of lifting motor. Light HL201 indicates the startup of safety brake. 2.1.1.1.3.8.1.3 Overshoot Bypass When lifting motor, motor for start and stop, motor for driving unit and amplitudechange motor over normal stop limit and make overshoot bypass emergency stop because of mechanical breakdown or some else reasons, key type bypass inverter SA212 should be operated in operation cabinet of motor room to reenergize overshoot limit bypass. In addition, motors can’t work normally until overshoot limit bypass is reset by means of making the relevant motors operate with reverse low speed in operation cabinet of motor room and the bypass inverter is reset too. 2.1.1.1.3.8.1.4 Lifting Safety Brake To assure the safety, lifting motor is equipped with safety brake beside normal working brake. After shutdown of amplitude motor at horizontal, key type inverter SA201 is operated to start safety brake separately for maintenance and repair easily. 2.1.1.1.3.9 Indoor Operation of Lifting Motor The lifting motor can be controlled in lifting room with the selections of manual and auto mode. 2.1.1.1.3.9.1 Energizing After Press the Stop button in operation cabinet of lifting room, lifting room is Page 24 of 160 available. 2.1.1.1.3.9.2 Manual Operation Turning switch SA205 to the rising direction, with lighting of lights HL206 and HL208, lifting motor start rising. When it comes to the middle (about 70 °), the pin of lifting motor rises manually and the light HL205 starts. Until lifting motor continues rising to the normal upper stop point, it shuts down. Release the lifting pin and descend lifting motor manual mode slightly. Till lifting slack-rope switch activates, lifting motor shuts down automatically. The pinning operation is finished. Turning switch SA205 to the rising direction, lifting motor slightly moves up to the normal upper stop point and stops firstly. After that, turning primary control switch SA205 to the descending direction, lifting pin descends manually. Release lifting pins when lifting motor over the middle position. After lifting motor continues descending to horizontal and lifting slack-rope switch activates, lifting motor shuts down automatically. The releasing operation is finished. 2.1.1.1.3.10 Operation of Other Important Mechanisms. 2.1.1.1.3.10.1 Coal Conveying System The work of coal system means coal drops from hopper to vibrating feeder, and then through filling pipe to terminal belt conveyor. The startup of vibrating feeder can be operated with button “Feeder Startup” (Button SB810) and “Feeder Shutdown” (Button SB811) at left interlock consoles in operator room. It also can be achieved with the “Feeder Shutdown” (Button SB901) and “Feeder Shutdown” (Button SB902) with hopper local operation cabinet. The frequency of vibrating feeder is coal flow rate and it is controlled by the inverter SA812 at left interlock consoles in operator room. When it works normally, startup of vibrating feeder is interlocked with terminal belt conveyor signal and coal mount in hopper. In feeding operation, feeder starts up when coal mount is more than 35%, and feeder shuts down when coal mount is less than 20%. Lifting and shutdown of hopper pickup board is can be operated with the button “up hopper pickup board” and button “down pickup-board of hopper” at left interlock consoles in operator room. It also can be achieved with the “up hopper pickup board” and “down pickup-board hopper” with hopper local operation cabinet. When coal is accumulated at hopper walls, “Vibrator Startup” ( button SB816、button SB817、button SB818) at left interlock consoles in operator room as well as “Vibrator Startup” ( button SB905) on hopper local operation cabinet is used to make vibrator work vibrating the coal. 2.1.1.1.3.10.2 Water system Water tank is set in ship unloader. Water level detecting device plays a very important role in automatic water-spay control process. Turn off the water spay motor when the water is in low level. The Page 25 of 160 water injection control of spray valve on hopper is controlled by feeding on the upper part of hopper. The water injection on inlet and the vibration feeder are in synchronous operation. When the water spray valve and the water injection valve are closed, the water return valve opens automatically. The control of water system includes two parts, one is for water spray motor and the other one is for spray magnet valves on both hopper and feeder. The water spray motor can be started up or shutdown through pushing the button SB814 and SB815 which is on left linkage control console in operation cab or pushing the button SB903 and SB9044 on hopper operation cabinet at site. Spray magnet valve on hopper is controlled by both the signal from button SA819 on left linkage control console in operator cab and the signal of starting unloading on upper part of hopper from grab bucket. For spray magnet valve on feeder, it is controlled by both the signal from button SA818 on left linkage control console in operator cab and the signal of feeder operating. 2.1.1.1.3.10.3 Operator cab The operator cab is driven by two alternate squirrel-cage motors. The control panel in operator cab supplies the power source and control power to these two motors. Choosing soft start the director when start up to start up the motor smoothly. The operation of operator cab is controlled by the button SA810 on left linkage control console. Only when both the switch of operator cab’s door and the amplitude transversal switch are closed strictly, the operator cab can operate normally. 2.1.1.1.3.10.4 Crane mechanism Moving unit of crane mechanism uses AC motor frequency control so as to start or brake smoothly and with good speed regulation performance Crane mechanism operation can be achieved in operator cab or on site, as local control panel is designed near the access door. Operator cab operation: push the close button on right linkage operation console in operator cab. When the main order switch is onward or backward on left linkage operation console, synchronous sound and light alarm, anti-creeper and motor arrester is opened, the crane mechanism operates by following the operator’s orders. Five degree speed adjusting can satisfy the normal production needing. Local operation: push the close button on local control panel. When the main order switch is onward or backward on local panel, synchronous sound and light alarm, anticreeper and motor arrester is opened , the crane mechanism operates by following the operator’s orders. Only one low speed degree is used for local operation and it is mainly for satisfy the needing of local anchor, commissioning and so on. When arrive to the terminal limiting, the crane should be stopped and do the inverted running. When the cable drum empty limiter is activated, operator should turn the key switch Page 26 of 160 SA702 to crane bypass position on local panel, and at same time, let the crane run inversely. After the cable drum empty limiter is reset, the crane can operate normally again. The crane power cable reel and control cable reel use TIC hysteretic cable reel. Compared with torque motor type cable reel, this one is smaller, has more rich functions, easier to install and maintain and near to constant tension. Besides, its output moment can be adjust according to the working condition and this cable reel is with fine auto brake character, no need braker, the cable reel operates smoothly and no damage after long-term operation. Please pay seriously attention that the motor using the cable reel can only be turned following the indicating direction signally. For the detail, see the instruction from the manufacture. When the vent speed is over setting value, never operate the crane. Drive the crane to anchor hole to be anchored after the operation be finished. 2.1.1.1.3.11 Safety devices The safety devices on ship unloader should be durable and its protection level should not be less than IP65 The following safety devices should be provided on ship unloader (Not limited to this): Limiter for lifting height and drop height; Grabber position limiter for coal unloading; Grabber lifting overload protection device; Secondary limiter on the stroke end of Secondary limiter on the stroke end of Anti-collision protection device for ship unloader; Stretch angle limitation and overspeed fall down protection Cable break protection device; Rotary type identify sound and light warning signal for ship unloader moving Install light control red aviation obstruction lights on the top of ship unloader Vent speed alarming signal Wire cable anti-relaxation protection device Allocate complete safety devices in every stage for electrical protection devices according to the system settings’ needing. 2.1.1.1.3.12 Emergency shutdown When each mechanism need to shutdown, turn the corresponding main order switch Page 27 of 160 back to zero. Take electric braking to decrease the speed close to zero and then do mechanism brake , while if electric apparatuses fault or in other emergency condition, push the emergency button on right linkage operation console and do mechanism brake immediately. Take same action if emergency shutdown is needed in other parts. To restart operation, the emergency shutdown button should be reset. 2.1.1.1.3.13 Others Push close button when shut down the machine. The monitor in operator cab not only supplies the operation information to the operator, but also offers maintenance and fault information. If fault happens, after it is treated, the operator should push SB803 fault reset button and then push the close button to supply the power again. 2.1.2 Bucket Wheel Stacker & Reclaimer 2.1.2.1 Equipment description DQ1250/1250.40 Boom bucket wheel stacker reclaimer (BWSR) is a kind of large, continuous and efficient bulk cargo stacking & Reclaiming equipment, developed,designed and manufactured by Changchun Generating Equipment Co., Ltd, China for PLTU 1 Jatim - Pacitan (2×315MW) Coal Fired Steam Power Plant project,Indonesia.This machine has the function of unidirectional stacking and shuttling reclaiming. There are interlocking protection among long travel drive, Slew, luff, bucket wheel drive and boom conveyor etc transmission part (detailed information refer to the instruction in each Chapter/Section). Operator must read “Instruction” carefully and master daily operation and maintenance before starting to work; if operation is not proper, not only can reduce the service life of equipment, but also can cause the accident. CHANGCHUN GENERATING EQUIPMENT CO.,LTD,CHINA 2.1.2.2 Technical specification 2.1.2.2.1 Type of equipment D Q 1250 / 1250 .40 40…slewing radius; Page 28 of 160 Stacking capacity 1250 t/h; Reclaiming capacity 1250t/h; Reclaiming; Stacking; 2.1.2.2.2 Natural Condition of the coal yard Coal yard type: shuttling type layout Environmental temperature: +5℃~+50℃ Coal density: 0.8~1.2t/m3 Height of stockpile: 12m above the rail, 2 m below the rail 2.1.2.2.3 Main parameter of equipment General parameter: Rated stacking capacity 1250 t/h Rated reclaiming capacity 1250 t/h a Long travel Traveling speed: Operating speed 5m/min Commissioning speed 15m/min Wheel base and wheel gauge: 8m x 8m Motor power: 6x7.5kW Reducer type: FH127GDV132M4BM/HF Transmission ratio of reducer: i=170.83 Rail clamps type: TZT-J250 (hydraulic spring type) Limit switch of anchor device: WLCA12 Limited switch for anti storm mooring arrangement XS4-P30MA230 b Slewing unit Slewing radius: 40m Slewing speed: 0.02~0.12r/min Slewing angle: ±110° Motor type: Y180L-8 Motor power: 2x11kW Page 29 of 160 Reducer type: ZHP5.32L-ex Transmission ratio of reducer: i= 738.6 Brake type: YWZ9-200/E23 Over torque limited switch for Slew TL-N10MY1 c Bucket-wheel mechanism Reclaiming capacity: 1250t/h Outer diameter of bucket-wheel: Φ6300mm Rotational speed of bucket-wheel 6.5r/min Bucket volume : 0.51m3 Bucket quantity : 9 nos. Driving device parameter: Motor power: 90kW Reducer type: ZHP5.33K Output torque of the reducer 94535Nm Type of fluid coupling YOXA500 d Luff unit Lifting angle luff Up 9.54°, luff down 10.61° Lifting speed : 4 ~ 6m/min ( at center of bucket wheel) Type of hydraulic cylinder 320MP5MMBYLS14M1550M1144 Type of oil pump motor Y180M4A-B35 Rated working pressure: 16MPa e Boom conveyor Length of boom conveyor 41.9m Rated conveying capacity 1500t/h Belt width x belt speed: 1400mm x3.15m/s Idler diameter: φ133mm Trough angle of idler: 35° Take up type Heavy bob take up Driving device parameter Page 30 of 160 Motor type: Y280M-4 Motor power: 90kW Reducer type: MC3RLHF07+1FAN Transmission ratio of reducer: i=20 Limited torque type fluid coupling YOXNZ-500 Brake type: YWZ9-300/E50 Dual direction pulling wire switch type KLT2-I Misalliance detecting switch type: FPK-12-30 boom conveyor material flow detecting switch type: Longitudinal splitting protection switch type: HFZL-K Speed sensor type: SJK-B-Ⅲ Driving device parameter Motor type: Y280M-4 Motor power: 90kW Type of reducer: MC3RLHF07+1FAN Transmission ratio of reducer i=20 Limited torque type fluid coupling YOXNZ-500 Brake type: YWZ9-300/E50 g Water prinkling system Water tank volume: 10m3 Type of water pump D6-25X3 multistage centrifugal pump Flow of water pump: 6.25m3/h Delivery lift: 75m Type of motor equipped with water pump: Y132S1-2 Motor power 5.5kW Rotational speed of motor: 2950r/min Liquid level replay : UQK-02 Magnetic valve: ZCLF-40 Water pressure entering into water tank: 0.1~0.2(MPa) Page 31 of 160 h Power cable reeler device Cable specification: 6000V, GKFB-3x35+3x16/3Pmm Cable cross-section dimensions: 71.8mmx31.3mm i Reeler device Cable specification : 380V,YEFBG-24x2.5mm2+2x4Gmm 2 Cable cross-section dimensions: 99mmx19mm j Transfer chute Electrical thrustor DT30050-20II k Limited switches device Anti-collision device of boom rack: FKLT2-I Other limited switches: WLCA12 Note: Other limit switches refer to boom rack lifting limited position, slewing angle, slewing luff and terminal limited position of Long travel and tripper car luff end limited switch etc. L Detection device Detection device for traveling distance: TRD-GK30-BZ type rotary encoder Detection device for slewing angle: E6C3-AG5C type rotary encoder Detection device for lifting angle: E6C3-AG5C type rotary encoder Detection device for material level: 20-39 type inclining switch 2.1.2.4 Equipment Structure 2.1.2.4.1 Section 1 General Structure The equipment (see details in general drawing DQ9711.0ST) consists of bucket wheel mechanism, Super steel structure, boom conveyor, main machine ladder, walkway stairs and platform, lifting unit, Long travel, portal, transfer chute, impact pulley bracket ,slew unit, central lubrication system, limited switch device, detection device, tripper car, ladder platform of tripper car, electric room, electrical system, operator’s cabin and bracket, nameplate, counterweight assembly, water sprinkling device, power cable reel drum device, control cable reel drum device, Slew deck, support pivot, foundational layout and load etc. Super structure of main machine is an integral structure which consists of front boom rack, pylon, counterweight boom and front and back bracing , all parts will be connected by pin roll which fixed by block. Head part is bucket-wheel mechanism; back part is counterweight assembly which can adjust the balance of super structure. Super structure is fixed on slew deck by support pivot, the upper part of the support Page 32 of 160 pivot and the end part of the pylon will be hinged joint; and lower pivot support should be welded with top surface of slew deck. The completed structure can waggle around the support pivot point, Hydraulic cylinder which lie between slew deck and pylon acts can achieve integral luff of super structure. Slew support bearing is mounted between upper and lower pedestal ring, upper pedestal ring supports the slew deck, and lower pedestal ring is fixed on the portal. Slew driving device is fixed on the slew deck, and through output axis pinion of slewing reducer, the spur pinion is meshed with big gear ring which is fixed under the bearing of lower pedestal ring, which shall transmit upper structure to rotate around slew center. Pivot of traveling mechanism is welded with support leg of portal. This part will be assembled on jobsite, and then welded together. Pylon Pull rod Cab Pull rod Counterweight assembly Support pivot Counterweight stack Bucket wheel mechanism Bucket wheel boom rack Pitch cylinder 2.1.2.4.2 Detailed structure of unit and operating features 2.1.2.4.2.1 Bucket wheel mechanism oil Slewing mechanism Bucket-wheel mechanism mainly consists of bucket wheel body, bucket wheel axle, bearing assembly, ring chute, sliding chute, guide chute device and bucket wheel drive device etc. Bucket wheel body is cell less type; it has the merits of rapidly discharge. Bucket wheel mechanism has nine buckets total, they are evenly distributed at the external of the wheel body circle, and fixed by pins and bolts, ferromagnetic wearing resistance disassembled bucket teeth will be installed on the entrance of the bucket , Bucket blade position has the protective layer which is made of wearing resistance electrode by building up welding. In order to be convenient for discharging the material, bucket wheel shaft relevant horizontal should set up 7° tilt angle which will be installed vertical bucket wheel body. Ring chute shall be installed inside bucket wheel body circle, and 5 to 10mm gaps should be remained between ring chute and bucket wheel body, so as to be sure the bucket can lift the coal reclaimed from the coal yard to discharging chute which is on the upper part of the bucket wheel body, through sliding chute to the boom conveyor, then through guide chute delivering along Page 33 of 160 bucket wheel boom conveyor reclaiming direction. The working surface of ring chute and sliding chute are all installed wearing resistance liner easy replaced. Bucket wheel drive device adopts mechanically-driven, and mechanically-driven device consists of motor, fluid coupling, bucket wheel drive reducer (Zollern), torque limited device, lubrication system etc. Bucket wheel drive reducer is orthogonal hollow shaft planet transmission; it is combined with motor and fluid coupling into one body and will be fixed on bucket wheel shaft through expanded sleeve. Lever-type torque limited device will be installed on bucket wheel drive reducer, which function is when excavating force of the bucket exceed 1.5 times of designing value, the limited switch in torque limited device start action, it will cut off the circuit automatically, and carry out overload protection. Forcible lubrication system consisting of motor and pump should be installed on high speed shaft side of the reducer and pressure protection device should be equipped. 2.1.2.4.2.2 Long travel Structure Traveling mechanism mainly consists of Φ630 drive wheel bogie assembly, Φ630 non driven wheel bogie assembly, equalizer, rail clamps (hydraulic spring type), anchoring device, rail cleaner, end buffer, pin roll, block and pivot etc. Φ630 drive wheel bogie assembly mainly consists of drive trolley frame, vertical “three-in-one” reducer, wheel assembly, middle shaft, gearbox/gear case etc. Traveling mechanism is installed at low part of support leg of portal. All wheels are the same specification, which is double-rim type. All gear transmission adopts the closed structure and grease lubrication. Reducer adopts vertical bevel-helical hollow shaft and surface hardened tooth gear reducer should be connected to middle gear shaft with shrinking disc which has the merit of compact structure, small size and light weight etc. Traveling mechanism adopts VVVF to realize variable speed traveling. Normally, working speed is 5 m/min, and the commissioning speed is 15 m/min Page 34 of 160 2.1.2.4.2.3 Slew unit Structure Slewing mechanism mainly consists of slewing drive device, three rows column roller assembled bearing, pedestal ring, flange, gear, gear cover, and fasteners. Slewing drive consists of motor, reducer, brake, torque limited coupling, engine base and cover etc. Slewing mechanism is installed between portal and slew deck. Lower part of lower pedestal ring is fixed on the portal, while upper part of lower pedestal ring is connected with external ring of large slewing bearing; Upper part of upper pedestal support the slew deck, while lower part of upper pedestal ring is connected with internal ring of large slewing bearing; Slewing drive is installed at rear part of slew deck; drive gear on output axle of reducer is meshed with outer gear of large slewing bearing, motor generates transmission force to make slew deck slewing around portal , and further finish main machine slewing. Roller bearing in three rows Driving device Rotary plate Small driving gear Gear cover Pedestal Operation and maintenance of slew bearing After about 100 hours operation, inspect pre-tight torque of bolt at inner ring and outer ring , later, inspection interval is each 500 hours operation. Stop machine for inspection if abnormal conditions such as noise, impact, and abrupt increase of power occur. After big bearing is installed, according to actual conditions, fill lubricating Page 35 of 160 grease meanwhile slewing the bearing to make grease evenly distribute until grease is squeezed out from seal lip. Fill lubricating grease for interval of 40hours, filling interval may be shortened under severe environmental conditions and dusty condition. New grease shall be refilled after long time stop operation fore and after. 2.1.2.4.2.4 Boom conveyor Structure Boom conveyor mainly consists of conveyor drive, diamond rubber-faced transmission pulley, rubber-faced bend pulley, heavy bob take up device, trough idlergroup, reversible automatic upward aligning idler, low-leveling idler group, parallel lower idlers group, cleaner, Polyester conveying belt, boom conveyor protection device (misalignment detecting device, pulling wire switch and speed sensor) and transmission part. Driving device consists of motor, fluid coupling, brake, vertical bevel-helical hollow shaft and surface hardened tooth gear reducer(SEW), machine block and housing etc. Motor power is transferred to driven pulley by means of reducer, and further to transmit belt conveyor to run. Forward and reverse transmission will complete stacking and reclaiming operation. 1 3 4 5 11 8 10 2 6 7 9 1. Direction diverse drum 2. Cleanser 3. Belt 4. Idler group 5. Belt conveyor protection device 6. Hammer take-up device 7. Supporting hinge pedestal 8. Pillar 9. Rotary plate 10. Driven drum 11. Driving device 2.1.2.4.2.5 Super steel structure Super steel structure mainly consists of bucket wheel boom rack, pylon, counterweight boom, pivot, bracing, connection plate, pivot axle, and fixing plate etc. Bucket wheel mechanism is installed at front part of super steel structure. Boom conveyor is mounted on bucket wheel boom; counterweight unit is hung at rear part of counterweight frame. The super steel structure along with its auxiliary mechanisms shall be driven by lifting hydraulic cylinder to make luff motion around support pivot point. 2.1.2.4.2.6 Luff unit 2.1.2.4.2.6.1 Structure Luff unit is hydraulic lifting type. it adopts dual action hydraulic cylinders, two ends of Page 36 of 160 the cylinders will be connected to slew deck and the pylon separately with pivot , through the telescopic cylinder realize the super steel structure lifting. Lifting hydraulic mechanism of main machine mainly consists of lifting hydraulic station, hydraulic blocks, hydraulic cylinders, pipeline, pipe joint, hoses, and seal rings. Lifting hydraulic station consists of motor, hydraulic pump, electromagnetic control valves, oil filters, overflow valves, hydraulic-control check valves, gate valves, pipelines, pipe joints, seal rings, pressure gauges, liquid level/temperature gauges and oil drain valves. Luff action is carried out by expansion of hydraulic cylinder. Hydraulic system shall assure dual hydraulic cylinders work at the same time to realize a safe, stable, reliable work of lifting system. Start, stop, unloading (overpressure protection) of pump shall be carried out in hydraulic station. Flow may be adjustable within allowable scope. When ambient temperature is too low, oil shall be heated; if conditions like over-temperature, overpressure, and choking of oil filter occur, warning signal shall send off to realize overload protection. Lifting hydraulic cylinder may be stopped and maintained at any positions. Hydraulic system consists of hydraulic power station and pipeline etc. Considering about the working environment is outdoor and much dust, hydraulic pump station adopts cabinet-type structure. Manometer and thermometer shall be installed for indicating the pressure and the temperature. At the same time, protection against overpressure device should be installed to ensure lifting unit operating safely and reliably. This system can carry out the pump starting, stopping, unloading (overpressure protection), Flow may be adjustable within allowable scope. When ambient temperature is too low, oil shall be heated; if conditions like over-temperature, overpressure, and choking of oil filter occur, warning signal shall send off to realize overload protection. So as to make lifting hydraulic cylinder to be stopped and maintained at any positions. 2.1.2.4.2.6.2 Cautions during operation a. Filter shall be installed at oil inlet and outlet of pump, which shall prevent polluted particles from damaging parts. Once filter of return oil is choked, warning signal shall automatically send off; operation shall be stopped, operation may start only after filter is cleaned or replaced. b. Frequently observe pressure, speed and temperature to see whether they are normal (normal working temperature is 15~70℃), if abnormal conditions occur, quickly find out and repair failure. c. Frequently observe whether oil is leak at joint surface of elements, pipeline and oil cylinder, observe whether abnormal noise occurs; if any one of the above conditions occur, quickly find out and repair failure. d. When the equipment stops, switch should be in “stop” position. 2.1.2.4.2.6.3 Maintenance and Services a. The hydraulic pump station should be frequently maintained and serviced. Page 37 of 160 Cleanness of hydraulic oil shall be maintained according to requirement specified in relevant standard. Otherwise, element may be damaged and service life may be affected. Hydraulic oil shall be replaced at least once a year. Filter shall be cleaned or replaced if oil is replaced. New hydraulic oil filled must be filtered and then fill in. b. During the process of operation, frequently check whether pipeline and elements are properly sealed, if leakage occurs, sealing parts shall be replaced in time. c. If the hydraulic station is not used for long time, periodic start of pump station should be needed (once for 1~2months) and unloading lifting action should be done several times to avoid any corrosion on parts of system. d. Common faults and faults removal method Failure symptoms Possible causes Possible causes Motor does not rotate or makes “buzz” noise (1) provide power supply (2) Lack of phase; (3) Failure of electrical circuit; (4) Damage of motor; (1) To supply power ; (2) Replace fuse; (3) Check circuit and clear failure; (4) Repair or replace; Output of pump flow shall not meet the requirement, and noise level increases (1) Low oil level in oil tank; (2) Reverse rotation of pump; (3) Air leakage at oil suck inlet; (4) Damage of pump; (1) Refill oil; (2) Adjust phase; (3) Exclude the failure; (4) Repair or replace; Serious heating-up (1) Same as above (1); of pump (2) Same as above (2); (3) Disalignment between motor and pump axle; (1) Same as above (1); (2) Same as above (1); (3) Re-adjust alignment Pressure not up in system (1) Clear or open damp hole; (2) Repair or replace; (3) Repair or replace; (4) Replace; built (1) Valve core of overflow valve is blocked or damp hole is choked; (2) Overflow valve is damaged; (3) Electromagnetic valve 14 does not change over; (4) Pressure gauge is damaged; Oil cylinder expands (1) Pressure of overflow valve or contracts too does not slowly reach set value; (2) Failure in overflow valve; (3) Angle of sloping cam plate of pump is less; (4) Opening of non-return throttle valve is less Page 38 of 160 (1)Re-adjust pressure; (2)Remove such failure according to above mentioned method; (3)Increase angle of sloping cam plate; (4) Same as (1) 2.1.2.4.2.7 Oil cylinder can not (1) Hydraulic one-way valve is stay at a random blocked or damaged; position (2) Electromagnetic valve 15 is blocked or damaged; (1) Clean, repair or replace; (2) Repair or replace; Oil cylinder does not (1) Electromagnetic valve does expand or contract not change over; (2) Serious leakage in oil cylinder; (3) Throttle valve is closed; (1)Check whether power supply is normal; If it is normal, clean or replace valve; (2) Repair oil cylinder; (3) Adjust opening of throttle valve Limited switches Limited switches device consists of boom boom rack anti-collision device, slewing angle limit, Slewing luff cross-system limit, long travel drive end limited switches and boom luff limited switches. 2.1.2.4.2.8 a. Boom rack anti-collision device: FKLT2-I switch shall be installed at two sides of middle/front part of head boom. When bucket wheel boom travels, if steel wire rope touches coal pile or other obstacle, switch shall be actuated to send off signal, meantime power supply of slewing motor and travel motors will be cut off in order to prevent head boom rack from colliding with obstacles. b. Slewing angle and slewing luff limit: WLCA12 travel switches shall be adopted; slewing angle limited switch is installed between slew deck and pylon to control slewing scope of bucket wheel boom under the equipment is in working status of stacking/reclaiming or under condition of cross-system; slewing luff limited switch is installed between pylon and slew deck to control lifting scope under condition of cross-system slewing. c Long travel drive end limit: WLCA12 switch is adopted, and shall be installed on non driven wheel bogie assembly of long travel mechanism to control travel scope. d Luff limit of boom rack: WLCA12 traveling switch will be adopted and installed between slew deck and portal to control luff limit scope of equipment bucket wheel boom . e Limited switch for tripper car WLCA12 switch should be adopted for tripper car Limited switch, It will be installed at tripper car luff unit to control the level of stacking and reclaiming of the tripper car. Detection device Detection device consists of traveling distance detection device, slewing angle detection device, luff angle detection device and material level detection device. Traveling distance detection device is installed on rear part buffer of traveling Page 39 of 160 mechanism to detect travel distance. Meanwhile, it will detect travel distance under working condition of automatic stacking/reclaiming and will detect limit for travel end. Slewing angle detection device is installed on drive gear of slewing unit to detect slewing angle of bucket wheel boom rack; Meanwhile, it will realize to control the working condition of automatic stacking/reclaiming and control the function of the end limited switch; Lifting angle detection device is installed on support pivot to detect lifting angle of bucket wheel boom rack. it will realize to control the working condition of automatic stacking/reclaiming and control the function of the end limited switch; Material level detection device is installed at front part of bucket wheel boom rack to detect material position below bucket wheel. Meanwhile, it will control the working conditions of automatic stacking 2.1.2.4.2.9 Central lubrication device Central lubrication device consists of bucket wheel central lubrication device, traveling central lubrication device, lifting central lubrication device and slewing central lubrication device. Bucket wheel central lubrication device is installed at head of front boom rack, which lubricates two bearing seats of bucket wheel mechanism; Traveling lubrication device is installed on travel trolley bracket, which lubricates bearing of wheel axle. Lifting central lubrication device is installed near luff unit, which lubricates hydraulic cylinder and the pivot bearing of the support pivot. Slewing central lubrication device is installed on portal platform, which lubricates three rows column roller bearing assembly of slewing mechanism. Central lubrication device of bucket wheel consists of electrical pump, high pressure hose, filter, distributor, pipeline and accessories The distributor adopts slice feeding mode, pressure oil sent by electrical pump make the plunger in the distributor generate feeding and reciprocating motion orderly, and the oil will be forced, quantified and ordered sending to each lubricating points 2.1.2.4.2.10 Tripper car Fully functional tripper car mainly consists of single-wheel non driven wheel bogie assembly, main tripper car and up-and-down auxiliary tripper car, main tripper car belt conveyor, auxiliary tripper car luff mechanism, tripper car steel structure, head coal chute, linkage assembly and auxiliary tripper car belt conveyor etc , which function should be applicable for stacking and reclaiming work condition. During the process of stacking, coal coming from the belt conveyor will drop on tripper car conveyor through auxiliary tripper car conveyor via Single-wheel transfer chute, then coal will be delivered to middle non driven wheel bogie assembly chute through head part coal chute and transferred to boom belt conveyor, by which materials are conveyed and threw down to coal yard. During the process of reclaiming, bucket wheel mechanism will take coal from coal yard to drop on boom belt conveyor, through transfer chute; coal will be delivered to yard conveyor of system. Tripper car ladder and platform shall be installed on the tripper car, water sprinkling system and water source device and power & control cable reel drum will be installed on tripper car bottom beam. The tripper car will be connected with main Tripper car structure steel Main tripper car belt conveyor Page 40 of 160 Tripper car luffing mechanism Tripper car machine depending on connecting rod assembly. Electrical room is installed on bottom beam. 1 2 3 4 5 1. Metal structure of main tail cart 2. Belt conveyor of main tail cart 3. Single-wheel driven loop wheel machine 4. Variable amplitude mechanism of auxiliary tail cart 5. Auxiliary tail truck 2.1.2.5 Operation mode and features of the equipment 2.1.2.5.1 Section1 System Survey There is one set of bucket wheel stacker reclaimer(Drawing No: DQ9711ST.0) in this project, the equipment will be laid out, which can stack coal from two sides of coal yard, can reclaim coal from coal yard and transmit coal out through yard conveyor, Power supply(cable reel drum) is located in middle of traveling distance of Bucket wheel stacker reclaimer. 2.1.2.5.2 Mechanical operating mode and feature 2.1.2.5.2.1 Stacking operation process Stacking operation process includes traveling-oriented stacking, rotary-oriented stacking and spot stacking. a) Intermittent traveling stacking (Refer to process drawing), material is stacked layer by layer row by row in an intermittent traveling spot manner. Stacking of equipment starts from the first point 011 of the first row, meanwhile, pile height detector will measure height of each stacked pile (or controlled artificially, following the same), the detector sends off command signal to control the travel mechanism to make a minor movement. Stacking continues pile by pile until it reaches the specified scope of traveling to change over to next row, stacking continues in reverse direction from 02-1; When stacking of equipment finishes the first layer of all rows, it will change over to stacking of the second layer, and the like until it finishes stacking of the last pile. Intermittent traveling stacking process may form rectangular material pile; therefore its utilization ratio of Page 41 of 160 stockyard is higher with less dust, which is helpful to adjacent environment. As to different transmitted quantity, length of stacking can be adjusted, in this way; relatively regular pile may be stacked. Intermittent traveling stacking b) Continuous rotary stacking (Refer to process drawing), height of boom rack is set as the same of preset height of stacking, boom rack stacks in out and back rotary manner until set times are met, and then travel mechanism makes a minor set movement, in sequent order 1-2-3, operation will continue. Rotary stacking process in this occasion which transmission quantity of raw material is not continuous or relatively les, length of stacked pile may be preset according to transmission quantity to form a relatively regular pile, therefore a high Page 42 of 160 Continuous rotary stacking c) Intermittent rotary + intermittent traveling spot stacking Intermittent rotary + intermittent traveling spot stacking shall refer to process drawing of intermittent rotary + intermittent traveling spot stacking. Stacking operation starts from the first pile layer by layer in order to reduce dust. Height detector will send off command instruction to change over next layer until the last layer is finished. Height of boom rack is kept unchanged; boom rack will rotate according to preset direction and angle to the second pile, stacking operation continues; after boom rack arrives at rotation scope, travel mechanism shall move in a preset minor distance until stacking reaches a preset pile length, operation may stop. Intermittent rotary + intermittent traveling spot stacking Page 43 of 160 2.1.2.5.2.2 Reclaiming operation process Reclaiming process includes rotary layer reclaiming and spot slope reclaiming. a) Rotary layer reclaiming (Refer to rotary layer reclaiming process drawing), according to its pile height, it is divided into layer subsection reclaiming and rotary layer non-subsection reclaiming. The first operating mode : Layer subsection automatic reclaiming: first of all, driver operates the stacker reclaimer to travel, rotary and luff mechanism to move bucket wheel to starting point of top layer of pile (single positioning rotation), reclaiming starts its operation under control of rotation, when it reaches to a preset rotation scope, travel mechanism will make a minor preset distance (feeding quantity), according to preset length of material supply section Lm (or preset rotary times), after reclaiming of the first layer is finished, operation changes over to next layer; rotary angle of each layer is determined by angle of repose and number of layers; luff height is determined by preset number of layers, traveling distance is determined by feeding quantity. When reclaiming of the bottom layer is finished, reclaiming will change over the next section. Bucket wheel will be placed at start point of top layer of the second section, reclaiming operation continues; Length of material supply section is preset according to principle that boom rack does not touch material pile. The second operating mode : Rotary layer non-subsection reclaiming: its working efficiency is the highest to avoid overload danger of bucket wheel and boom rack caused by collapse of material pile, which is suitable in stacking low and short material pile. Boom rack cannot touch material pile. In order to realize purpose “Rotary layer quantitative reclaiming”, under semi-automatic control, rotary speed of boom rack should change according to 1/COSφ, and make further feedback according to current of bucket wheel drive motor. Normally, rotary angle is 10°~70°, rotary speed adopts frequency conversion speed within 10°~60° according to 1/COSφ, if it is within 60°~70°, φ should be 60°. Rotary layer reclaiming Page 44 of 160 b) Spot slope reclaiming (end face reclaiming) Refer to spot slope reclaiming (end face reclaiming) process drawing, it is a kind of working process which is “first stacking, first reclaiming, intermittent operation, and its working efficiency is the lowest. During the process of operation, material pile easily collapses and results in overload of bucket wheel. When driver adopts the above several methods of reclaiming, driver should reclaim coal from top layer of material pile, and should observe condition of material pile at all time to avoid that head or bottom of boom rack touches or collides material pile during slewing operation of bucket wheel. In order to avoid damaging the equipment, continuous traveling reclaiming mode of Long travel is not allowed. Spot slope reclaiming 2.1.2.6 Operation regulations of equipment 2.1.2.6.1 Operating regulations of the mechanical parts Operation mode a. Single-action operation Each mechanism of bucket wheel stacker/reclaimer shall make separate start/stop operation in operator cabin. b. Interlock operation When bucket wheel stacker/reclaimer makes interlock operation, the following operation procedures shall be observed, otherwise it will not operate. (1) Stacking interlock operation procedure Transfer/middle chute baffle plate is closed; auxiliary tripper will be luffed to stacking position; Bucket wheel boom conveyor carries out stacking operation-main tripper car conveyor carries out stacking operation and yard conveyor also carries out stacking operation. Page 45 of 160 (2) Reclaiming interlock operation procedure Transfer/middle chute baffle plate is opened; auxiliary tripper will be luffed to reclaiming position; yard conveyor also carries out reclaiming operation; bucket wheel boom conveyor carries out reclaiming operation and bucket wheel mechanism start operating. 2.1.2.6.2 Operating regulations about hydraulic parts After luff motor starts, pump begins to supply oil to system, at this time, electromagnetic valve is in state of power off; oil flows through middle position of electromagnetic valve back into oil tank. When control switch is in state of “luff ascend”, electromagnetic valve will be electrified, oil will flow into non-rod cavity of luff cylinders passing through hydraulic one-way valve, one-way valve at right side of oneway throttle valve, hydraulic one-way valve at right side of lock block (hydraulic oneway valve). Piston rod in oil cylinder will extrude. Oil in rod cavity will flow into oil tank passing through throttle valve in one-way valve at left side of hydraulic one-way valve and electromagnetic valve. When control switch is in state of “luff descend”, electromagnetic valve will be electrified and begins to make action, its oil flow direction is reverse to that of “luff ascend”. 2.1.2.6.3 Operating regulations of electrical operation 2.1.2.6.3.1 Preparations before startup 2.1.2.6.3.2 a Do all the preparations before startup of the stacker reclaimer; b Check the HV switch panel is energized and observe the indicating gauge and ON/OFF indicator; c Check all emergency buttons are restored to original states. Power supply 2.1.2.6.3.2.1 Computer power source This equipment uses a computer with ~6kV 50Hz HV load and the power is supplied by the cable drum. There are voltage gauges located in the 1×0A HV electrical panel in the electrical room and in the 2×1 operation panel in the operator cab. The purpose is to provide convenience for the operators in the electrical room and operator cab to monitor the computer power supply on the equipment. 2.1.2.6.3.2.2 LV dynamic power When the 6kV 50Hz HV computer is activated, the voltage of power is transformed into 380V 50Hz. It can be used as a LV power supply through the isolation switch V2 QS1 and frame type air breaker V2 q1 in the 1×1 LV electrical panel. The LV power supplies each motor to drives the operation of each mechanism. 2.1.2.6.3.2.3 LV control power source Page 46 of 160 When the 6kV 50Hz HV computer is activated, the voltage of power is transformed into 380V 50Hz three-phase power. It can be used as power supply for complete unit control, illumination, maintenance and central lubrication through the isolation switch V1 QS1 in the 1×1 LV electrical panel. (1) Control power source: serves as the complete unit control power source after it goes through the isolation switch V1 QS1 and then the control and isolation transformer V1 T1 (~380V/~220V). (2) Illumination power: serves as the complete unit illumination and socket power after it goes through the isolation switch V1 QS1 and then the circuit breaker V3 q1. (3) Maintenance power: serves as the complete unit maintenance power after it goes through the isolation switch V1 QS1 and then the circuit breaker V3 q1. (4) Central lubrication power: serves as the complete unit central lubrication power after it goes through the isolation switch V1 QS1 and then the circuit breaker V5 Q1. 2.1.2.6.3.3 Distribution of electrical system Electrical equipment of this system are distributed in the electrical room and operator cab. 2.1.2.6.3.3.1 Electrical room a. HV room (1) Control transformer HV1 T1. (2) Dynamic transformer HV2 T1. (3) HV in-coming circuit of the 1×0A HV electrical panel. (4) HV feedback circuit of the 1×0B HV electrical panel. b. LV room (1) 1×1 LV electrical panel: LV power circuit. (2) 1×2 LV electrical panel: PLC main station and auxiliary control circuit. (3) 1×3 LV electrical panel: control circuit for the crane travel mechanism, cable drum, and rail clamping device. (4) 1×4 LV electrical panel: control circuit for the slewing, lifting, water spraying, intermediate section hopper damper, and bucket wheel guide through. (5) 1×4 LV electrical panel: control circuit for the bucket wheel, boom belt, auxiliary trailer alternation, and trailer belt. c. Operator cab Page 47 of 160 1. 2×1 left side operation platform: there are gauges and operation switches located. (1) Gauge: indicator on the 6kV HV computer power supply; (2) Indicator: indications of HV power CB closing and opening; (3) Buttons with lights: indications of control power source closing and opening; (4) Buttons with lights: indications of control power source closing and opening; (5) Buttons: loosening and tightening of the trail clamping device; (6) Buttons: closing and opening of control power source CB; (7) Main order switch: activation and deactivation of the wiper; (8) Main order controller: moving, stopping and retracting of the crane. 2. 2×2 right operation platform: operation buttons and switches are located. (1) Mushroom button: emergency shutdown button (in case of any accident); (2) Transferring switch: control of stack reclaimer (reclaiming, shutdown and taking); (3) Transferring switch: selection of operation mode (single operation, interlock, and semiautomatic); (4) Transferring switch: transferring control of auxiliary trailer (changing of coal stacking, stopping and taking transferring); (5) Button: startup the crane and give out alarm. Signals are restored; (6) Button: operation of lifting oil pump and control of deactivation; (7) Main order switch: selection of high speed and low speed of the crane; (8) Main order switch: system interlock (interlock and disconnection); (9) Main controller: slewing (left, stop and right); (10) Main controller: lifting (up, stop and down); (11) Buzzer: failure alarm. 3. 2×3 LV control panel: main and auxiliary control circuit of the PLC program control. 4. Programmable end PT: used for equipment monitoring (1) State display: running states of each mechanism of the stacker reclaimer are displayed; (2) Position limiting display: activation of the protection position limiter of each mechanism of the stacker reclaimer is displayed; (3) Failure list: present failure alarm lists are displayed; Page 48 of 160 (4) Parameter setting: setting of lifting and slewing times during operation of semiautomatic stack reclaimer. Manual interruption and button disconnection are carried out during semi automatic operation process; (5) Current indication: display of motor current of boom conveyor belt, trailer belt, stack reclaimer, crane, and slewing device; (6) Digital display: travel distance, slewing angle and lifting angle of the crane; (7) Single activation control: single activation of boom conveyor belt, stack reclaimer, intermediate section hopper damper, reclaimer guide through, trailer belt and oil heater. 2.1.2.6.3.4 Operation and sequence during preparation: Before the activation of the equipment, operators are required to lift up the anchoring manually and check the CB is completely closed on each control panels in the electrical room. Close the CB s of HV power, control power source, and dynamic power. Loosen the rail clamping device and select a control mode. The specific operation method and sequence are shown in the following: 2.1.2.6.3.4.1 Lifting of anchoring Operators are required to manually lift up the anchoring at two-side bogies, in order to close the anchoring limits at two sides 2.1.2.6.3.4.2 Closing of HV power Enter the electrical room and check the 1×0A HV power panel voltage display gauge has the computer power with 6kV HV load. If the computer power 6kV is normal, closing of the HV CB can be done. Press the HV POWER CB CLOSING on the 1×0b HV electrical panel to close the CB. After the CB is closed, the indicator of HV POWER CB CLOSED is on. At this time, CB of the HV power is closed. 2.1.2.6.3.4.3 Closing of control power source CB CB of control power source can be closed after CB of the HV power is closed. First enter the operator cab. Use keys to close the KEY SWITCH on the left operation platform before closing the control power source CB. Press the CONTROL POWER SOURCE CB CLOSING button on the left operation platform and the CONTROL CB CLOSED indicator will be on, indicating closing of control power source is finished. Note: the PLC programmable controller and PT programmable end are energized for long term, which is not influenced by the control power source 2.1.2.6.3.4.4 Closing of power supply CB The closing of power supply can only be done after the control power source CB is closed. Page 49 of 160 Press the POWER SUPPLY CB CLOSING button on the left operation platform, and the relevant indicator will be on, indicating the CB closing is finished. 2.1.2.6.3.4.5 Releasing of trail clamping device Press the TRAIL CLAMPER RELEASING button on the left operation platform and it can be displayed on the state indicating display at the programmable end. The relevant TRAIL CLAMPER RELEASED indicator is on, indicating it is released already. 2.1.2.6.3.4.6 Selection of control mode Controlling modes the stack reclaimer can be divided into single act control, interlock control, and semi-automatic control. These three modes can be transferred freely. One mode has to be decided before operation of the equipment Note: these three modes cannot be transferred during operation By operating the transferring switch of CONTROL MODE SELECTION on the right operation platform, one mode can be selected. On the display of STATE INDICATION at the programmable end, the relevant SINGLE ACT, INTERLOCK and SEMIAUTOMATIC indicating lights will be on, indicating the control mode is already selected After preparation work of the above mentioned sequence, the normal operation of stack reclaimer can be done 2.1.2.6.3.5 Control of stack reclaimer mechanisms 2.1.2.6.3.5.1 Single action control Transfer the CONTROL MODE SELECTION on the right operation platform to SINGLE ACTIVATION, so that the complete unit is in single activation control mode. Single activation control mode refers to individual startup and shutdown of each mechanism of the stack reclaimer Note: This mode is only used during commissioning and maintenance of each mechanism, which has to be approved by the production coordinator. There must be operators during operation to monitor and maintain a. Crane travel single activation control system (1) The moving speed of the crane can be selected either in high speed or in slow speed by the CRANE SPEED CONTROL main order switch on the right operation panel. One speed has to be decided before the crane starts to move. The slow speed is normal working speed for the crane. The high speed is abnormal moving speed or the speed during trial operation. Note: do not choose the high speed during normal working process. (2) The moving direction of the crane can be achieved by operating the main order controller on the left operation panel. The relevant CRANE MOVING Page 50 of 160 FORWARD and CRANE MOVING BACKWARDS indicators programmable end STATE INDICATION DISPLAY will be on. on the (3) The main order controller that controls the crane moving direction either forwards or backwards can only be transferred (to the opposite direction) when the crane maintains a outage state for a while. (4) The crane ceases moving as it reaches the forward or backward limiting positions. The indicators of CRANE MOVING FORWARD LIMITING POSITION, CRANE MOVING FORWARD LIMIT, CRANE MOVING BACKWARDS LIMITING POSITION and CRANE MOVING BACKWARD LIMIT will be on on the programmable end LIMITING POSITION INDICATION display. (5) During crane moving process, the motor current can be observed at the programmable end. b. Cable drum single activation control (1) There is no individual switch controlling the operation of the cable drum. The cable drum operates at the same time when the crane moves. The relevant CABLE DRUM OPERATING indicator is on on the programmable end STATE INDICATION display. (2) During the cable drum operation, the drum stops operating as the tension limiting action is exceeded. At the same time, the crane stops operating. On the programmable end FAILURE LIST display, there is an alarming tip indicating DRUM TENSION EXTENDS. At the same time, there is audible and visual alarm. At this point, personnel caused failures have to be removed and the press the SIGNAL RESTORE button on the right operation panel can be activated once again. c. Water spraying single activation control The control of water spraying system is achieved by the programmable end. (1) Water spraying can only be carried out when no SHORT OF WATER IS WATER TANK display appears on the programmable end STATE INDICATION display. (2) Enter the programmable end SINGLE ACTIVATION CONTROL display and click the ACTIVATE and DEACTIVATE buttons of the spraying pump. Operation and shutdown of the spraying pump can be achieved. On the programmable end STATE INDICATION display, the relevant WATER SPRAYING PUMP ON indicator is on. (3) During water spraying of stacker reclaimer operation, enter the programmable end SINGLE ACTIVATION CONTROL display and click the SPRAYING DURING STACKING button and the reclaimer starts spraying. When spraying Page 51 of 160 is completed, enter the programmable end SINGLE ACTIVATION CONTROL display and click the RECLAIMER CEASES SPRAYING, and the reclaimer stops working. (4) During water spraying of stacker reclaimer, enter the programmable end SINGLE ACTIVATION CONTROL display and click the SPRAYING DURING RECLAIMING button and the reclaimer starts spraying. When spraying is completed, enter the programmable end SINGLE ACTIVATION CONTROL display and click the RECLAIMER CEASES SPRAYING, and the reclaimer stops working. (5) Stop water spraying when the SHORT OF WATER IN WATER TANK indicator at the programmable end STATE INDICATION display is on in case of damage to the water pump and motor. At this point, fill water in the water tank till the WATER TANK FULL indicator on the display is on. Water spraying can be done at this point. d. Slewing single activation control (1) Left slewing and right slewing can be achieved by operating the transferring switch of the main order controller on the right operation platform. The relevant LEFT SLEWING and RIGHT SLEWING indicators are on on the programmable end STATE INDICATION display. (2) When the stacker-reclaimer slews to the outermost left and right limit, it will stop. The relevant LEFT SLEWING END, LEFT SLEWING LIMIT, RIGHT SLEWING END, and RIGHT SLEWING LIMIT are on the programmable END INDICATION display. At the same time, there is audible and visual alarming. At this point, the slewing can only follow the opposite direction. (3) Slewing stops operating as the collision prevention device works. On the programmable end FAILURE LIST display, there are alarms of SLEWING LEFT COLLISION PREVENTION and RIGHT COLLISION PREVENTION with the audible and visual alarming. At this time, the stacker-reclaimer slews to the opposite direction. (4) When the stacker-reclaimer slews under the system belt, it stops operating as the prevention devices works. On the programmable end FAILURE LIST display, there are LEFT SLEWING NO-GO and RIGHT SLEWING NO GO with the audible and visual alarm. At this point, the stacker-reclaimer slews to the opposite direction. The lifting moves upwards. (5) When the slewing over torque limit protection device works, slewing stops operating. On the programmable end FAILURE LIST display, there is SLEWING OVER TORQUE alarming display with the audible and visual alarm. At the same time, remove the failures manually and press the SIGNAL RESTORE button on the right operation platform and the equipment can be reactivated. Page 52 of 160 (6) Current of the slewing motor can be observed at the programmable end during the slewing process. e. Lifting single activation control (1) Operation and shutdown of the lifting oil pump can be achieved by pressing the relevant ACTIVATE and DEACTIVATE buttons on the right operation platform. (2) Lowering and lifting of the boom can be achieved by transferring the forward and backward of the main order controller on the right platform. On the programmable end STATE INDICATION display, the relevant BOOM LOWER and BOOM LIFT indicators are on. (3) The lifting stops operating as it reaches the lifting set position, maximum limit, lowering set position and minimum limit. On the programmable end the SET POSITION INDICATION display, the relevant LIFTING LIFT SET POSITION, LIFT MAX LIMIT, LOWERING SET POSITION, and LOWERING MIN LIMIT indicators are on with the audible and visual alarm. At this point, the lifting can only moves to the opposite direction. (4) When the lifting lowering moves the no-go zone and the limit protection device works, the lifting stops operating. On the programmable end FAILURE LIST display, there is LOWERING NO-GO ZONE alarm with the audible and visual alarm. At this time, the lifting can only lift, but cannot lower down. (5) Lifting stops operating when the oil pump has failures like oil blockage, overpressure, low oil level, and super high oil temperature. On the programmable end FAILURE LIST display, there are alarms like LIFTING OIL BLOCKAGE, LOW PRESSURE, LOW LEVEL and SUPER-HIGH TEMPERATURE with the audible and visual alarm. At the same time, remove the failures manually. It can be reactivated by pressing the SIGNAL RESTORE button on the right operation platform. f. Boom conveyer belt single activation control (1) Single activation control of the boom conveyer belt can be achieved by the programmable end control. (2) Enter the programmable end SINGLE CONTROL display, and click the buttons controlling the boom conveyer belt like STACK, RECLAIM and STOP. Relevant work will be done as the button is clicked. On the display, the relevant BOOM CONVEYER BELT STACK, and RECLAIM indicators will be on. (3) During operation, when the primary off-tracking protection device works, the boom belt operates normally. On the FAILURE LIST display, there will be PRIMARY OFF-TRACKING alarm with the audible and visual alarm. When the secondary off-tracking limit protection works, the conveyer belt stops Page 53 of 160 operating. On the FAILURE LIST display, there will be SECONDARY OFF – TRACKING alarm with the audible and visual alarm. At this point, the failures have to be removed manually. Press the SIGNAL RESTORE button on the right platform, and it can be reactivated. (4) During normal operation, the boom conveyer belt stops operating as the belt radial laceration protection, speed monitoring protection and hopper coal accumulation detecting device work. On the programmable end FAILURE LIST display, the relevant RADIAL LACERATION, BELT SLIPPAGE, and COAL HOPPER BLOCKAGE alarms will appear with the same audible and visual alarm. At the same time, the failures have to be removed manually. Press the SIGNAL RESTORE button on the right platform, and it can be reactivated. (5) Current of the boom conveyer belt can be observed at the programmable end during operation of the belt. g. Bucket wheel single activation control (1) Single activation control of the bucket wheel can be achieved by the programmable end. (2) Enter the programmable end SINGLE ACTIVATION CONTROL display, and click the buttons controlling the bucket wheel like ACTIVATE and DEACTIVATE. On the display, the relevant BUCKETWHEEL OPERATING indicator will be on. (3) During the bucket wheel operation, when the lubricating oil pump flow meter is activated, the bucket wheel stops operating. On the programmable end FAILURE LIST display, there is alarm like BUCKETWHEEL LUBRICATING OIL PUMP FLOW LOW alarm will appear with the audible and visual alarm. At the same time, the failures have to be removed manually. Press the SIGNAL RESTORE button on the right platform, and it can be reactivated. (4) When the slewing over torque limit protection device works, the bucketwheel stops operating. On the programmable end FAILURE LIST display, there is SLEWING OVER TORQUE alarming display with the audible and visual alarm. At the same time, remove the failures manually and press the SIGNAL RESTORE button on the right operation platform and the equipment can be reactivated. (5) Current of the bucket wheel can be observed at the programmable end during operation of the bucket wheel. h. Single activation control of intermediate hopper damper (1) Single activation control of the intermediate hopper damper can be achieved by the programmable end. Page 54 of 160 (2) Enter the programmable end SINGLE ACTIVATION CONTROL display, and click the buttons controlling the intermediate hopper damper like STACK, RECLAIM and STOP. By operating like this, the relevant work can be done. After the damper moves to its position, on the display, the relevant intermediate hopper damper STACKING POSITION and intermediate hopper damper RECLAIMING POSITION indicators will be on. i. Single activation control of the bucket wheel guide through (1) Single activation control of the bucket wheel guide through can be achieved by the programmable end. (2) Enter the programmable end SINGLE ACTIVATION CONTROL display, and click the buttons controlling the bucket wheel guide through like STACK, RECLAIM and STOP. By operating like this, the relevant work can be done. After the guide through designated position is reached, on the display, the relevant bucket wheel guide through STACKING POSITION and bucket wheel guide through RECLAIMING POSITION indicators will be on. j. Trailer conveyer belt single activation control (1) Single activation control of the trailer conveyer belt is achieved by the programmable end. (2) Enter the programmable end SINGLE ACTIVATION CONTROL display, and click the buttons controlling the trailer conveyer belt like ACTIVATE and DEACTIVATE. By operating like this, the relevant work can be done. On the programmable end STATE INDICATION display, the relevant TRAILER CONVEYER BELT RUNNING indicator will be on. (3) During trailer conveyer belt operation, when the primary off-tracking protection device works, the trailer conveyer belt operates normally. On the FAILURE LIST display, there will be PRIMARY OFF-TRACKING alarm with the audible and visual alarm. When the secondary off-tracking limit protection works, the trailer conveyer belt stops operating. On the FAILURE LIST display, there will be SECONDARY OFF –TRACKING alarm with the audible and visual alarm. At this point, the failures have to be removed manually. Press the SIGNAL RESTORE button on the right platform, and it can be reactivated. (4) During normal operation of the trailer conveyer belt, it stops operating as the belt radial laceration protection and speed monitoring protection work. On the programmable end FAILURE LIST display, the relevant RADIAL LACERATION and BELT SLIPPAGE alarms will appear with the same audible and visual alarm. At this time, the failures have to be removed manually. Press the SIGNAL RESTORE button on the right platform, and it can be reactivated. (5) Current of the trailer conveyer belt can be observed at the programmable end during operation of the belt. Page 55 of 160 k. Auxiliary trailer switchover single activation control (1) Single activation control of the auxiliary trailer switchover can be achieved by the transferring switch on the operator cab right operating platform and local operation. (2) In the operator cab, switch the AUXILIARY TRAILER SWITCHOVER CONTROL to AUXILIARY TRAILER STACK. The trailer is switched to stack. The specific transferring sequence is in the following: --- energize the switchover oil pump of the trailer, lift the trailer, lift it to stacking position limit, stop there. At this point, the relevant AUXILIARY TRAILER STACKING POSITION indicator is on until the transferring process is finished on the programmable end STATE INDICATION display. (3) In the operator cab, switch the AUXILIARY TRAILER SWITCHOVER CONTROL to AUXILIARY TRAILER RECLAIM. The trailer is switched to reclaim. The specific transferring sequence is in the following: --- Energize the switchover oil pump of the trailer, lower down the trailer, lower it to reclaiming position limit, stop there. At this point, the relevant AUXILIARY TRAILER RECLAIMING POSITION indicator is on until the transferring process is finished on the programmable end STATE INDICATION display. (4) Before the auxiliary trailer is locally transferred, switch the local controlling switch in the local box to LOCAL CONTROL. After the transferring, switch it to OPERATOR CAB, and then the operation in the operator cab can be done. There are emergency deactivation buttons in the local operation box. When emergency failures occur during transferring process, press the emergency shutdown button and stop the trailer. The emergency button is a kind of mushroom head like button. After the failure is removed, rotate a angle IAW the arrow indicated direction if unlocking is needed. (5) Local stacking switchover of the trailer is achieved by operating the local operation box. At this time, the trailer switchover oil pump is energized ad the trailer is lifted up to the stacking position limit and stops there. At the same time, on the STATE INDICATION display on the programmable end, the relevant AUXILIARY TRAILER STACKING POSITION indicator is on. Till now, the stacking switchover is finished. (6) Local reclaiming switchover of the trailer is achieved by operating the local operation box. At this time, the trailer switchover oil pump is energized ad the trailer is lowered down to the reclaiming position limit and stops there. At the same time, on the STATE INDICATION display on the programmable Page 56 of 160 end, the relevant AUXILIARY TRAILER RECLAIMING POSITION indicator is on. Till now, the reclaiming switchover is finished. Note: before the auxiliary trailer is switched over, other transferring switches have to be in ZERO position. Do not operate other mechanisms. 2.1.2.6.3.5.2 Interlock control Turn the CONTROL MODE SELECTION change-over switch on the right operation panel to INTERLOCK position, and then the integrated equipment will be in the interlock control state. The interlock control mode is the interlock operation in single control mode, namely, the corresponding mechanisms of bucket-wheel stackerreclaimer are in interlock operation. The protection of each mechanism in interlock control mode is the same as that in single control mode The operation of travel, drum, water spraying, lifting and slewing mechanisms of crane and the auxiliary trailer in interlock control mode is completely the same as that in single control mode a Reclaiming interlock control Notice:the auxiliary trailer must be switched to reclaiming position before putting interlock control into operation. (1) Turn the RECLAIMING CONTROL change-over switch on the right operation panel to RECLAMING position, and the corresponding mechanisms will be started in the following order: ——the system belt operates and reclaims coal; ——the bucket-wheel guide chute falls down (in reclaiming position); ——the middle coal falling damper lifts up (in reclaiming position); ——after delay for a certain period of time, the cantilever belt operates in reclaiming direction; ——after delay for a certain period of time, the bucker-wheel operates. (2) After finishing the operation mentioned above, the operating lights of corresponding mechanisms turn on on the STATE INDICATION menu of programmable menu. At the same time, BUCKET-WHEEL STACKERRECLAIMER RECLAMING light turns on. (3) The reclaiming work of bucket-wheel stacker-reclaimer can be fulfilled by controlling the corresponding operation of other mechanisms following the operation of single control mode. b. Stacking interlock control Notice: the auxiliary trailer must be switched to the stacking position before putting the stacking interlock control into operation. Page 57 of 160 (1) Turn the STACKING CONTROL change-over switch on the right operation panel to STACKING position, and the corresponding mechanisms will be started in the following order: ——the bucket-wheel guide chute lifts up (in stacking position); ——the middle coal falling damper lifts up (in stacking position); ——after delay for a certain period of time, the cantilever belt operates in stacking direction; ——after delay for a certain period of time, the trailer belt operates; ——after delay for a certain period of time, the system belt operates in stacking direction. (2) After finishing the operation mentioned above, the operating lights of corresponding mechanisms will turn on on the STATE INDICATION menu of the programmable menu. At the same time, BUCKET-WHEEL STACKERRECLAIMER STACKING light turns on. (3) The stacking work of bucket-wheel stacker-reclaimer can be fulfilled by controlling the corresponding operation of other mechanisms following the operation of single control mode 2.1.2.6.3.5.3 Semi-automatic control The semi-automatic control operation is divided into two parts: semi-automatic stacking and semi-automatic reclaiming, which allows the manual interference in semi-automatic operation conditions a. Semi-automatic reclaiming control Notice: the auxiliary trailer must be switched to reclaiming position before put the semi-automatic control into operation. (1) Before putting the semi-automatic reclaiming into operation, the working surface can be cleared in interlock mode and then switched over to semiautomatic mode if the shape of coal pile in coal yard is irregular. (2) In interlock control mode, move the crane to the preset coal reclaiming position and turn the CONTROL MODE SELECTION change-over switch to SEMI-AUTOMATIC position. (3) Then turn the STACKING-RECLAIMING CONTROL change-over switch on the right operation panel to RECLAIMING position, and the bucket-wheel stacker-reclaimer will start up the guide chute, middle hopper damper, cantilever belt and bucket wheel in the program sequence. (4) When the bucket-wheel stacker-reclaimer is started up, the cantilever is in the position that is the first reversal point. The original slewing direction of the Page 58 of 160 cantilever is controlled by TURN LEFT and TURN RIGHT of master controller on the right operation panel. (5) The angle of the second reversal point is confirmed by STOP of the master controller on the right operation panel. (6) After confirming, the crane starts to move forward for a distance, and then the cantilever starts to rotate in a reverse direction (the second reversal point). When it slews to the first reversal point and stops, the crane moves forward for a distance again and gets to the second reversal point in the reverse direction, and then continues to move forward and turns in a reverse direction and repeats to work in this way till it stops. (7) Enter the PARAMETER SETTING menu of the programmable terminal, and the semi-automatic reclaiming process flow can be temporarily stopped by clicking MANUAL INTERFERENCE button. At this time, the following parameter setting can be done: ——Adjust the angles of the first reversal point and the second reversal point by left or right switchover of the master controller on the right operation panel; ——Adjust the reclaiming position by forward or backward switchover of the master controller on the left operation panel; ——Adjust the cantilever height by forward or backward switchover on the right operation panel. After confirming, enter the PARAMETER SETTING menu of the programmable terminal to realize the semi-automatic operation to be carried out according to the new parameter by clicking MANUAL INTERFERENCE RELEASE button. Page 59 of 160 Page 60 of 160 b. Semi-automatic stacking control Notice: the auxiliary trailer must be switched to stacking position before putting the semi-automatic control of stacking into operation. (1) In the interlock control mode move the crane to the preset stacking position. (2) Turn the CONTROL MODE SELECTION change-over switch on the right operation panel to SEMI-AUTOMATIC position. (3) Enter the PARAMETER SETTING menu of the programmable terminal to set the lifting times and slewing times of the cantilever. (4) Turn STACKING-RECLAIMING CONTROL change-over switch on the right operation panel to RECLAIMING position, the bucket-wheel stackerreclaimer will start up the guide chute, middle hopper damper, cantilever belt and trailer belt in the program sequence. (5) Confirm the original slewing direction of the cantilever by TURN LEFT and TURN RIGHT of the master controller on the operation panel. Then turn back to STOP position after stopping for a moment and the semi-automatic reclaiming will be started. (6) When the material level works, the cantilever will lift up for a certain angle. Every time when the material level works once, the cantilever lifts up once. The cantilever will not stop lifting up until it gets to the preset lifting times. (7) When the material level works next time, the cantilever will slew a certain angle in the original direction. Every time when the material level works once, the cantilever slews once. The cantilever will not stop slewing until it gets to the preset slewing times. (8) When the material level works next time, the crane will move backward for a distance. (9) When the level meter works next time, the cantilever will slew for a certain angle in the direction opposite to the original direction. Every time when the material level works once, the cantilever slews once. The cantilever will not stop slewing until it gets to the preset slewing times. (10) When the material level works next time, the crane will move backward for a distance. (11) When the material level works next time, the cantilever will slew for a certain angle in the original direction. Every time when the material level works once, the cantilever slews once. The cantilever will not stop slewing until it gets to the preset slewing times. (12) When the material level works next time, the crane will move backward and then turns in reverse direction. After that, the crane will move Page 61 of 160 backward and turns in a natural direction, and then moves backward and repeats the operation in this way till the equipment stops. (13) Enter the PARAMETER SETTING menu of the programmable terminal and the semi-automatic stacking-reclaiming flow can be paused by clicking MANUAL INTERFERENCE button. At this time, the following parameter setting can be done: ——Enter the PARAMETER SETTING menu of the programmable terminal to adjust the lift times and slewing times of the cantilever; ——Adjust the slewing angle of the cantilever by left or right switchover of the master controller on the right operation panel; ——Adjust the stacking position by forward or backward switchover of the master controller on the left operation panel; ——Adjust the cantilever height by forward and backward switchover of the master controller on the right operation panel. After confirming, enter the PARAMETER SETTING menu of the programmable terminal to realize the semi-automatic operation by clicking MANUAL INTERFERENCE RELEASE button according to the new parameter. (14) Refer to the attached drawing two for the semi-automatic stacking process flow Page 62 of 160 Page 63 of 160 2.1.2.6.3.5.4 Interlock control Interlock control refers to the interlock between the system belt and bucket-wheel stacker-reclaimer when it is in operation. When the bucket-wheel stacker-reclaimer is in normal operation, turn the INTERLOCKING WITH THE SYSTEM change-over switch on the right operation panel to INTERLOCK position. When the bucket-wheel stacker-reclaimer is in commissioning or maintenance state, turn the INTERLOCKING WITH THE SYSTEM change-over switch on the right operation panel to RELEASE position a. Reclaiming interlock Enter the STATE INDICATION menu of the programmable terminal; when the SYSTEM ALLOWING RECLAIMING light turns on, the bucket-wheel stackerreclaimer can come into normal reclaiming work state and send out BUCKETWHEEL STACKER-RECLAIMER RECLAIMING signal to the system program control room. When the system belt stops operation due to fault, the reclaiming work will automatically stop At this time, all the change-over switches on the operation panel must be switched to the stop position to prevent corresponding mechanisms automatically restarting up when the system recovers to normal state b. Stacking interlock Enter the STATE INDICATION menu of the programmable terminal; when the SYSTEM ALLOWING STACKING light turns on, the bucket-wheel stackerreclaimer can come into normal stacking work state and send out BUCKETWHEEL STACKER-RECLAIMER STACKING signal to the system program control room. When the bucket-wheel stacker-reclaimer stops operation due to fault, the stacking work of the system belt will automatically stop 2.1.2.6.3.5.5 Common control Common control operation refers to the control that can be used to operate the bucket-wheel stacker-reclaimer in single, interlock and semi-automatic control modes a. Emergency shutdown In an emergency condition, press EMERGENCY SHUTDOWN button on the right operation panel to immediately cut off the dynamical power and control power of the whole equipment to stop the bucket-wheel stacker-reclaimer In an emergency condition, the emergency shutdown pulling wire in the middle of the cantilever and the trailer to stop the bucket-wheel stackerreclaimer b. Fault reset Page 64 of 160 Fault reset is used to release the self-locking of the fault signal sent out during the operation of bucket-wheel stacker-reclaimer. Press FAULT RESET button on the right operation panel can release the fault signal If the fault signal still alarms after pressing the fault reset button, the maintenance staff needs to check it. Reset the signal again after the fault is released c. Startup alarm Startup alarm is used for the sound and light alarm before starting up each mechanism of bucket-wheel stacker-reclaimer. Press STARTUP ALARM button on the right operation panel can fulfill the alarm operation The sound and light alarm starts automatically when the crane is moving d. Wind speed monitoring The wind speed can be monitored on the wind speed indicating instrument in the cab. The wind speed alarm signal automatically alarms to warn the operator to stop working, and the rail clamp will automatically clamp tightly e. Lighting control Pressing LIGHTING POWER ON button on the left operation panel can turn on the projecting light of the whole equipment. Pressing LIGHTING POWER OFF button on the left operation panel can turn off the lighting projecting light of the whole equipment. Pressing LIGHTING POWER ON button on the local lighting control button box can turn on the lighting projecting light of the whole equipment. Pressing LIGHTING POWER OFF button on the local lighting control button box can turn off the lighting projecting light of the whole equipment; 2.1.2.6.3.6 Operation after finishing work 2.1.2.6.3.6.1 Clamping of rail clamp After pressing RAIL CLAMP CLAMPING button on the left operation panel, the corresponding RAIL CLAMP CLAMPING light turns on on the STATE INDICATION menu of the programmable terminal, indicating the rail clamp has clamped tightly. Thus, the operation can proceed 2.1.2.6.3.6.2 Power-off of dynamical power After pressing DYNAMICAL POWER OFF button on the left operation panel, the DYNAMICAL POWER OFF INDICATION light turns on and the DYNAMICAL POWER ON INDICATION light turns off. At this time, the dynamical power-off operation is finished Page 65 of 160 2.1.2.6.3.6.3 Power-off of control power After pressing CONTROL POWER OFF button on the left operation panel, the CONTROL POWER OFF INDICATION light turns on and the CONTROL POWER ON INDICATION light turns off. At this time, the dynamical power-off operation is finished After control power is off, take off the key on KEY SWITCH on the left operation panel. Then the operator can leave the cab 2.1.2.6.3.6.4 Anchor falling The operator should put the anchor near the trolley at the two sides of the equipment to open the anchor limit devices at the two sides before leaving At this time, the normal operation of bucket-wheel stacker-reclaimer is finished, and then the operator can leave 2.1.2.6.3.7 Operation safety precautions 2.1.2.6.3.7.1 Operation safety precautions (1) The operator in the cab must follow the commander’s order and pay attention to the surrounding conditions and the condition of coal inside the yard. At the same time, when the bucket-wheel stacker-reclaimer is operating, the operator is not allowed to leave the operation position. (2) The rail clamp must be loosened before the operating mechanism of the crane moves. If the anchor is locked before that, it should be unlocked, too. At the same time, the condition of the rail also needs to be paid attention to before the operation of crane. The operating mechanism of the crane is operating in adjusting mode, so the slewing and lifting mechanisms and so on are not allowed to operate in operation. Besides, when the crane is operating, the operator should pay attention to the position of transfer station to prevent collision of the bucketwheel stacker-reclaimer, etc. (3) The safety device of each part should be frequently checked. The equipment only can be started when making sure the safety device is in good conditions. (4) In operation, operation with a rush should be avoided to prevent impact and vibration to the bucket-wheel stacker-reclaimer and coal, causing hidden trouble. Therefore, the operation must be steady. (5) During reclaiming, it is not allowed to dig deeply to prevent accident happening due to coal stack collapse. (6) In slewing, lifting and crane operation, the operation can not only be stopped depends on the limit switch because the limit switch is only used as a kind of protection measure. Once the limit switch is out of use, severe accidents might happen. Therefore, the habit that uses operating switch to control the operation must be developed. Page 66 of 160 (7) The door of the cab should be well closed during operation in the cab. (8) Overload must be prevented during reclaiming. For the overload of a few times, the overload capacity must not exceed 20% of the load 2.1.2.6.3.7.2 Precaution items required to be checked during the operation of bucket-wheel stacker-reclaimer When the bucket-wheel stacker-reclaimer is operating, the person in charge of work should often inspect the following items to make sure the bucket-wheel stackerreclaimer is in good and safe working state (1) whether the motor, bearings, speed reducer, coupling or brake has abnormal sound, vibration and heating; whether the speed reducer body, drum, shaft or wheel is cracked or broken, and especially, whether obvious abnormity can be found through the abrasion condition of the wheel. (2) Whether the bolts, nuts and shaft end retaining plate are loose or drop. (3) Whether each brake works normally, and inspect the abrasion condition of the brake shoe. (4) Whether the lubrication oil inside the speed reducer is proper; whether there’s oil leakage; whether lubrication oil is fully distributed in other lubrication parts. (5) Whether each limit switch is out of use. (6) Inspect the conveying condition of the cantilever belt conveyor. (7) Pay full attention to the stacking condition of spilled coal because the normal work of the bucket-wheel stacker-reclaimer and the correct transmission of limit switch signal will be influenced if too much spilled coal is stacked. In this way, the stacked coal in the following positions must be cleared in time. ——The two sides of traveling rail for crane ——Slewing center ——The traveling platform at the two sides for cantilever belt conveyor If abnormity is found when inspecting each part mentioned above, the equipment must be shut down immediately for treatment and then can continue to operate after treatment. 2.1.2.6.3.7.3 Precautions to windstorm When wind speed is ≥20m/s, the bucket-wheel stacker-reclaimer is not allowed to be operated. Therefore, preparation must be done in advance when windstorm alarm is sent out: the bucket-wheel stacker-reclaimer must be moved to the anchor parking position and the rail clamp of the crane must clamp tightly. At the same time, the anchor must be in locking position. The cantilever must be put on the windbreak stake and locked. Inspect and lock the doors and windows of Page 67 of 160 electric room and the cab, and cut off the power supply 2.1.2.6.3.8 Maintenance of electric equipment Frequent maintenance of electric equipment is a necessary condition for ensuring normal, safe and reliable work of bucket-wheel stacker-reclaimer Each kind of maintenance period should be decided by the working condition of the bucket-wheel stacker-reclaimer and environmental condition. The maintenance system listed below refers to general conditions 2.1.2.6.3.8.1 Daily maintenance Daily maintenance is carried out by the bucket-wheel stacker-reclaimer when taking over shift every day. The maintenance range is as follow: (1) Clean dust, dirt and oil attaching to the external part of the electric equipment; (2) Detect the heating condition of motor, electromagnet, controller contact and resistor by hand; (3) Inspect whether the bearing leaks oil and whether the electric wire joint of the main equipment is clamped tightly or not. (4) Make a good record of all special observed conditions. (5) Dust and scrap iron should be prevented entering the internal part of the equipment when opening the cover of observation hole or shell 2.1.2.6.3.8.2 Ten-day maintenance Ten-day maintenance is carried out by electric maintenance staff, but the bucketwheel stacker-reclaimer operator also needs to join in it. The maintenance range is as follows: (1) Clean dust and oil dirt attaching to the internal part of the electric equipment; (2) Observe the abrasion conditions of motor brush holder, carbon brush and slip ring. (3) Monitor whether the sound of motor, electromagnet, relay and contactor is normal during operation. (4) Maintain and repair the contact of the controller, contactor and switches and coat them with a thin layer of vaseline 2.1.2.6.3.8.3 Annual maintenance Annual maintenance is carried out by electric maintenance staff The maintenance range is as follow Page 68 of 160 (1) Take apart the electric equipment to clean and maintain the equipment support. (2) Clean the rolling bearing of the motor and change new lubricating grease for it; (3) Measure the clearance between the stator and rotor; if it is uneven, the rolling bearing needs to be changed. (4) Measure the insulation resistance and take drying treatment measure if necessary. (5) Various faults found during annual maintenance have been treated. (6) The parts that can’t be repaired during annual maintenance should be replaced. (7) The annual maintenance range should be decided by the actual abrasion and the using degree 2.1.2.6.3.8.4 Fire treatment Dry type fire extinguisher must and only can be provided for the bucket-wheel stackerreclaimer. The most common type is carbon tetrachloride fire extinguisher. It is not allowed to use foam extinguisher. The dry sand only can be used to extinguish fire on lead but can’t be used to extinguish fire on motor When there’s fire, the power supply should be cut off first. At this time, emergency switch or emergency button can be used to open the main contactor or main circuit breaker in the power distribution cabinet. When the lead in front of the power supply cabinet catches fire, the incoming line circuit breaker or fuse of the bucket-wheel stacker-reclaimer should be opened, or the circuit breaker of the feeder line of the ground system. The bucket-wheel stacker-reclaimer that catches fire should be cleaned and dried, and the electric equipment and electric line should be checked. It only can be reused after it is repaired and meets the requirements 2.1.2.7 Safety operation regulations of the equipment 2.1.2.7.1 Safety operation regulations 2.1.2.7.1.1 Operators shall be professional staff, be trained, and shall pass examination. 2.1.2.7.1.2 It is prohibited that stacking/reclaiming capacity will exceed specifications described in the “Instructions”, it is prohibited that luff angle scope, slewing angle scope and other limit scope shall exceed the specified scope. Under normal working condition, stacker/reclaimer shall work in environmental temperature +5℃~+50℃,stacker/reclaimer shall work normally under 7 grade wind velocity .Often check whether position of limit switch is correct, check whether brake ction of brake is reliable, it is prohibited to change limit switch at random, it is prohibited to adjust the brake. 2.1.2.7.1.3 Bucket wheel stacker/reclaimer shall work only when wind speed is less than 25m/s, Page 69 of 160 since brake of rail clamps and travel mechanism makes action only when wind speed is less than 25m/s. Once bucket wheel stacker/reclaimer is blown away by wind, it is difficult to make further braking action. Therefore, rail clamps shall be maintained well at all time, and periodically check reliability of wind force warning system. Following requirements shall be observed during operation of the equipment: a. When wind speed exceeds 25m/s(Grade 7 wind), warning system sends off warning signal, operation shall be stopped immediately. b When wind speed is predicted to exceed 25m/s, control room shall have sufficient time to move bucket wheel stacker/reclaimer to be anchored and clamped, meanwhile, bucket wheel should be quickly landed. c When wind speed reaches 25m/s, any work shall be halted, the equipment shall be anchored at anchor position, rail clamps shall be clamped, bucket wheel should be landed. 2.1.2.7.1.4 During the process of operation, when electricity suddenly is cut off or voltage in power line fluctuates greatly, driver shall cut off master switch as soon as possible, each control switch shall be reset. 2.1.2.7.1.5 During the process of operation, filling oil, cleaning and service are forbidden; Power supply shall be cut off when the equipment stops for maintenance. 2.1.2.7.1.6 Tools and spares shall be stored in special-purpose box or cabinet, they shall not be placed anywhere at random. Flammable, explosive materials shall not be allowed to store on the equipment, in operator’s cabin and electrical room, dry fire extinguishers shall be equipped. 2.1.2.7.1.7 Often clean oil dirt, rainwater, ice and scattered coal block and coal powder on ladder and platform. 2.1.2.7.1.8 As to electrical part, specialized staff shall be arranged to make check and maintenance, electrical safety instructions shall be strictly observed. 2.1.2.7.1.9 Motor and other electrical equipments shall be well grounded. 2.1.2.7.1.10 End-user shall develop safety operation and maintenance rules. 2.1.2.7.1.11 Rules shall be observed in normal operation, in preparation work prior to operation and recording after operation. 2.1.2.7.1.12 Driver’s responsibility Fully understand mechanical structure, working principle, technical parameters, assembly and operation and maintenance methods. Strictly observe safety operation rules. 2.1.2.7.1.13 Preparation work prior to operation Pay attention to climate change according to weather forecast, pay special attention Page 70 of 160 to condition of strong wind in order to safeguard bucket wheel stacker reclaimer. Prior to normal start-up, besides rules required in power generation plant, check the following: 2.1.2.7.2 a. No obstacle should be on rail and within operation scope of equipment. b. No obstacle should be on cable; c. Release all fixing devices; d. Voltage of power supply should be controlled within +5%~-15% rated voltage scope. Caution during operation Instantaneous forward and reverse rotation of driving device is strictly prohibited. A short period of pause shall be given in change of rotation direction in order to stabilize operation. 2.1.2.7.2.1 Lifting, traveling and slewing limit switches shall only be used in emergency stop of failure; as to normal stop, switches (button) on control console shall be used. A short period of pause shall be given in change of rotation direction in order to stabilize operation. 2.1.2.7.2.2 Driver shall concentrate his attention on operation and observation, especially during the process of slewing and lifting operation, to avoid any collision between the equipment and coal pile or any construction facility. In the operation of automatic stacking/reclaiming, driver shall strengthen monitoring of working conditions. 2.1.2.7.2.3 If sudden failure occurs in operation of equipment, use emergency stop switch to stop the equipment. 2.1.2.7.2.4 Too much coal accumulated on head of boom rack may affect normal luff action, which shall be removed in time. 2.1.2.7.2.5 Patrol inspection in operation of equipment Besides driver, patrol inspector shall be arranged; check the following: a) Whether abnormal noise, vibration, heating-up exist in motor, bearing, transmission device and hydraulic oil cylinder. b) Bolt, nut, end cover, fixing plate of mechanical parts shall not be loosened or damaged. c) No crack of welding joint or obvious deformation occurs in any structural elements. d) No oil leakage in reducer after the reducer is filled fully; other parts shall be totally lubricated e) Emergency stop switch and pulling wire switch shall be used for stopping Page 71 of 160 machine if failure occurs. 2.1.2.7.3 2.1.2.7.4 Caution during hydraulic operation a. Oil filter shall be installed at oil suck inlet and oil return inlet of pump to prevent polluted particles in oil from entering into and damaging parts. Warning signal will send off if oil return filter is choked, motor of oil pump will stop power supply until filter elements are cleaned or replaced. b. Frequently observe whether pressure, speed, temperature are normal (normal working temperature shall be 15° ~ 70°), if abnormal conditions occur, causes shall be found out, failure shall be solved c. Frequently observe whether oil leakage exists in connecting surface of parts, in pipeline and oil pipeline, whether abnormal noise exists in operation; if one of the above conditions occurs, find out causes in time, properly repair the failure. d. When the equipment stops operation, switches shall be in “stop” position. Check after storm When wind speed exceeds 25m/s, after wind stops, check the followings: 1. No obstacle exists on travel rail of equipment; 2. Anchor device of travel mechanism and anchor seat on ground foundation shall not be broken. 3. No crack exists in main mechanical structures (like pylon, counterweight boom, boom rack, portal, machine body frame, support legs etc). 4. Operator cabin, electrical room, electrical parts and elements shall not be moistened or damaged. 5. Power supply cable and cable reel drum shall not be damaged. After bucket wheel stacker/reclaimer is confirmed to be normal, refill oil to all lubricating points, first of all, commissioning the equipment in low speed unloading, only after limit switches can work normally, to run the equipment in full speed. 2.1.2.7.5 Check after earthquake After earthquake, check the followings, only after all damaged parts are replaced or repaired, normal operation may be allowed. 1. No obstacle on rail, rail accuracy shall comply with the requirements specified in Appendix 1. 2. No crack at weld of structures. 3. No damage in operator cabin and electrical room. 4. No loss or damage in electrical parts. Page 72 of 160 After the equipment is confirmed to be normal, refill lubricants to any lubricating point, first of all, commissioning the equipment in low speed unloading, only after limit switches can work normally, to run the equipment in full speed. 2.1.2.8 Maintenance and services of the equipment 2.1.2.8.1 Daily inspection 2.1.2.8.2 2.1.2.8.3 a. Oil leakage in gearbox, hydraulic system and brake. b. Working conditions of contactors and relays. c. Temperature rise condition of motor d. Damage and misalignment of the conveying belt ; e. Soundness of signal and lighting. Weekly and monthly inspection a. Wear of brake shoes, pin and brake disc; b. Deformation of metal structure, crack and weld; high-tension bolt connection; c. Whether bolt is screwed, whether support bracket and base off or loosen. d. Whether metal powder exists in lubricating grease extruded from bearing. e. Insulation conditions of control cabinet, motor, and other electrical elements. f. Action of limit switch and safety devices. g. Whether crack exists in brake disc, coupling, axle and pulley. h. Lubricating condition of lubricating points Quarterly and yearly inspection a. Calibrate accuracy of various instruments b. Oil pollution in reducer box, if necessary, filter/clean or replace the oil. c. Whether wiring terminal of motor is loose, whether other electrical terminals are damaged. d. Attrition of wearing plate on bucket chute and other wearing parts. e. Working status of cable reels, check whether damage exists in slip ring. f. Action reliability of brake and rail clamps. g. Wear of reducer gear, roll bearing and slide bearing, clean reducer and replace h. Corrosion of structures,according to the actual condition,repaint once for 2~3 years. oil. Page 73 of 160 i. Check whether long travel rail accuracy is within control limit according to Appendix I. 2.1.3 Water Wiper 2.1.3.1 General description of equipment Water wiper is mainly used for the belt in the open air in the coal yard to wipe accumulated rain water on the belt conveyor in time during startup. In this way, rain water accumulated on the belt conveyor is prevented from being carried to the transfer station during operation. It is mainly consisted of frame, water wiping plate, idler, connecting rod, chute and actuator of electric pushing rod. The working process is that the water wiper is fixed, the idler in the chute rises to move the belt upward to attach to the water wiping plate, so rain water carried by the operating belt conveyor can be wiped in time. During ascending, the idler is lifted by means of one electric pushing rod driving one lever so as to wipe rain water accumulated on the belt 2.1.3.2 Technical specification Parameter name Parameter data Parameter name Parameter data Type SZC 1000 Motor power 1.5 KW Belt width 1400 Rise angle plough head Type of pushing rod DT100030 Acting time ≤5 S Installation position On C-3 belt conveyor Installation number 1 set of 250 2.1.3.3 Check and preparation before startup  2.1.3.3.1 Check the following items: the equipment installation has been finished; the frame is well fixed and not loose; the idler frame moves up and down freely, and the idler rotates flexibly 2.1.3.3.2 Before supplying power, do manual test first and shake the hand wheel to see running condition of the whole equipment; at the same time, adjust the initial end and stroke of the electric pushing rod 2.1.3.3.3 Add lubricating grease in all transmission parts 2.1.3.3.4 The traveling direction of the electric pushing rod is correct 2.1.3.4 Startup and commissioning 2.1.3.4.1 Supply power to the electric pushing rod; check the contact between the water wiping plate and the belt is good; start up the belt of this section to operate 2.1.3.4.2 Check the contact between the water wiping plate and the belt is good 2.1.3.4.3 Check the electric pushing rod is not overheated in operation Page 74 of 160 2.1.3.4.4 Loosen the adjusting screw to loosen the contacting block. 2.1.3.4.5 Adjust the distance between the contacting block and the travel switch to move them in the required positions 2.1.3.4.6 Screw down the adjusting screw to fix the contacting block and then supply power to do test till the equipment gets to the best working state 2.1.3.6 Shutdown and precaution 2.1.3.6.1 Put the electric pushing rod in retracting position and cut off power of the motor 2.1.3.6.2 Confirm the water wiping plate has lifted up and the idler frame has been back to the horizontal position, and then coal can be supplied to the belt 2.1.3.7 Fault, solution and prevention Fault description Fault cause Fault treatment Electric pushing rod No power in motor or fault Check the power supply or out of work in internal transmission dismantle the pushing rod part mechanism to check. Incomplete wiping water Bad contact between water Adjust the wiping plate and fix wiping plate and belt the bolts; adjust the frame; check whether the rotating mechanism of the idler frame is jammed and treat it. 2.1.4 Bulldozer 2.1.4.1 General description of equipment In coal yard, to cooperate with the bucket-wheel stacker-reclaimer to stack and reclaim coal, two bulldozers are provided in coal yard, which are use to clean up and shove coal 2.1.4.2 Technical specification 2.1.3.3 Check and preparation before startup 2.1.4.3.1 Comprehend the conditions of coal yard and coal shoving task 2.1.4.3.2 Check, maintain, adjust and fix the shovel following the daily routine maintenance items 2.1.4.3.3 Check whether fuel, lubrication oil and cooling water are sufficient and add them if they are insufficient. It is forbidden to smoke or get close to open flame when adding fuel oil, so as to avoid fire 2.1.4.3.4 Check whether the electric line insulation and each switch contact are good 2.1.4.3.5 It is forbidden to stand inside the bucket, on the arm link, crawler and bulldozer crest Page 75 of 160 slab 2.1.4.3.6 Before operating the bulldozer, big stones or other obstacles should be cleared if they are in working area 2.1.4.4 Startup and commissioning 2.1.4.4.1 Check whether all pipes, operating valves, working oil cylinder and oil pumps of the hydraulic system leak and are abnormal 2.1.4.4.2 Put the joystick of the main clutch in NEUTRAL POSITION and start the engine. Check whether all instruments, transmission mechanism, working device and brake mechanism are normal. The work can be started after confirming all is correct 2.1.4.4.3 For night work, the working place should be provided with good lighting 2.1.4.5 Check and adjustment during operation 2.1.4.5.1 It is forbidden to stand on the crawler or the support of the shovel blade 2.1.4.5.2 The bulldozer should be operated stably; do not shovel too deeply; the shovel blade should not be strongly moved up and down; it is proper that the distance between the shovel blade and the ground is 0.4m; do not lift the shovel blade too high 2.1.4.5.3 When the bulldozer is traveling on the slope, the uphill gradient should not exceed 25°, the down slope gradient should not exceed 35°, and the transverse gradient should not exceed 10°. Transverse travel is forbidden on the steep slope (above 25°) 2.1.4.5.4 Heavy turning movement is not allowed when the bulldozer is running in the steep slope in longitudinal way. The bulldozer should be operated at low-speed when going up and down the slope and it is not allowed to change the speed Throw-out of gear sliding operation is forbidden when descending the slope 2.1.4.5.5 On the way to ascend slope, if the engine shuts down suddenly, put the shovel blade on the ground immediately, step down and lock the brake pedal; when the bulldozer is stopped steadily, disconnect the main clutch, put the gearshift lever in neutral position and fix the crawler or tyre tightly with a triangle block, and then restart the engine 2.1.4.5.6 When the bulldozer is shoveling coal at the angle above 25°, filling-digging operation should be done first. The bulldozer only can start work when it can keep self-balance 2.1.4.5.7 When a number of bulldozers work in the coal yard at the same time, the distance between the front one and the back one should not be less than 8m and the distance between the left one and the right one should not be less than 1.5m 2.1.4.5.8 The bulldozer is forbidden to be turned heavily and quickly when it is under load or operating at high speed. 2.1.4.5.9 In working time, the operator is not allowed to leave the work post at will 2.1.4.5.10 It is forbidden to maintain and get on or get off the bulldozer when it is operating. Page 76 of 160 2.1.4.6 Shutdown and precaution 2.1.4.6.1 Dust and dirt attaching to the external part of the bulldozer should be flushed and cleaned after work 2.1.4.6.2 Check, maintain, adjust, lubricate and fasten the bulldozer in the routine maintenance way 2.1.4.6.3 ground Move the bulldozer to flat and safe place and put down the shovel blade on the 2.1.4.6.4 The operator must shut down the engine and lock the door and window before leaving 2.1.4.7 Common faults and solutions Fault characteristics Reason Solutions The rotating speed of 1 generator is constant and 2 the ammeter sways greatly. Wiring is not good. The rotating speed of 1 generator is changing and the ammeter does 2 not sway. 3 The ammeter good. Put through the circuit but 1 the starter does not 2 rotate. 3 4 The belt adjustment appropriate. 1 tension is not 2 is not 1 Adjust tension. the replace belt Replace it. 2 Check and the line. The generator has fault. 3 Repair the generator. The wiring is not good. 1 The starting switch is not good. Check and the line. 2 Change the switch. The wiring is not good. The power accumulator insufficient. in 3 is 4 Charge accumulator. replace replace the Replace the switch. The switch is not good. When the generator stops The oil pressure gauge is rotating, the oil pressure damaged. gauge indication is not zero. The oil pressure gauge 1 sways greatly or oil pressure gauge indication is low. Check and the line. The oil amount in bottom case insufficient and air absorbed into the pipe. Page 77 of 160 Replace the oil pressure gauge. oil 1 is is 2 oil Add oil following the rules. Check the recovery of oil leakage point. 2 The connector leaks oil. 3 The oil pressure gauge is damaged and the filter is blocked or its installation is inappropriate. Oil pressure gauge 1 indication is too high. 2 Steam sprayed from the 1 upper part of water tank radiator 2 Oil viscosity is too high. 3 Wash the oil filter or replace it again. 1 Change oil following the rules. Oil pressure gauge is broken. 2 Replace the pressure gauge. oil The cooling water is 1 insufficient and leaks. 2 The belt of fan is loose. 3 The cooling system is polluted. 4 The cooling plate is blocked. 5 The water thermometer is broken. Add water. The water temperature is 1 too high. The thermostat is not 1 good. Replace thermostat. 2 The thermostat is not 2 well sealed. Change the thermostat sealing. The water thermometer 1 indication is too low. The water thermometer 1 is broken. Replace thermometer. The plug part does not contact well. Check the plug. 3 4 5 2 The engine cannot start 1 (the swirling starter has already been used). 2 3 4 2 Adjust the belt. Wash the system. Clear point. the blocking Replace the thermometer. The fuel oil pipe is 1 blocked. Clear the pipeline. Air enters into the fuel 2 system. 3 The injection pump or oil injection nozzle is not good. 4 The starter rotating Discharge air. Page 78 of 160 cooling water the water fuel Replace the injection pump or oil injecting nozzle. Check system. electric speed is low. 5 The engine vibrates. 5 Feed more fuel. The fuel is insufficient. The absorbing side of fuel Treat the leak part. pipeline leaks air. The steering joy stick has 1 malfunction. 2 3 The clearance 1 adjustment is not good. 2 The joy stick movement is not good. Adjust the clearance. The oil amount insufficient. Make up oil to the prescribed oil amount. is 3 Inform maintenance adjustment. the for Step down the brake The brake is not good or the Adjust it. damper; the equipment travel range is too big. cannot stop. The crawler falls off; the The crawler is too loose or chain wheel is worn too tight. abnormally. The shovel rises slowly or 1 does not rise at all. Adjust it. The hydraulic system 1. pressure is low or out of work. 2. The operating switch is out of work. 2 2.2 Equipment of Coal Handling System 2.2.1 Belt Conveyor 2.2.1.1 General description of equipment Inform maintenance for treatment. Maintain or replace it. The belts before no.3 transfer station are designed in single series. The belt width is 1400mm, with speed at 3.5m/s and conveying capacity of 2000t/h. The belts from the stacker-reclaimer to the main building are designed in double way. C-1.C-2.c-3 and c7 are all single-way belts which are installed in coal yard and emergency coal hopper. The double-way belt conveyor will be designed as: B=1200mm, v=3.15m/s, Q=1250t/h while the belt A/B of C-6 installed in the coal bunker will be designed as: B=1400mm, v=2.5m/s, Q=1250t/h, according to the electric sledges installed at the two sides. 2.2.1.2 General application principle: One of the two belts is in operation while the other is standby. Both of the belts can operate at the same time. 2.2.1.3 Check and preparation before startup 2.2.1.3.1 Check whether the foundation and the connecting bolts in all parts have been Page 79 of 160 fastened. 2.2.1.3.2 Check whether the welded parts in the side lack of weld or not. 2.2.1.3.3 Check whether sufficient lubrication oil have been added to the motor, speed reducer and bearing pedestal according to the requirements. 2.2.1.3.4 Check whether the electric signal, control protection and insulation meet the requirements. 2.2.1.3.5 Check the groove inclination direction of the transmission drum with herringbone rubber surface; press the button to start up the motor quickly and then release the button to shut down the motor to confirm its running direction. 2.2.1.3.6 Fill oil in the hydraulic coupler and confirm the oil capacity after press the button to start up the motor quickly and then release the button to shut down the motor to check whether the running direction of the motor meets the requirements. 2.2.1.3.7 There should be no obstacles around the motors, speed reducer and belts; the anchor bolt should be fixed steadily; the earthing wire is good; the guardrail, coupling safety cover and dustproof device should be intact. 2.2.1.3.8 The oil of each part is sufficient; the oil quality is good; there is no severe oil leakage (the oil level of the speed reducer should not be less than the specified oil level).The head and rear drum, fraction increasing drum, turnabout drum, moveable drum, upper and lower idler and adjusting drum should be intact without roll release. There is no coal accumulation; all rotating parts are in good lubricating states, without a lack of oil. 2.2.1.3.9 All tension devices (moveable tension device, Trolley type tension device and lead screw tension device), and the adjusting idler are flexible, without roll release; the steel wire rope should be in guide wheel chute, without wire break or damage; the counterweight device is proper and does not contact the ground. 2.2.1.3.10 The inversion brake and the stopper plug are in correct positions and play good functions. 2.2.1.3.11 The coal wiping plate and cleaner are flexible and play good functions. 2.2.1.3.12 The coal falling pipe and lining plate inside the pipe and the set screw are intact; there is no foreign matter and no accumulated coal; the rubber lining part of the guide chute belt lining part is intact; there is no fly coal powder during coal loading and no foreign matter blocking; the width of the newly replaced belt lining part is proper; the coal can pass smoothly. 2.2.1.3.13 There should be no warning board for the (if there is, find out the cause and eliminate, and then the equipment can be started up); the indications of power supply indication light and ampere meter are normal; the positions of the interlock operation switch and the emergency button are correct and in good use states. The coal interruption, coal blocking, deviation, coal level, equipment position, limit, low speed and coal plough ascending and descending signals are good. 2.2.1.3.14 The lighting is sufficient. 2.2.1.3.15 The turnover plate is flexible and plays good function. Its position is correct. Page 80 of 160 2.2.1.3.16 The coal plough is flexible, plays good function and can freely ascend and descend, without coal blocking or running. 2.2.1.3.17 There should be no water, frost, foreign matter on the belt; the belt has no severe damage, no bonding gap and coal leakage, and its tension is suitable. 2.2.1.3.18 The belt scale and the magnet separator operate well. 2.2.1.3.19 The dust removing device can be put into use. 2.2.1.4 Startup and commissioning 2.2.1.4.1 Manual no-load test running 2.2.1.4.1.1 Start the equipment one by one in the backward coal flow direction after the system check is finished. The next equipment only can be started after confirming the last equipment is operating normally. 2.2.1.4.1.2 The no-load test running of the system should be no less than 2 hours. 2.2.1.4.2 Programmable control no-load test running Switch to programmable control position on PLC menu and press the start button, and then the system will start the equipment one by one in backward coal flow direction. 2.2.1.4.3 Interlock test running 2.2.1.4.3.1 In manual or programmable no-load test running process, if any of the equipment is stopped, the equipment which runs before it should be stopped immediately while the one which runs after it should keep running. 2.2.1.4.3.2 In manual or programmable no-load test running process, if the equipment has test switch protection, deviation, coal blocking or belt tearing signal, the running equipment before it should be stopped while the one after it should keep running. 2.2.1.4.4 On-load test running 2.2.1.4.4.1 On-load test running needs to be done after manual or programmable control startup, the load should be increased gradually, in accord with 20%-50%-80%-100% of the rated load. The test running time under each kind of load should be no less than 2 hours. Decide whether the full-load startup and running test under the load of 110%-125% of the rated load should be done according to the system process flow requirements. 2.2.1.5 Check and adjustment during operation 2.2.1.5.1 Observe whether the running parts have friction or not; if there is, adjust those parts to prevent belt damage. 2.2.1.5.2 Check whether the conveying belt deviates or not; if it deviates 5% of the belt width, it should be adjusted. Page 81 of 160 2.2.1.5.3 Check whether each part has abnormal sound or vibration. 2.2.1.5.4 Check whether the speed reducer, hydraulic coupler and other lubrication parts leak oil or not. 2.2.1.5.5 Check whether the temperature rises of lubrication oil or bearing are normal. 2.2.1.5.6 Check whether the contact between the wiping plate of the cleaner and the conveying belt is normal. 2.2.1.5.7 Check whether the tension device has block or obstruction or not. 2.2.1.5.8 Check whether the connecting bolts of the foundation and each part are loose or not. 2.2.1.6 Shutdown and precautions 2.2.1.6.1 The belts can be stopped after confirming there is no coal on the last belt. Stop the equipment one by one according to the coal flow direction if manual shutdown mode is used; if programmable control shutdown mode is used, press the shutdown button directly. 2.2.1.6.2 It is not allowed to use the belt conveyor to do work beyond the design regulations. 2.2.1.6.3 Overload operation is not allowed. 2.2.1.6.4 All safety alarm devices should be in good states. 2.2.1.6.5 There should be no obstacle in the passage to the emergency shutdown switch. 2.2.1.6.6 There should be enough lighting equipment is each loading part. 2.2.1.6.7 The operation should be carried out strictly following the regulations. 2.2.1.6.8 The operator and patrol inspector should make a good record when finding the equipment operation is abnormal and shut down the equipment in emergency conditions. 2.2.1.7 Faults and solutions Fault description Fault cause Solution Coal leakage of The belt deviates or is belt damaged. Adjust the bottom centering idler or the head transmission drum; shut down the equipment and adjust the whole equipment frame if the situation is serious. Repair the belt in time if it is damaged. Belt slip Adjust the tension device. Overheating bearing transmission The belt is too loose. The bearing lacks of oil or Add oil or change lubrication oil; of the oil quality deteriorates; control the operating load and forbid the equipment operates Page 82 of 160 drum for too long time under no overload operation. overload. Failed startup of There is coal on the belt Clear part of coal and restart. belt conveyor in shutdown process. 2.2.1.8 Patrol inspection regulations of coal handling system To ensure safe and stable operation of coal handling system, the operators all should have high resposibility and the thought of SAFETY FIRST and carefully do equipment patrol inspection following the regulations. During patrol inspection, the inspection method of SEE, LISTEN, TOUCH and SMELL should be adopted. That is: See: completely inspect the appearance of the equipment. Listen: Listen to see whether the parts of all rotating equipment have abnormal sound or not. Touch: inspect the temperature and vibration of the rotating equipment bearings, motors and gearbox. Smell: smell whether the equipment has perculiar smell or not. 2.2.2 Idler a. Trough idler Trough idler is generally consisted of three short idlers; the axis of the short idler in the middle and the axis of the short idlers at the two sides forms an angle which is called the trough angle of the idler. The trough angle of the belt conveyor is 35°. As figure a is showing, the idler body is generally made of seamless steel pipe, but seamless steel pipe is replaced by seamed steel pipe in some places now. The idler of the belt conveyor of the company is in a seamed steel pipe welding structure. No.2 lithium base grease is used for lubrication and labyrinth seal is used for the seal of the idler. b. Parallel roller Generally, parallel roller is a long idler which is mainly used as the idler for the under layer belt (below idler for short), supporting the belt of no-load section, shown as figure b. c. Impact idler The function of impact idler is to decrease the impact of coal on the belt at the coal loading part to protect the belt. Page 83 of 160 The impact idler is divided into rubber type impact idler, spring plate type impact idler and spring plate type apron impact idler, shown as figure c. Common idlers a) Trough idler group b) parallel idler c) impact idler d) inclined straight idler d) Self-centering idler Various belt conveyors inevitably have different deviation phenomena in operation process due to many random factors, so a certain number of self-centering idlers should be installed The reversible self-centering idler is used for double-way operation belt conveyor, whose structure is shown as figure 5-2. Its working process is like this: the two curve plates at the left and right sides and the friction disc fixed on the idler shaft produce certain friction force to make the support slew. When the belt deviates, it contacts the left curve plate or the right one and produces a friction torque through the curve plate to make the support rotates a certain degree so as to achieve the centering aim. The double-way centering idler cancels the vertical idler, so the abrasion to the belt edge is slight when the belt deviate and it is widely used. Figure 5-2 MTS type reversible self-centering idler Page 84 of 160 1. Support 2. Left curve idler 3. Left idler 4. Middle idler 5. Right idler 6. Right idler 7. Steel beam of trough 2.2.3 Tension Device The function of tension device of belt conveyor: ensure the belt has enough tension; make the drum and the belt produce required friction force; limit the sag of belt in support idlers; leave a certain length for rebonding belts. a. Trolley type tension device: the tail drum is installed on the trolley; the heavy hammer pulls the trolley through the steel rope and guide pulley to move along the belt conveyor in longitudinal direction, shown as the figure below. Trolley type tension device 1. Heavy hammer 2. Pulley block 3. trolley 4. winch b. Heavy hammer tension device. It is consisted of two turnabout drums and a tension drum, which is usually installed in the place where the empty belt of the conveyor is near the driving drum, with the minimum belt tension. The tension drum and the moveable frame can move together along the vertical guide rail, shown as the following figure. Page 85 of 160 Heavy hammer tension device 1. and 2. Guide drums 3. Tension drum 4. Sliding framework 5. Guide rail 6. Heavy hammer 2.2.4 Cleaning Device In the operation process of the belt conveyor, slight coal particle will adhere to the belt , cause belt deviation and increase the movement resistance, so belt conveyor is usually equipped with cleaning device. The spring cleaner is one device to scrape off the coal on the belt via spring pressing on coal scraper. The coal scraper is produced by improved alloy blade and fits with head coal falling hopper. The coal cleaned off will fall into head hopper. There are empty section cleaners in front of return tail drum, vertical tension device and middle driving device. Page 86 of 160 H-type P-type Schematic drawing of cleaner working position 2.2.5 Auxiliary Equipment 2.2.5.1 Motor 2.2.5.1.1 Strictly carry out the relevant regulations on motor operation in Auxiliary Operation Regulations. 2.2.5.1.2 Regulations of allowable motor startup times 2.2.5.1.2.1 In normal conditions, squirrel cage motor can be continuously started two times in cold state, and the interval is not less than 5min; it can be started once in cold state. Only during trouble shooting or when the startup time is not more than 2s ~ 3s, the motor can be started once more. 2.2.5.1.2.2 Refer to startup time interval table 1 when doing dynamic balance test. Table 1 Startup time interval table Motor capacity Startup time interval Below 200kW No less than 0.5h 200~500kW No less than 1h Above 500kW No less than 2h Remark: The condition that motor is restarted after less than 1 hour’s continuous operation or after more than 1 hour’s continuous operation and shutdown for 4 hours is called as cold state; except the condition mentioned above, the other ones are all called as hot states. 2.2.5.1.2.3 When the motor is started, the programmable control or the local operator should closely monitor the starting current and starting time of the motor; when the starting time exceeds the starting time limit, the operator should immediately press STOP Page 87 of 160 button and find out the cause. 2.2.5.1.2.4 The starting time limit of the coal handling equipment is specified as follows. 2.2.5.1.2.5 The starting time of the belt conveyor should not be more than 5 seconds (normally, 2 ~3s). 2.2.5.1.2.6 The starting time of the coal crusher should not be more than 10 seconds (normally, 7s). Remark: starting time refers to the time interval that the current returns to normal current from starting current when the motor is started. 2.2.5.1.2.7 The motor only can be started before the insulation is measured to make sure it meets the standard when the motor is maintained, moistened or has been in standby state for more than 15 days. 2.2.5.1.2.8 In motor operation, the vibration value measured at each bearing should not exceed the following value, referring to table 2. Table 2 Bearing vibration value of motor 2.2.5.1.2.9 Rated rotation speed(r/min) 3000 1500 1000 750 and below Vibration value(doubleamplitude) mm 0.05 0.085 0.10 0.12 The motor can be operated in accord with the rated parameters on the nameplate provided by the manufacturer when then rated cooling air temperature is 35℃ ~ 40℃. When the cooling air temperature is more than the rated value, the operation parameters should not be more than the allowable temperature of the motor. 2.2.5.1.2.10 The operating value of each part of the motor should follow the following table (table 3). Table 3 Temperature value of each part of motor Name part of each Insulation Stator winding Rotor winding Maximum allowable Maximum allowable temperature(℃) temperature rise(℃) Grade A 95 60 Grade B 115 80 Grade E 110 75 Grade F 120 85 Grade B 105 70 Page 88 of 160 Grade E 100 65 Stator iron core 100 65 Slip ring 105 70 Sliding bearing 80 45 Rolling bearing 100 65 See Table 4 for the bearing temperature limits of each mechanism in operation Table 4 Bearing temperature limits ROTARY BERING PULLEY BEARING GEAR BOX 80℃ 70℃ 70℃ 2.2.5.2 Gear box 2.2.5.2.1 Function and advantages of gear box 2.2.5.2.2 (1) Function: the function of gear box is to shift the high speed low torque mechanical energy of motor into low speed big torque power to fit operation of mechanical equipment. (2) Advantages: it has tight structure, wide application, permanent drive ratio, high mechanical efficiency, long service life, small pressure on shafts and beings. Inspections and precautions before gear box is put into operation (1) Inspections before the gear box is put into operation a. Check whether the fastenings are firm; b. Check whether the lubrication was filled into the mechanism on oil pointer scale following specification; (2) Precautions for gear box operation a. Check the firm and reliability condition of fastenings, lube oil surface conditions, oil tank leakage conditions, and bearing heating or sound conditions; b. The gear box is forbidden to be operated without lubrication oil; c. Clean the box when changing lubrication oil; d. Do not open the inspection plate when it is unnecessary in order to keep it Page 89 of 160 free from sundries and dust; e. Do not overload the gear box; f. Keep the gear box clean. 2.2.5.2.3 Common faults and correction methods FAULTS CAUSES CORRECTION Lube oil heated up 1. Too much lube oil 1. Inform maintenance . 2. High oil viscosity 2. Change lube oil 3. Bad radiating effect on the box surface 3. Timely contaminants 1. Foreign matter entered into bearing 1. Inform maintenance Bearing heated up 2. Incorrect bearing coupler installation 3. Bearing damaged remove surface 2. Inform maintenance 3. Inform maintenance 4. Adjust the coal feeding amount 4. Overload. Oil leakage between 1. Bad sealing end cap and gear 2. Vent cap blocked box body 1. Reapply sealing paint Noise in transmission 1. Contact maintenance to adjust clearance; gear 1. Improper clearance; Vibration overlimited 2. Uneven working surface due to worn gears; 1. Elastic block of high speed shaft damaged; 2. Motor coupler disalighned, the rotation center unbalanced; 3. Big clearance between high speed bearings or damaged bearings. 4. Anchor bolts become flexble, or coupler bolts released. 2.2.5.3 Coupler Page 90 of 160 2. Clear vent cap 2. Inform maintenance; 1. Inform maintenance 2. Inform maintenance 3. Inform the maintenance operators 4. Fasten the bolts. a. Components and working principles of coupler (1) The hydraulic coupling consists of: driving coupler, elastic block, driven coupler, back auxiliary chamber, pump wheel, turbine, and transmission shaft. (2) The working principle of hydraulic coupling: in the hydraulic coupling which uses kinetic power of liquid to couple the motor and mechanism for power transmission, there is no direct mechanical contact between the driving and driven apparatuses, thus cause no mechanical wearing. The main shaft of pump connects with the motor main shaft directly or through gears, and the turbo shaft connects with the main shaft of coal crusher. Pump impellers and turbo impellers share a symmetrical distribution and the same physical dimension, and they are facilitated with longitudinal radial impellers. The working oil which fills the turbo impeller form a oil chamber between the turbo. During work, the motor shaft drives the pump impeller to rotate at a high speed, and the working oil flows at high pressure and speed from the inner side (inlet) to the outer side (outlet) of pump impellers under the centrifugal force to impact the turbo impeller, and drive the turbo to rotate in the same direction with pump. The working oil returns into the pump impeller inlet after it flows from the outer side of turbo into its inner side with a decreasing speed and pressure, in a circulation. Thus the motor transfers the mechanical power into the kinetic power and pressure potential power of working oil which were transmitted again to coal crusher in the form of mechanical power on output shaft, thus realized a flexible transmission of motor shaft power. b. The advantages of hydraulic coupling: it has long life span, simple structure, reliable performance and little maintenance. c. Attentions for operation of hydraulic coupling (1) Check whether the shield of hydraulic coupling is form or not before rotate it; (2) The hydraulic should operate stablly without abnormal sound or leakage; (3) The working oil temperature should not exceed 90℃ during continuous operation; Repeated startup is forbidden to prevent working oil from over temperature; (4) Check the wearing condition of elastic plate or block in coupling joint in schedule, and change if necessary; (5) Do not disassemble the coupler when unnecessary, to keep the sealing and assembly precision. d. Common faults of hydraulic coupling FAULTS Failed to reach rated CAUSES CORRECTION 1. Faulty driving motor 1. Inform maintenance Page 91 of 160 rotation speed or incorrect connection; 2. Brake fault of driven 2. Inform maintenance mechanism which 3. Reduce oil volume caused overload; 3. Oil over filled. Fusible alloy melted 1. Oil inadequated filled or leaked 2. Heavy overload, working mechanism trigged; 1. Inform maintenance 2. Reduce load 3. Prevent frequent startup 3. Repeated startup 2.2.5.4. Brake 2.2.5.4.1 Components and working principle of brake The brake on fuel devices usually adopts double brake shoes, which is simply structured and reliable. Brake is a safety device to reliably stop the operating equipment. Brakes are normally installed onto the high speed shaft of gear box, and constant close type brake, which holds the brake wheel in normal condition, will only be released by hydraulic driving unit when the motor is working. 2.2.5.4.2 The application and maintenance of brake a. Check whether the driving unit works normally on each shift, inspect if there is oil leakage, maintain a certain oil level, define whether the travel is inadequate or the brake shoes smoke; b. Check the oil quality every 6 months. Change the oil when foreign materials entered into the oil or when the oil deteriorated, pull the rod up and down for a few times to exhaust the air, fill adequate oil to the level below oil level signing plug hole. c. Choose hydraulic oil in following manner: No.10 transformer oil under an ambient temperature of 0-20℃; No.20 engine oil under an ambient temperature of 20-45℃; No.25 transformer oil under an ambient temperature of -15-0℃; 2.2.5.4.3 Common faults of brake FAULTS Brake shoe smoke CAUSES CORRECTION emits 1. Connecting pins seized by 1. Inform maintenance to change corrosion; Page 92 of 160 2. Hydraulic driving unit fails 2. Inform maintenance to rise; 3. Inform maintenance 3. Obstructions on control 4. Inform maintenance part of hydraulic driving unit 5. Timely make up oil 4. Inadequate clearance between brake shoes or tilted brake shoes; 5. Hydraulic lacks of oil driving unit Burnt smell during 1. Uneven clearance braking between brake wheel and brake band; 2. Auxiliary spring fails, and brake band pressed on brake wheel without returen; 1. Inform maintenance to adjust the clearance. 2. Inform maintenance 3. Inform maintenance 3. Rough working surface on brake wheel. 2.2.6 Ring Hammer Type Coal Crusher 2.2.6.1 Technical specifications Technical specifications for ring hammer type coal crusher Specification for the complete machine Model KRC12X29 Type Ring hammer type Rated output 1200t/h Bearing model (SKF) 22338w33c3 Number 2 sets Rotor diameter 1200mm Rotor length 2900mm Rotor mass (kg) 11000 Rotor linear speed 47.1m/s Intake fuel lumpiness ≤400mm Page 93 of 160 2.2.6.2 Output fuel particle size ≤25mm Handling targets Soft coal, anthracite, lignite and Rows of ring type hammers 4 rows Gear ring hammer piece weight/number 56Kg/12 Ring hammer piece weight/number 63Kg/14 Rotor mass 9890 kg Dimension: Length X Width X Height (mm) 3300X4440X1950 Complete machine mass (Kg, without motor) 30000 Working principles The coal briquettes, after entering into the crusher, will be crushed by the ring type hammer in high rotation speed, and the primary crushed coals rush into the crusher board and screen to be crushed in a second time. At the same time, coal briquettes collide between themselves and output small pieces of coal to be pressed, cut and grinded again on the screen by rotary ring hammer, and finally come out of the crusher from screen holes. Uncrushed debris such as iron ores are collected into de-ironing room by rotor. 2.2.6.3 Structure of ring hammer type coal crusher The ring hammer type coal crusher is mainly composed of machine body, casing, rotor, ring hammer, screen plate supporter, screen plate adjuster and hydraulic system etc. 2.2.6.4 2.2.6.5 Operation of coal crusher a. Put the change-over switch on local control cabinet to LOCAL. b. Startup the coal crusher after systematic belts are normally started up. c. Stop the coal crusher after the belt before it was stopped for 30 seconds. d. Put the control switch to REMOTE CONTROL after the machine was shutdown. e. When the coal crusher needs to be started or stopped for maintenance and repairing, contact remote control operators and prepare relative safety measures. Inspections before operation of coal crusher a. Ensure that each indication light, button, selection switch, temperature and vibration detecting devices are intact, and selection switch is on REMOTE CONTROL position. b. The connection bolts on all parts are not flexible or released. Page 94 of 160 2.2.6.6 c. Safety shields of each rotary part are firm and reliable. d. Keep the adjusting bolt for screen plate stemmed out at a certain length, ensure its lubrication and the tightness of bolt cover. e. Observe hole and man hole should be tightly sealed, the pins and fastening bolts are firm, and there is no crack or big wearing on ring hammer and crusher plate. f. The hydraulic coupling should rotate flexibly without oil penetration or leakage, and the surface temperature should no be more than 90℃. g. There is no block or serious coal jam within the machine h. There is no flexibility or damage to the adjusting bolt of screen plate. Common faults and correction manners for coal crusher Faults Causes Corrections The output particle obviously increased ( > 30mm) 1. Big clearance between screen plate and ring hammer Contact maintenance 2. Fractured screen holes. 3. Over worn ring hammer. Fierce vibration 1. Ring shaft or ring hammer fractured, lost of coal crusher balance 2. Bearing damaged 3. Big installation error between motor and hydraulic coupling (big misalignment) Contact maintenance for condition 1, 2, 3 and 4; Stop coal crusher to clean debris or jammed coal 4. Uneven feeding caused uneven wearing to ring hammer 5. Hard foreign material or coal jam in coal crusher Bearing over 1. Operation with big load for a long time temperature 2. Inadequate or deteriorated lubrication oil 3. Excessive lubrication oil that reduced the bearing clearance too much 4. Bearing damaged 1. Adjust the load 2. Contact maintenance 3. Contact maintenance 4. Contact maintenance Continuous 1. Unbreakable foreign materials entered 1. Stop for treatment knocking sound 2. Screen plate flexible and knocked by Page 95 of 160 in coal crusher hammer 2.3. Contact maintenance 3. Hammer shaft over worn Output obviously decreased 1. Uneven feeding 1. Adjust the coal amount on belt 2. Inadequate crushing clearance 2.3 Contact maintenance 3. Screen holes jammed Coal crusher 1. Excessive water content or coal amount jammed 2. Debris entered 3. Coal feeding chute jammed or the next stage belt slides 2.2.7 Inclination Variable Isochoric Roller Screen 2.2.7.1 Specifications Data 2.2.7.2 Number Width Model mm BDS-12Ⅲ14 12 1400 Capacity 2. Stop for clearance 3. Remove sliding or coal jam Granularity Efficiency mm 1250 1. Adjust the output 30 % 90 Drive form Chain Mass kg 10800 Application Roller screen is the screening device used in coal handling system for thermal power plant. After screening, coal pieces smaller than the screen holes fall into the equipment below screen, and pieces bigger than the screen move forward on the screen and were entered into coal crusher. Roller screen is used to prevent coal jam, which is applicable when water content in raw coal is heavy. BDS type inclination variable isochoric roller screen, which is developed on the basis of common roller screen, has higher performance, wider application and better adaptability to materials. 2.2.7.3 Work principle and structure The inclination variable isochoric screen is a new type of screen plate design based on isochoric screening. The section by section screen plates are composed of several screen shafts, which form a cross inclination sectional screen plate with the decreasing inclination on each section along the feeding direction. Materials that entered into the screen will first be quickly separated on the bigger inclination section, and then flow to the secondary inclination and small inclination screen plates to be fully separated. Page 96 of 160 Small material will directly pass the screen, and big blocks will be discharged to outlet. BDS inclination variable isochoric roller screen is designed into two sections of screen plates with different inclinations. Wherein, the screen closed to coal falling part has bigger inclination, with 20-30°of plate angle near coal feeding mouth, and the inclination has material outlet is 5-15. Unit with bypass systems make it easier to inspect the rolling of turbine, to make it more convenient for the maintenance of roller screen. The distribution plates will actuate through the electric thrust rod. 2.2.7.4 2.2.7.5. Main characteristics: 1. The inclination of screen plate at the intake section is big, which force the material to flow quickly into the next section and eliminated the jam or block caused by accumulated coal. 2. The speed of material slows down in the process when the screen plate inclination decreases, and material will be gradually separated on each section and form approximate isochoric screening. 3. As the material flow gains speed due to increased screen plate inclination, unit screening capacity increased, which improved the systematic efficiency. 4 The increased natural flowing speed of material reduced the possibility for materials to stick together, and since the front section screen (intake section) which has the biggest sticky possibility is designed with large screen shaft distances, penetration was improved to reduce the jamming and sticky possibility to a maximum extend. 5. It adopts big hexagon type screen plate, and adjacent screen plates forms a screening hole too. This type of screen plates can remove the stuck coal on the shafts automatically, which considerably reduced the possibility of jam and increased screening efficiency. 6. Add shaft cleaner according to the water content of the coal to reduce the coal which may stick on the shaft under overvalued water content. 7. It adopts full sealing casing which causes limited dust. 8. It adopts chain type driving, which makes a simple, safe and reliable driving system that is convenient for repair and maintenance. 9. It adopts ZG40M n 2 screen plate with wearable and durable life span. Commissioning Commissioning of the roller screen are divided into no-load operation and loaded operation. a No-load operation 1). Check and remove the tools, steel parts or other substances on the screen plate. Page 97 of 160 2). Recheck whether the lubricated parts were properly lubricated lubrication agent. with enough 3). Operate the turning gear to manually rotate the screen shaft for a circle. Make sure there is no blocking on any rotary part. 4). Connect the power supply and inching once after the preparation works are finished, in order to make sure whether the rotary direction of screen shafts is correct, i.e. make sure the materials on the screen surface will move to direction of outlet. Incorrect direction requires an immediate modification to the motor connection. (5) Inching the power supply for several times and continue to operate if it rotated normally. No-load test running should last for 2 hours, and stop the system if there is any abnormal condition to check and resume before reactivate. b. Loaded test running (1) Loaded running can be carried out two hours later than no-load test running. (2) Startup the roller screen and gradually increase the feeding rated processing ability. amount until (3) Observe the operation condition of the device during load increasing, stop and handle the abnormal condition if any. Remove all the residual material in the screen before restart up. (4) Stop feeding during normal shutdown and wait until the coals are exhausted before shutdown. (5) Loaded operation should last for more than 1 hour. 2.2.7.6 Operation specifications 1. Put the change-over switch on the local control panel to MANUAL position. 2. Sequentially start up the roller screen after the belt conveyor and coal crusher were normally started. 3. Stop the roller screen 30 seconds after the upstream belt conveyor had stopped. 4. Put the control switch to REMOTE CONTROL position after process was finished. the shutdown 5. Put the interlock switch onto LOCAL position when the roller screen needs to be directly startup for maintenance or other purpose, inform the remote control operators to take safety measures in advance. 6. Start up without load when using the roller screen and feed coal after it enters into normal operation. Keep an even feeding and do not increase the feeding amount suddenly. Page 98 of 160 7. Do not stop the machine with load if there is no special condition. Stop feeding before shutdown, and wait all the coals are removed. 8. Before restart up after emergent shutdown under loaded operation, remove the coals manually and then inching several times to start. 9. Keep the lubricated parts in good lubrication condtion. Lubricate the gear box according to the manufacturer instruction, and the bearing supporters should be lubricated with dry oil. The gear box should be checked once a month to ensure it is full of dry oil. Lubricated the chains with dilute oil in each week and clean them every half a year. 10. Check and remove the sticking and blockings if any on each shift. 11. Remove the stones stuck into the screen by reversing the motor if it is uneasy to do manual cleaning. 2.2.7.7 2.2.7.8 Preventative measure of roller screen: a. Start up roller screen firstly, and then feeding, the opposite procedure is not allowable. b. After putting roller screen into service, periodically check running state and change lube oil regularly. Roller screen problems and solutions Problems Causes Solutions Roller screen t 1. Foreign material block screen shaft ripped 2. Overload operation. 1.Clear sundries Bearing temperature over high 1.long time high load running 1.Adjust load 2. Lube oil shortage or deteriorated. 2. Ask maintenance repair. for 3. Ask maintenance repair. for 2.Contact maintenance for repair 3. Bearing damaged. Obviously output decreasing 1. Uneven coal feeding. 1. Adjust belt coal flow. 2. Screen plate blocked. 2. Coal block on 1. watery coal and excessive coal screen 2.Foreign matters exist in the Page 99 of 160 Ask maintenance repair. 1. Adjust output. 2.Shutdown for clearing for equipment 2.2.8 Magnetic Separator 2.2.8.1 Self-cooling belt magnetic separator 2.2.8.1.1 Overview The self cooling belt magnetic separator does the natural cooling by the self heat radiation structure; the belt can rectify the off-track automatically, do the center control, continuously iron adsorption and discharge. The automatic iron discharge is carried out by the circulation motion of motor-driven belt together with scraper. The iron separator is totally 5 sets, one at front of ship unloader belt, one at front of C3 belt. The width of iron separator belt at ship unloader and C3 are 1400mm; others are 1200mm wide. Two separators at 2.2.8.1.2 Specifications Specifications of self-cooling belt magnetic separator 2.2.8.1.3 Type RCDD-14T2 Radiation type Natural cooling Belt width 1400mm Hanging height 400mm Excitation power ≤21.0KW Drive power 5.5 KW Magnetic induction 120mT Control cabinet type GLA-D Equipment quantity 5 sets Total weight 8.3t/set Structural principle The self cooling belt electromagnetic separator is composed by permanent magnet, unit support, iron discharge belt, driving pulley, driven pulley, idler and electric gearbox. The motor connects together with the gearbox; the automatic iron discharging is achieved by the belt driven by the motor and the circulating iron discharging movement of its scraper. 2.2.8.1.4 Inspection before operation (1) No "prohibited operation" brand on control cabinet in site, ammeter reading is zero, the power LED is on, voltmeter indication is normal. The position of selector switch is correct, the button indicators are all normal. Page 100 of 160 2.2.8.1.5 (2) No screw loosing and falling off from rotating parts and traveling crane. (3) No impurities on magnetic separator, iron pieces should be cleaned up, fixed flying rings should be firm. No obstacle in crane travel and separator position is correct. (4) Separator power wiring is well and earthing device is in good condition. (5) No block in iron box of separator, no iron accumulation in the entrance. (6) The belt should be checked without tearing, offset, stuck, scratch, and too tight or too loose, joints and disposable iron belt scraper are well-fixed. Startup and commissioning. (1) Switch on power supply, green indicator lamp on the panel of control cabinet turns on showing the cabinet enters standby status. (2) Press the START button, red indictor turns on, voltmeter indication is within rated voltage range. When the ammeter indication goes up to stable value, the cabinet and iron separator was put in normal operation. (3) Iron separator test run should be no less than 2 hours. Only after the separator being supervised and runs normally can it be put into operation for production. (4) Closely observe operation status as well as capability of sucking and throwing iron. The capability and efficiency of main unit can be checked by manually throw irons of different weight and shape to coal material. Adjust the height and obliquity of equipment if necessary. (Too heavy and too sharp irons are not allowed to be put in when performing the test.) (5) After 24 hours continuous trial production, if no problems, the equipment can be put into normal service. 2.2.8.1.6 Normal operation check and adjustment (1) Startup device of separator is in good condition. There is no abnormal noise, no scouring smell; voltage is under limit value; magnetic suction is normal. During operation, pay attention to separator working conditions, operators can leave only after the magnet is running normally. (2) When belt conveyor is running, do not withdraw magnet separator or switch off separator. If the operation is necessary, stop belt first, and then withdraw the separator. (3) Electromagnetic iron separator temperature can not exceed 100℃ when it is in operation. (4) The equipment should be kept clean. But strictly forbid spray water to the separator or clean it with wet cloth. (5) Frequently check bolts connecting magnet and racket is loose or not, if it is, Page 101 of 160 tighten it timely. The self-unloading scraper should be in good condition, change a new one if it is damaged. 2.2.8.1.7 Shutdown and precautions (1) After belt is stop, stop electromagnetic iron separator. (2) During operation, start iron separator first and then start belt conveyor; the shutdown procedure is opposite. (3) During operation of this separator, the current of equipment hot state is lower than that of cold state. (4) Self-unloading belt tension bolts are basically adjusted before delivery; do not adjust the bolts if not necessary. (5) When testing rotary direction of self-unloading belt conveyor of separator, the rotation should not exceed two turns.. (6) Strong magnetic field exists when the iron separator is running so that easily magnetized goods like wrist watch and instrument should not approach it. 2.2.8.1.8 Problems and solutions of self-cooling belt type electromagnetic iron separator Problems Causes Solutions Weakened suck and throw iron capability Hanging height or obliquity is changed. Adjust equipment hanging height and obliquity. Poor contact between terminal box and power cable Cased by vibration of sucking and throwing iron, etc. Serious vibration and unacceptable noise Connection part loose. Retighten the connection points Manual travel crane can not be moved Foreign matters block the rail and stop the traveling wheel, or the rail is deformed. Check the rail and repair. 2.2.8.2 Self-cooling disk electromagnetic iron separator 2.2.8.2.1 Overview Remarks Reconnect the cable. Disc type electromagnetic iron separator is a kind of suspended equipment which can continuously operating with motor-driven single rail travel structure. It is installed two sets. Two sets of disc type iron separators were installed in the middle of C-4AB belts. The two iron separators for C-4AB were equipped with one set rectifier cabinet. The two iron separators runs by turns, which can be operated by centralized control and or local manual control. 2.2.8.2.2 Technical specifications Page 102 of 160 2.2.8.2.3 Equipment type PDC-12T2 Heat radiation type Natural cooling Belt width 1200mm Hanging height 350mm Excitation power ≤17.6KW Electric car power 0.8KW Magnetic induction density 120mT Control cabinet type GLA-XⅢ Equipment amount 2 sets Equipment total weight 5.3t/set Working priciple When the magnetic separator is activated, the iron articles in the material will be aspirated quickly by the magnetic field force. When there is a certain amount of the aspirated iron, move the Magnetic separator out of the belt, cut the power, discharge the iron to the abandon iron hopper, then go back to the upward of the belt, reset the power supply in order to remove the iron article. 2.2.8.2.4 Working characteristics The self cooling disk electromagnetic separator does the natural cooling by its self heat radiation structure; it has the small volume, good heat radiation and electric iron discharging control, it also can use the program or the manual control to achieve the iron adsorption and abandon of the Magnetic separator. 2.2.8.2.5 Check and preparation before startup (1) Check connection of both sides of hanging device is reliable; all screws, suspending ring of hoisting structure must be firm and complete. (2) The preliminary hanging height of iron separator is ≤300mm(measuring as per assemble drawing). If angle of inclination is necessary, the height should be ≤300mm, the obliquity check is also necessary. (3) Align the apogee of the ejected coal at the coal discharger head to the center of magnetic field as possible. (4) Check acousto-optic alarm system is available or not by deliberately make small troubles. (5) Servo travel mechanism, rail insulation rubber layer and protective plate should Page 103 of 160 be firm and complete. 2.2.8.2.6 Startup and commissioning. (1) Switch on power supply, green indicator lamp on the panel of control cabinet turns on showing the cabinet enters standby status. (2) Press the START button, red indictor turns on, voltmeter indication is within rated voltage range. When the ammeter indication goes up to stable value, the cabinet and iron separator was put in normal operation. (3) Iron separator test run should be no less than 2 hours. The separator only can be put into operation for production after it is being supervised and which runs normally (4) Closely observe operation status as well as capability of absorbing and throwing iron. The capability and efficiency of main unit can be checked by manually throw irons of different weight and shape to coal material. Adjust the height and inclination of equipment if necessary. (Too heavy and too sharp irons are not allowed to be put in when performing the test.) (5) After 24 hours continuous trial production, if no problems, the equipment can be put into normal service. 2.2.8.2.7 Normal operation check and adjustment (1) Startup device of separator is in good condition. There is no abnormal noise, no scouring smell; voltage is under limit value; magnetic suction is normal. During operation, pay attention to separator working conditions, operators can leave only after the magnet is running normally. (2) When belt conveyor is running, do not withdraw magnet separator or switch off separator. If the operation is necessary, stop belt first, and then withdraw the separator. (3) Electromagnetic iron separator temperature can not exceed 100℃ when it is in operation. (4) The equipment should be kept clean. But strictly forbid spray water to the separator or clean it with wet cloth. (5) Frequently check bolts connecting magnet and racket is loose or not, if it is, tighten it timely. The self-unloading scraper should be in good condition, change a new one if it is damaged. 2.2.8.2.8 Shutdown and precautions (1) After belt is stop, stop electromagnetic iron separator. (2) During operation, start iron separator first and then start belt conveyor; the shutdown procedure is opposite. Page 104 of 160 (3) During operation of this separator, the current of equipment hot state is lower than that of cold state. (4) Strong magnetic field exists when the iron separator is running so that easily magnetized goods like wrist watch and instrument should not approach it. 2.2.8.2.9 Fault and Solution Problems Causes Solutions Weakened suck and throw iron capability Hanging height or obliquity is changed. Adjust equipment hanging height and obliquity. Poor contact between terminal box and power cable Cased by vibration of sucking and throwing iron, etc. Serious vibration and unacceptable noise Connection part loose. Manual travel crane can not be moved Dolly band-type brake over tight. 2.2.9 As received Coal Sampling Device 2.2.9.1 Overview Remarks Reconnect the cable. Retighten points the connection Remove rear end hood of motor fan, loose the fixing screw. The brake should be adjust to the point that after the motor is power off, the dolly still can move forward 50-150mm. The is only for motor-driven dolly. This coal sampling device is scraper type, the scraper take coal samples from belt accurately. The scraper is driven by motor via gearbox. The increase or decrease of sample depends on sampling frequency of each cycle, i.e. time span decide quantity of samples. Middle sampling device of as received coal is installed on C-1A belt conveyor at T-0 transfer station, which are totally 2 sets. The sampling device is mainly composed of sampling machine, coal feeder, crusher, divider, sample collector, bucket elevator as well as electrical control system, assemble platform, and complete enclosed unit control room. The excess coal will drop to C-1A belt conveyor. 2.2.9.2 Technical specifications Page 105 of 160 2.2.9.2.1 Sampling (material feeder) Type SF-40C SF-65C 2.2.9.2.2 Line Speed (mm) (m/s) 400 0.015~0.25 50~150 adjustable adjustable 0.015~0.25 25~100 adjustable adjustable 650 Power Drive Collocation (kw) 1.1 UDY1.1-XW4/43 1.5 UDY1.5-XW5/43 Rotor spec Input granularity Output granularity ≤ mm ≤ mm Motor Type Hammering Power Capability t/h HJC0302 300×200 50 3 Y112M-4 4 KW 2 HJC0403 400×300 150 6 Y132M-6 5.5 KW 6 HJC0404 400×400 150 6 Y200L2-6 22 KW 9 Power Power Device Coal sample reduction Typ e Suitable belt width (mm) RSDL-40 2.2.9.2.4 Door Height Crushing Type 2.2.9.2.3 Belt Width 400 Hatch size Line speed (m/s) (kw) 0.724 0.75 (mm) 38~50 Brake Motor Reducer Coal feeding (each belt coal feeder is listed) Type Belt Width Line Speed Door Height (m/s) Power (kw) Drive Collocation (mm) SF-40C 2.2.9.2.5 400 0.015~0.25 50~150 adjustable adjustable Sample collector Page 106 of 160 1.1 UDY1.1XW4/43  Ty Number Cubage(Li tre) Power (KW) 6 25 0.75 pe SC-R6 2.2.9.2.6 Drive Device Brake Motor Reducer Coal returning equipment (bucket elevator) Hoisting Height 2.16~28.16 m Transport Capability 1.33 m 3/h Cubage of hopper 0.2 L Run speed of hopper Reducer Motor 0.79 m/s Type Power 2.2.9.2.7 BWD 1.1~11/17 1.1 KW Electrical part Operation mode: Auto/manual/semi-auto Operation system functions: a) interlock b) delay startup and delay shutdown c) running period 30s adjustable Equipment total power:   25kw Power supply: 400VAC 50HZ Operation mode: Auto/manual/semi-auto 2.2.9.3 Check and preparation before startup 2.2.9.3.1 Check system equipment is finished and the single test running is eligible. 2.2.9.3.2 Check safety facility is finished firmly and reliably. 2.2.9.3.3 Make sure distance between cutter and belt is 13mm. 2.2.9.3.4 Check the tablet getting close to switch, and the power supply is connected the moment the cutter gets off the belt on the rear part of cutter. 2.2.9.4 Startup and commissioning 2.2.9.4.1 Manual Operation 2.2.9.4.1.1 Put “auto, stop, manual” on front panel of the sampling control cabinet to “Manual”. Page 107 of 160 2.2.9.4.1.2 Start up bucket elevator, collector, splitting device, coal crusher, primary material feeder and sampler in sequence. 2.2.9.4.1.3 The system equipment should be running without load for 2 hours after being normal. 2.2.9.4.2 Programmed controlled operation 2.2.9.4.2.1 Put “auto, stop, manual” on front panel of the sampling control cabinet to “Manual” after the unload-running is finished. 2.2.9.4.2.2 Press AUTO STARTUP button and system begins program-controlled running. 2.2.9.4.2.3 Interlock test: during system operating, disconnect the power supply for any equipment in the system or send the emergency signal, the main power supply should be disconnected and the equipment before the emergency equipment should be stopped, but the equipment behind the emergency equipment should keep operating. 2.2.9.4.2.4 System sequence startup sequence Equipment Allowed conditions Motor three ways System is in automatic state and motor three way has no emergency. Crusher Bucket elevator is running, startup is delayed and the splitting device has no emergency. Dredging device During crusher operating, interval operating after initial sampler is acting, and the dredging Material feeder During crusher operating, the startup is delayed and the material feeder has no emergency. System operating During material feeding, the system operation signal is sent out and the signal light is on. Initial sampler Sealing tape device is operating, and the material feeder is running and the initial sampler has no emergency. System clearing a. During system operation, press CLEANING STARTUP or the transmitter is stopped. b, When the cleaning emergency happens or collector is full Splitting device Interval running after initial sampler is acting and the splitting device has no emergency. Sample collector If the present collector sample number reaches to the pre-set value, it is automatically moving to next tank and the sample collector has no emergency. Page 108 of 160 2.2.9.4.2.5 Cleaning process 2.2.9.4.2.5.1 Press the CLEANING button when system is in operation to perform cleaning. 2.2.9.4.2.5.2 Stop the main belt when system is in operation. 2.2.9.4.2.5.3 During system operation, there are failures that can be corrected by cleaning, such as primary sampling scoop failure, feeder failure, crusher failure, divider failure, collector failure, and failure resulting from coal blockages. During cleaning process, stop primary sampling device while keeping the other devices in operation for ventilation. 2.2.9.4.2.6 System alarm Sampling system failures will be indicated on the operation panel. When one device fails, the upstream equipment will be shutdown and downstream equipment will continue running to ventilate the system. After causes have been ascertained and corrected, the alarm reset button must be pressed to restart up system and to reset alarm circuit. The information that shall be indicated on the touch panel is as follows: Primary sampling probe failure 2.2.9.4.2.7 Feeder failure Clogged coal induced failure Crusher failure Unblocker failure Divider failure Sample collector failure Operation with load 2.2.9.4.2.7.1 Open the bucket elevator three-way damper and ensure that it is in the correct position. 2.9.4.2.7.2 When coal is on a belt which has a sampler, start up the sampler by program control. 2.2.9.5 Checks and adjustments during operation 2.2.9.5.1 Check to ensure that the blade of sampler is not too close to the belt to prevent belt wear. Adjust when necessary. 2.2.9.5.2 Check to ensure that the lube oil in the primary feeder gearbox is of appropriate quality and that oil level is normal. The belt should not be off-track. Adjust the take-up unit if necessary. 2.2.9.5.3 When particle size increases, check the crusher hammer. If it is seriously worn, replace it. 2.2.9.5.4 There are oil holes and air plugs in the collector driving device. The gearbox should be filled with standardized gear oil. Check oil level is normal. 2.2.9.5.5 Check that the bucket elevator does not vibrate and is not overheated; there is no friction between bucket edge and casing; the gearbox oil quality and level are both correct. 2.2.9.6 Shutdown and precautions Page 109 of 160 2.2.9.6.1 Stop the sampler after the coal feeder belt is shutdown. 2.2.9.6.2 Press the stop button when carrying out program shutdown. Manual shutdown should be done in the opposite order of manual startup. 2.2.9.6.3 Confirm there is no coal in the equipment when stopping manually to avoid an on-load startup in the future. 2.2.9.7 Faults and solutions Faults Causes Feeder belt goes off Belt is too loose track Solutions Adjust take-up unit Coal sample in collector Upstream devices or divider Start up unblocker. If fails becomes less or non- sampling pipes are blocked to start up, dismantle and existent inspect. Crusher started cannot be Coal is too wet or blocked by Disassemble crusher and foreign matter clear 2.2.10 Mechanical Sampler of As-Fired Coal 2.2.10.1 Overview A scraper type sampler is used to sample the as-fired coal. The sampler scraper precisely takes samples from the conveying belt. It is driven by a braking motor via a gearbox. Sampling increase or reduction can be done by changing the number of samples taken during each time frame, i.e. time intervals. There are two as-fired coal intermediate section mechanical sampling systems installed on the C-5AB belt inside the crusher room. The sampling device mainly comprises sampler, coal feeder, crusher, divider, collector, bucket elevator, electrical control system, installation platform, and wholly-sealed unit control chamber. The remaining particles directly fall onto the C-5AB conveyor. 2.2.10.2 Technical specifications 2.2.10.2.1 Sampling section Model SWAX100-00 Sampling frequency 180 times/batch (one batch is 8000t) Sampling frequency per hour 1-120 adjustable Size of sampler opening 150 mm Sampling speed 5 m/s Sampling intervals adjustable Page 110 of 160 2.2.10.2.2 2.2.10.2.3 2.2.10.2.4 Capacity of each sample 13 kg Rotating speed of sample scoop 61 RPM Linear speed 3.03 m/s Power 4 KW Crusher Model PSM-00 Crusher type reactive type Output 0- 2t/h Speed 1460RPM Motor type Y132M-4 Motor power 7.6 kW Inlet granularity 60 mm Outlet granularity 6 mm Division part Divider type RD-38-00 Divider mode: rotary type Sampling frequency per hour adjustable (6 times of the preliminary sampling) Divider opening size 40mm Sampling interval adjustable Division ratio 1:10-1:00 adjustable Rotational frequency 23RPM Motor power 0.26kw Electrical motor type R37DR63L4/BMG-M2 Cut width 28mm Particle size 10mm Coal supply (for each belt) Page 111 of 160 2.2.10.2.5 2.2.10.2.6 Equipment type JGP360J-00 Belt with skirt board: 360×6×2090mm (interal circumference) Output   0-2t Material particle size: ≤60mm Drive unit type: SA67/DT80K6/T Rotating speed: 4.1RPM Power: 0.37KW Speed: 0.032m/s Drive pulley: steel linearφ160×400 Driven pulley steel linearφ160×400 Sample collector: Equipment type: RSC4/8-00 Whole power 0.37KW Rotational frequency 2.1RPM Electrical motor type RCL60-30XLY-0.37-1-23 Sample bucket capacity 10L  Number of sample buckets: 4 Coal-returning equipment (bucket elevator) Bucket elevator type: TD-100-00        Output:  0-4m 3/h Bucket width: 100mm Bucket capacity : 0.16L Buckets pitch: 200mm Belt speed 1.4m/s Drive pulley: φ400 Driven pulley: φ316 Motor power: 2.2KW Page 112 of 160 2.2.10.2.7 Electrical part Operation mode : automatic/manual/semi-automatic Operation system functions: a) interlock b) delay startup & delay shutdown. c) operation cycle: adjustable per 30s. d) can run continuously Total equipment power: 26kw Electric power supply 400VAC 60HZ Control mode automatic/manual/semi-automatic 2.2.10.3 Checks and preparations before startup 2.2.10.3.1 Ensure the complete installation of the equipment and single unit test runs are passed. 2.2.10.3.2 Ensure the thorough and tight installation of the safety facilities. 2.2.10.3.3 Ensure the safe separation of 13mm between cutter and belt. 2.2.10.3.4 Check the sensitive panel near the switch. Make sure it is power-on behind the cutter as soon as it passes the edge of the belt. 2.2.10.4 Startup and test run 2.2.10.4.1 Manual operation 2.2.10.4.1.1 Put the AUTO, STOP, MANUAL switch on the panel in front of the sample control panel to MANUAL. 2.2.10.4.1.2 Start up successively the bucket elevator, collector, divider, crusher, primary feeder and sampler. 2.2.10.4.1.3 The equipment in the system should be operated for 2 hours with no-load after it is found to be in normal condition. 2.2.10.4.2 Program operation 2.2.10.4.2.1 After no load running, put the AUTOMATIC, STOP, MANUAL switch on the panel in front of sampling control cabinet to AUTOMATIC. 2.2.10.4.2.2 Press the AUTO START button. The system will start running in program operation. 2.2.10.4.2.3 Performing the interlock test: during operation of the system, cut the power supply or send a fault signal to any equipment. The equipment upstream of the equipment being tested should immediately stop operating. The equipment downstream should running continue. 2.2.10.4.2.4 System sequential start program Page 113 of 160 Equipment Allowable conditions Motorized 3-way valve System in automatic state; motorized 3-way valve fault-free Crusher Bucket elevator in operation; delayed start; divider fault-free Unblocker Crusher in operation; staggered operation are initial sample, unblocker fault-free Feeder Crusher runs, delayed start, fault-free feeder System operation Feeder runs, system operation signal outputs, signal indicator on Primary sampler Rubber belt runs,feeder runs,beginning mining machine faultfree System cleaning a. System runs, press CLEANING START button or shut down the conveyor; b. Faults requiring cleaning or all collection tanks full Divider Intermittent operation after activation of primary sampler; no fault in the divider Sample collector Sample number of collection tanks reaches to preset value, moves to next tank automatically; sample collector fault-free 2.2.10.4.2.5 Cleaning program 2.2.10.4.2.5.1 Press the cleaning button when system is running. 2.2.10.4.2.5.2 Main belt stops when system is running. 2.2.10.4.2.5.3 If there are some faults of system that need to be removed (sampling scoop fault, feeder fault, crusher fault, divider fault, collector fault, coal jamming fault) when system running. During cleaning, primary sampler stops sampling, but the rest of the equipment continues running to clean out the system. 2.2.10.4.2.6 System Alarm Sampling system fault will display fault information via using operation panel. When occurs fault, the upstream equipment will be shutdown and the downstream equipment will continue running to empty system. After ascertaining and removing the alarm causes, push the alarm reset button to restart system and reset the alarm circuit. The information that shall be indicated on the touch panel is as follows: Primary sampling probe fault Clogged coal induced Feeder fault Crusher fault Page 114 of 160 Unblocker fault Divider fault Sample collector fault fault 2.2.10.4.2.7 Operation with load 2.2.10.4.2.7.1 Open the bucket elevator three-way damper and ensure that it is in the correct position. 2.2.10.4.2.7.2 When coal is on a belt which has a sampler, start up the sampler by program control. 2.2.10.5 Inspection and adjustment during operation. 2.2.10.5.1 Check to ensure that the blade of sampler is not too close to the belt to prevent belt wear. Adjust when necessary. 2.2.10.5.2 Check to ensure that the lube oil in the primary feeder gearbox is of appropriate quality and that oil level is normal. The belt should not be off-track. Adjust the take-up unit if necessary. 2.2.10.5.3 When particle size increases, check the crusher hammer. If it is seriously worn, replace. 2.2.10.5.4 The driving device of collector has oil filter hole and vent plug. The gearbox can be filled with standard gear lube. Check lube level promptly in order to ensure lube level is normal. 2.2.10.5.5 Inspect to ensure there is no vibration and overheating for elevator burner and no friction between bucket and shell. Additionally, make sure lube quality and lube level of gearbox are normal. 2.2.10.6 Shutdown and precautions 2.2.10.6.1 Stop operating sampler after coal conveyor stops. 2.2.10.6.2 There are oil holes and air plugs in the collector driving device. The gearbox should be filled with standardized gear oil. Check oil level is normal. 2.2.10.6.3 Check that the bucket elevator does not vibrate and is not overheated; there is no friction between bucket edge and casing; the gearbox oil quality and level are both correct. 2.2.10.7 Faults and Solutions Faults Feeder belt goes off track Causes Belt is too loose Solutions Adjust take-up unit Coal sample in collector Upstream devices or divider Start up unblocker. If fails to becomes less or non-existent sampling pipes are blocked start up, dismantle and inspect. Page 115 of 160 Crusher cannot be started 2.2.11 Electronic Belt Scale 2.2.11.1 Overview Coal is too wet or blocked by foreign matter Disassemble crusher and clear In order to calculate the quantity of as-received coal and as-fired coal, electronic belt scales are installed respectively on belt conveyors C-1A and C-5A/B. Working principle is as follows: belt scale consists of three main parts: weighbridge, speed sensor and integrator. The weighbridge of sensor with load can transfer the weight of materials on the belt into a voltage output signal that is directly proportional to the belt load. Speed sensors supply a series of pulses. Each pulse represents one unit length of a belt in operation. Pulse frequency is directly proportional to belt speed. The integrator receives signals from the load sensors and speed sensors and converts them to a digital signal. It gets parameters via microprocessor calculations. Weight signals are outputted by integrating load signals and speed signals. 2.2.11.2 Technical Specifications Parameters Rated output of coal handling system Parameter Data Parameters Parameter Data Trough C-1A belt conveyor 2000(t/h) Support idler unit C-5A/B belt conveyor 1000(t/h) Idler trough angle 35 Precision of ±0.25 (%) Idler diameter 108(mm) Belt conveyer scale Dimensions of belt conveyor Widt h C-1A 1400 (mm) C-5A/B 1200 (mm) Speed Control mode 2.2.11.3 3.5 (m/s) Program and local control Installation location On C-1A , C5A/B belt conveyors Power supply 220V 50HZ Quantity Checks and preparations before startup: 1) Check for dust and coal deposits on weighing bridge. 2) Check whether there is any coal or foreign matter stuck on the belt. 3) Check if there any changes to belt tension. Page 116 of 160 3 4) Check whether the reading on the indicator is zero. If not, adjust it to zero. 5) Set the span or set it to automatic mode. 2.2.11.4 Startup and commissioning 2.2.11.4.1 Close the power supply switch. Carry out the following operations if the power supply is in normal condition. 2.2.11.4.2 Defined total unit: Default unit: ton; optional unit: kilograms 2.2.11.4.3 Selection ratio units: Default unit: t/h; optional units: t/h, Kg/h, % 2.2.11.4.4 Defined maximum weighing volume ratio: tacit: default 10.0; minimum 1.0; maximum: 200,000,0. Select maximum volume ratio, choose weighing indexing: standardized: 1 option: 0.1, 0.01, 0.001, 1 2.2.11.4.5 Speed inputting category: default – external; option - outside, analog. 2.2.11.4.6 Choose standardized model: default, electronic setting: electronic setting, chain setting, weight setting. 2.2.11.4.7 Input standardized constant: maximum 1000, minimum 0, default 1 2.2.11.4.8 Carrying out displaying zero and span setting/ 2.2.11.4.9 Start up belt conveyer scale 2.2.11.5 Checks and adjustments during operation 2.2.11.5.1 Check whether there is any dust or coal accumulated on the weighing bridge. 2.2.11.5.2 Check whether there is any coal or foreign matter stuck to the belt. 2.2.11.5.3 Check whether the coal on the belt is evenly spread. Maintaining uniform conveying is a key condition for accurate measurement. 2.2.11.5.4 Check whether the take-up force of the belt changes. 2.2.11.5.5 Check whether the indication displayed is normal, and check and calibrate. 2.2.11.6 Shutdown and precautions 2.2.11.6.1 Belt conveyor scale can be shutdown only after the conveyer has stopped running. 2.2.11.6.2 Check whether there is any dust or coal deposits on the weighing bridge after shutdown. 2.2.11.6.3 Check whether there is any coal or foreign matter stuck to the conveyor belt. 2.2.11.6.4 Check whether the take-up force of the belt has changed. 2.2.11.6.5 Clean the belt and weighing bridge. 2.2.11.7 Trouble shooting and fault prevention Page 117 of 160 2.2.11.7.1 When there is a large difference between the displayed indication and the actual value, it is necessary to check whether zero shifting or span displacement has happened to the belt scale system. 2.2.11.7.2 The main reasons for zero shifting are as follows:  dust or material accumulated on the weighing bridge;  material stuck to conveyer belt;  uneven conveyer belt;  belt lengthened due to temperature characteristics of the material;  electric measurement component become invalid. Correct the fault based on the causes. 2.2.11.7.3 The main reasons for span displacement are most likely:  changes in tension of the conveyer belt;  increase or decrease in speed sensor rollers;  overload of pressure measuring elements;  fault in electronic measuring component. Correct the fault based on the causes. 2.2.12 Non Magnetic Metal Detector 2.2.12.1 Overview The magnetic separator only removes magnetic metal. It does not remove nonmagnetic metals such as manganese steel and copper clad aluminum. In order to keep as-fired coal free from metals, two sets of non-magnetic metal detectors are in located in the middle section of the C-4AB conveyor belt and behind the magnetic separator. They are used to detect non-metals in the coal, preventing non-metals entering the boiler and ensuring safe operation. 2.2.12.2 Technical specifications No. Parameter Data 1 Model LJT-12 2 Supply voltage ~230V±10% 3 Whole machine power ≤20W 4 Adaptive relative humidity 85% (40℃) 5 Adapt ambient temperature -10℃ - 40℃ Page 118 of 160 50HZ 6 Particle size <400mm 7 Material character ≤60% 8 Adaptive belt speed 0.8 - 4.0m/s 9 Adaptive width 1200mm 10 11 Base vibration range of <0.5mm sensor Sensibility Able to detect copper, aluminum, and other kind of non-magnetic metal object larger than 10mm. 12 Weight 15Kg 13 Location On C-4AB belt conveyer and behind magnetic separator 14 Quantity 2 2.2.12.3 Inspections and preparations before startup 2.2.12.3.1 Check the sensor has been fixed on conveyer frame and the instrument box has been fixed on wall space or frame. Check the position and stableness. 2.2.12.3.2 Ensure the following: secure power source, correct wiring connections in instrument box, and indicators in good condition. 2.2.12.4 Startup and commissioning 2.2.12.4.1 Put metal detector output control and interlock with belt conveyor into operation. 2.2.12.4.2 Open the box door. Close the power supply switch. The panel power indicators will turn on. After 30s, the detector will start operating. 2.2.12.4.3 Adjustment of sensibility: the user can adjust the sensibility based on the site condition. On the upper side of power panel, there is a needle potentiometer (2w1). Turn it clockwise to increase sensibility and vice versa. 2.2.12.5 Inspections and adjustments during operation. 2.2.12.5.1 Make sure the indicating signals on the panel work normally. The left indicator is the power indicator, which is always on when the equipment is operating. The right one is the signal indicator, which is always on and activates the output relay. 2.2.12.5.2 Inspect the LED level indicator. There is a row of LED indicator lights in the middle of the board which show the level signal when metal pass by the sensors. When the green indicator on the left section turns on, it means the noise signal system or some metals have been detected. When the red indicator on the right section turns on, it shows there is a harmful metal signal. Page 119 of 160 2.2.12.5.3 Pick metals out immediately when instruments detect harmful metals and alarm. 2.2.12.6 Shutdown and Precautions Only when the C-4AB belt conveyor shuts down can the metal detectors be stopped. Open the power switch. The indicator turns off. The detector stops working. 2.2.12.7 Faults, Solutions and Preventive Measures No. Fault Cause Solution prevention 1 Metal in the coal can still be detected and make the alarm sound. Too low detector sensitivity. Re-adjust. 2 3 4 5 and Sensors experience fault in pickup, Repair or replace. amplification, separation and transmission of signals. Faults in apparatus box, wiring, or Check alarm. wiring. and replace The alarm Too high detector sensitivity. Re-adjust sounds even if Sensors are installed close to metal Reinstall there is no like roller or electromagnetic magnetic metal in the separator. coal. 6 Faults in sensors, apparatus box, Repair or replace. wiring, and alarm. 2.2.13 Low Noise Anti-Blocking Mechanism 2.2.13.1 Overview The JZF type vibration anti-blocking mechanism is a kind of universal anti-blocking mechanism, using the YZO type vibration motor as the vibration source. It can prevent and eliminate the materials inside the storage hoppers, storage tanks or feeders. It is also the special equipment for anti-blocking equipment like tubular passages and toner hoppers to ensure the clear and smooth flow of material. On the top of the JZF type vibration anti-blocking mechanism is a YZO type vibration motor, and below is a stand, joined together by high strength bolts. The mechanism has high energy, low noise, low energy consumption, long service life and adjustable exciting force. 2.2.13.2 Model Technical specifications Silo Wall Matched mm Vibration Efficiency kg Page 120 of 160 Vibration Frequency Excitin g Foundatio Power n Blot Motor Force kg Opening Length X Width JZF-5 4.5-6 YZO-12-2 0.25 3000 250 124×150 380V 50Hz JZF-6 6-8 YZO-21-4 0.4 1450 500 130×170 380V 50Hz JZF-10 8-10 YZO-31-4 0.75 1450 800 130×170 380V 50Hz JZF-11 10-12 YZO-41-4 1.1 1450 1000 130×170 380V 50Hz JZF-15 15-25 YZO-51-2 2.2 3000 1200 156×180 380V 50Hz 2.2.13.3 Inspections and preparations before startup 2.2.13.3.1 Ensure vibrator bases are installed correctly and tightly. 2.2.13.3.2 Ensure the fixed bolts of vibration motors are all in place, with appropriate wiring. 2.2.13.3.3 Ensure the two symmetrically installed vibration device are 50-100mm apart from each other. 2.2.13.4 Startup and testing 2.2.13.4.1 Start the vibration motor up after inspections, confirming there are no abnormal vibrations and supplying power to the motor control box. 2.2.13.4.2 After two hours of operation without faults, vibration motors will go through an interlock test. If there is a blockage signal, the motor should be started up. When the alarm is activated, the signal will be transmitted to programme control, then the control room will send rapping signal to the rapping control cabinet. This makes the vibration motor rap automatically until the blockage has been removed. Then the blockage device will send the signal to monitor room, where the stoppage of rap signal will be delivered to the control cabinet to stop rapping. Finally, the rapper will be restored to its normal operation. 2.2.13.5 Inspections and adjustments during operation. 2.2.13.5.1 Ensure the fixed parts of rapper are all in place, working properly, and the motor is not overheated. 2.2.13.5.2 The transmission of vibration force generally ranges from 4 to 5 meters. 2.2.13.6 Shutdown and precautions Page 121 of 160 2.2.13.6.1 Stop vibration motors on site or by program control. 2.2.13.5.2 Cut off power supply to control casing during a long time shutdown. 2.2.13.7 Faults and Solutions Description Causes Solutions No rapping Vibration motor faults Check vibration motor Poor rapping Loose vibration parts or Re-fasten and blocked springs foreign matter remove 2.2.14 Coal Feeding Equipments 2.2.14.1 Impeller coal feeder 2.2.14.1.1 It is composed of driving electric motor, excitation speed adjustment clutch , speed reducer, Oldham (double slider) coupling、 conical gear reducer、impeller and moving actuator. 2.2.14.1.2 Working principles of the impeller coal feeder The coal filling progress of the impeller coal feeder is : the electric motor’s moving is controlled by the electric power control box, a series of mechanical driving force , the impeller immersed in the coal gap drives the coal when it is rotating, and after that the coal will be transferred to the belt by feed coal funnel 。The impeller coal feeder can local stop immediately at a point to drive the coal as well as in the condition of moving. it moves forward and backward in the driven of the positive & negativedirection rotation of the one-certain-speed electric motor. 2.2.14.1.3 Inspection before the operation of the impeller coal feeder a. To inspect the coal storage of the coal groove, and to check if some impurities intertwine the impeller b. To see whether the moving orbit is flat, straight, firm and not blocked; whether the moving impeller contacts the orbit surface well and has no out-of-orbit phenomenon. c. The coal driving actuator and moving actuator is both good; the protection cover of the shaft joint is complete and firm. claw. d. the oil level of each speed reducer should be in a normal range; no metamorphism and leakage phenomenon. e. feed coal funnel is unblocked; the coal damper in the bottom of the feed coal funnel should be good; the belt joint surface must be inseparable Page 122 of 160 and has no coal leakage phenomenon. 2.2.14.1.4 2.2.14.1.5 f. The earth line of all the electric motor, the gauges in the operating box, the switch, buttons, and LCD indicator should be all completely good. g. The cable for power supply has no mess overlapping phenomenon,and the cable-driving rolling wheel has no blockage, jam and out-of- orbit phenomenon. h. Every moving switch should be good and their position must be correct. i. The site illumination/ lightening and communication equipment are complete and good; the ash removing equipment should be in good and standby state. Operation of impeller coal feeder a. Close the main power supply switch and LCD indicator will be lighted. b. Select the programmable control mode Program or Local switch on the main control box by following the CCR shift leader’s orders. c. Startup the main electric motor, and at this moment, the adjusting operating machine should in a low-speed position,and it is forbidden to start it up in a high speed. d. After the main electric motor startup, gradually decrease the rotating speed to the needed value. e After the main impeller startup,the moving TV can be start up,and the coal feeder moves forward or backward. f. when the coal feeder changes its moving direction, start up another direction after the moving actuator stops. g. If press the “stop moving” button, the coal feeder will carry out the local pushing coal work. h. when the impeller coal feeder shutdown, first stop the moving actuator, then stop the rotation of coal pushing actuator after adjusting it to be in a low speed. Impeller coal feeder failure and treatment faults Press The Startup Button, But The Electric Motor Does cause 1.Power Supply Is Not Connected 2.Fuse Page 123 of 160 treatment 1. Energize The Power Source 2. Change The Fuse Not Rotate Damaged Rotating Speed Is Out Of Control 1.Controlled Silicon Breakdown 2.Relay Damaged Tell The Electric Maintenance Personnel To Carry On Maintenance Or Change It. 3.Printing Board Electric Circuit Socket Contact Unwell Big Truck Stop Moving 1.Impurities In The Orbit Or The Orbit Deformed 2.Not Restored After The Moving Open And Closed 3.Driving Actuator Failures 2.2.15 Coal Charging Equipment 2.2.15.1. Characteristics of plough materials unload 1. Clean Out The Impurities In The Orbit Or Carry On Maintenance And Regulation On The Orbit. 2.Inspect The Switch And Reset It 3. Tell The Maintenance Personnel To Carry On Maintenance On The Driving Actuator. (1) The material unload employs double-layer structure (major and minor), and the minor one is installed with cleaner of paddy rubber admixture. It has the functions of protecting the belt, no run-out materials, no leakage, and materials unloading cleanly. (2) The driving support is triangle-jointing structured, with the property of compact structure, strong intensity, proper and uniform load-carrying capacity, and pretty appearance. (3) The plough head is bi-adjusting structure, which means the plough head and coulter can be separately adjusted up and down. Page 124 of 160 2.2.15.2. (4) The crane uses adjusting structure, which reduces the phenomenon of run-out belt and quick abrasion of the belt and coulter; it improves the service life of material unload and belt. (5) The roller carrier is lengthened and its number increases to six group, with decreasing space. This design reduces the coulter’s abrasion and material leakage. (6) The material of coulter uses 16Mn, which has the advantage of good durability and long service life. Working principles of the plough –type coal unloader It is driven by an electric pushing rod and carries out its working or non-working state by the electric push rod’s back and forth movement. When the electric push rod pushes out, the driving arm return to lift the roller carrier to a set height (the theory centerline of belt); while the variable angle roller support transits to 0°from the initial angle, at this time the belt is in horizontal state while the plough head falls down to the belt surface to make the coulter tangent densely to the belt and the materials will be discharged statically. In converse, when the electric push rod draws back , and pull the driving arm to make the level roller carrier fall down to the same position with the middle roller in the groove roller support group. The variable angle roller carrier becomes the initial groove angle, at the same time the plough head raise and the material flow pass through normally. Non-working State of Plough –type Coal Unloader Page 125 of 160 Auxiliary plough cutter Working State of Plough –type Coal Unloader 2.2.15.3 2.2.15.4 2.2.15.5 Inspection before the plough-type material unloading operation. (1) No “no operation” tag on the site operating box; each coal plough is in the position of “rise” except the end silo plough which is in the fall-down state (2) Feed coal funnel has no coal blockage or jam,; coal plough is not stick to coals and impurities; air lock valve. The switch of air lock valve is flexible. (3) The coal plough blade should be flat, completely good, not abased seriously, and the link rod does not draw off, and the limit switch is completely good. (4) The couple between the electric push rod end and the plough blade is not draw-off; the driving device is good; the limit switch of “rise” and “down” places well and flexible. (5) Bolts in every parts are not loose and draw-off. (6) The convert switch is in the demand position. (7) The dust proof cover of the electric push rod is completely good. Operation of plough-type material unload (1) The power source switch is closed and the convert switch is in “ local” position. (2) Press the “rise” or “down” button on the site operating box, the coal plough will correspondingly “rise” or “down”. During the process, if need to stop it, just press the “stop” button. Faults and solution of the plough-type material unload Page 126 of 160 Faults Cause Solution The push rod moves unwell or the plough is blocked 1.Motor fails 1.To carry on maintenance and treatment 2.Impuritie s or coals stick to the coal plough 2.Clean out the stick coals and impurities Coal leakage 1. Coal plougher encounter s serious abrasion 3. Push rod is jammed by the couple bearing. 3. When the convert switch or power supply abnormal, ask the electric personnel to solve it. 1.To carry on maintenance and treatment 2.Inspect the limit switch and electric push rod. 2. Coal plougher is not in its position Coal ploughe r is not in its postion 1.Rotating shaft is jamed dead 2.Electric push rod loses functions. 3.Position limit switch loses functions. Page 127 of 160 1.To carry on maintenance and treatment 2.To carry on maintenance and treatment 3. To carry on maintenance and treatment 2.3 Coal Handling Equipment Control 2.3.1 Function and Components of Centralized Control 2.3.1.1 Function of centralized control a. To improve the reliability and safety of system operation; b. To lower workload of labor 2.3.1.2 Equipments in coal handling system: coal feeder impeller, bucket wheel machine, belt conveyer, disk iron remover, belt iron remover, one-sided plow discharger, bilateral plow discharger, sampling instrument, electric damper to three-direction, coal crusher. 2.3.1.3 Components of coal handling remote-control system Coal handling remote-control system is composed of three parts: programmable controller system, upper monitoring system, and industrial television system. 2.3.2 2.3.3 Centralized Control Mode 1) Centralized control: it refers to one-to-one remote operation to coal handling equipments in centralized control chamber. 2) Centralized program control: it refers to only send out startup and shutdown order in centralized control chamber after operation mode is selected, and the selected equipments can startup and shutdown in groups according to programmed process flow. 3) Local manual control: it refers to the operation mode of local single unit startstop equipment. Interlinking Criteria on Centralized Control Equipments: In normal circumstances, start equipments according to reverse coal flow direction, and stop equipments according to ordinal coal flow direction. In single-unit failure circumstances, stop immediately the operation of corresponding equipments according to reverse coal flow direction. The failure equipment continue to operate in order to decrease the possibility of coal blockage and bigger emergency. 2.3.4 The Main Coal Stack Mode for the Coal Handling System 1) Coal unload machine---bucket wheel machine---coal yard; 2) Coal unload machine---coal bunker; 3) Coal yard---bucket wheel machine one---coal bunker. 2.3.5 Inspection and Preparation before Centralized Control Operation 1) Check the handling work record carefully to find out the start-stop and operation condition of system equipments, and tell the watchmen on site to make a comprehensive inspection to equipments which they are in charge when it is in Page 128 of 160 static state. 2) Inspect that the alternate voltage of power supply cabinet in main control chamber is 220 v, and direct output voltage is 24V±15%, alternate branches small switches and direct branches small switches are all connected (including other remote stations) 3) Confirm that the host computer are in work state, and every modules are normal 4) Inspect all of protective relay in relay cabinet is prefered, no protective action. 5) Inspect all of equipments in main flow diagram are in shutdown state. 6) Inspect that the indication of coal level and high coal level in coal bunker is normal, and confirm the indication is identical to the real conditions. If there are any questions, please tell the watchmen on site to confirm. 7) Inspect that all of communication tool is normal. 8) Do the preparation work well before startup: a) Confirm the “remote and local” switch on the “remote”(including every controlled equipments in control chamber and on site). b) Confirm the central power switch in upper machine are connected, if it is stopped, please start up the upper machine. c) Confirm that the driver of coal unload machine and bucket wheel machine have already come. d) Contact with watchmen on site, and confirm that all of the preparation work have been done, and receive the startup response, and then implement remote-control startup operation. 2.3.6 The Start/Stop Operation of Coal Handling Procedural Control 2.3.6.1 The startup operation of “procedural control” 2.3.6.1.1 Move cursor to cancel the “zero position” button, when the main selected flow is “coal feeder”, the coal feeder method should be “procedural control”, and the coal distribution method should be “remote distribution”; when the main selected flow is “coal storage”, the coal feeder method should be “procedural control”. 2.3.6.1.2 Move cursor to click the “clear” button, and then click the “clear distribution” button to make the procedure in the initial state. 2.3.6.1.3 Move cursor to call out “main selected flow” display, choose one branch flow from eight main selected flows according to the operation mode and then the display will pop up this branch flow equipments. 2.3.6.1.4 Move cursor to choose the startup equipment according to the sequential coal flow, and the selected equipment of upper machine will be changed from blue to green. Page 129 of 160 2.3.6.1.5 After choosing is finished, if the upper machine pop up “valid flow”, it indicates that choice is right; if the upper display of upper machine pop up “ wrong flow”, it indicates that the choice is wrong, and it needs to rechoose until the upper display of upper machine pop up “valid flow”. 2.3.6.1.6 When there is a” valid flow” tooltip, move cursor to click “pre-start” button, and the language setting will remind the procedural control worker: “the selected flow damper have already started”, when click “remote distribution” button, it will remind the procedural control worker that: “the end bunker and the end plow falled off, and the other plow is started”; after several minutes, the finished damper will be changed into red, the indicative signals will come out, the indicative information “ startup is permitted” display will be clicked out in the upper display of upper machine. 2.3.6.1.7 If the damper is not in the proper place or the plow have no signal of falling down and lift up, the verbal equipments will remind “unmovable damper” or “unmovable plow”, at this time the watchmen on site should be told to inspect or dispose 2.3.6.1.8 If confirming that the damper have already in the proper place, but the signals is not right, you can move cursor to click the “ damper position” button to make the procedure not check whether the damper are in the proper place or not, click “clear” button, and then click the “”button until the upper display of upper machine pop up “”indication and sent out 2.3.6.1.9 When the “startup is permitted” signals come out, move cursor to click “remote startup” button, the selected flow equipment will be delayed to start up according to reverse coal flow until the last equipment are finished to start up, the “valid flow” and “startup is permitted” disappear; when the equipments is started, the upper equipments of upper machine will be changed from green to red. 2.3.6.1.10 According to the demands of selected flow and startup mode, order properly dumper or bucket wheel machine to pile and obtain coal 2.3.6.1.11 If parallel operation is necessary, one line should be operated according to 2.3.6.2 a The selected equipment should be changed from blue to green, when it is operating, it will turn to red, when one equipment turns out malfunction during operation, this equipment will emit breakdown signals b When click “remote startup” or “advance startup” button, the alarming ring along the line will operate automatically The shutdown operation of “procedural control” The shutdown of “procedural control” can be divided into two ways: one is that the procedure will stop feeding coal automatically in the process of coal feeder; the other is that procedural control watchmen will stop feeding coal or storing coal. 2.3.6.2.1 In the process of “procedure coal distribution”, when the sequential high coal level have been distributed, the upper display of upper machine will open “remote Page 130 of 160 distribution”, meanwhile, the selected flow will be delayed to shutdown according to the coal flow direction from coal supply, when it is shutdown, the procedural control watchmen need to inform the coal piling and obtaining driver of dumper and bucket wheel machine to shut down. 2.3.6.2.2 When the procedural control watchmen stop feeding or storing coal, firstly, order the coal piling and obtaining driver of dumper and bucker wheel machine to shut down, after confirming shutdown, move cursor to click “remote shutdown” button, the display of upper machine will open the window of coal supply shutdown, and then choose the coal supply of flow which need to shut down. 2.3.6.2.3 Move cursor to click “confirm” button, the operation equipments will be delayed to shut down automatically according to ordinal coal flow direction from coal supply, the equipments of upper machine will be changed from red to green after shutdown. 2.3.6.2.4 Inspect all equipments of the selected “remote shutdown” flow have already been shut down. 2.3.6.2.5 If parallel operation is necessary, one line should be operated according to 2.3.6.2.1~ 2.3.6.2.4 Procedures after the other line have already operated normally. 2.3.6.2.6 After all of equipments have been shut down, move cursor, click the display of “main selected flow”, choose the branch flow of shutdown, use cursor to click to clear away the selected equipments, the equipments on the upper machine will be changed from green to blue. 2.3.6.2.7 Move cursor to click “clear”, “clear distribution” button, make the procedure return to the initial state. 2.3.6.2.8 Move cursor to click “”button to cancel the entire control mode of coal feeder and coal storage. 2.3.6.2.9 Before handing over to the next shift, we should record the accumulative count and overload time of every belt scale, and then calculate them. 2.3.6.3 The startup operation of interlink manual control” 2.3.6.3.1 Move cursor to cancel the “neutral gear” button, when the firm main selected flow is “coal feeder”, the coal feeder method should be “interlock”, the coal distribution method should be “procedure distribution”; when the firm main selected flow is “coal storage”, the coal feeder method should be “interlock”. 2.3.6.3.2 Move cursor to click the “clear” button, and then click “clear distribution” button to make the procedure in the initial state. 2.3.6.3.3 Move cursor to open “main option flow” display, according to personal mode, choose one branch flow from eight main selected flow, and this display will pop up the choosing window of this branch flow. 2.3.6.3.4 Move cursor to choose equipments which need to be started up according to the Page 131 of 160 ordinal coal flow, the equipments in host computer will be changed from blue to green. 2.3.6.3.5 After choosing, if the upper display in host computer pop up a “valid flow” tooltip, it indicates that the choice is right; if the display in host computer pop up a “wrong flow” tooltip, it indicates that the choice is wrong, and it needs to rechoose again until the display in host computer pop up “valid flow”. 2.3.6.3.6 When there is a “valid flow” tooltip, there are two ways to operate damper and coal plowing a. The first method: move cursor to click “pre-start” button, at this moment, sound mechanism will indicate procedure-control watchman: “the damper of selected flow is ready”, “procedure distribution” will indicate that: “the plow of coal bunker tail falls down, and the rest plow will lift up. b. The second method: observe the main flow display of host computer, if the selected damper is ready, the ready damper will be changed to red; if any dampers are not ready, after local watchmen check and make sure it is ready, the dampers can be operated, move cursor to open “auxiliary equipment” display, press the manually controlled damper button to make the dampers in the right place; move cursor to open “coal distribution display”, use cursor to make the raw coal bunker fall down and the rest ones lift up. c. If there are no signals of ready damper, the falling plow and the lift up plow, the sound mechanism in host computer will indicate that “unmovable damper” or “unmovable plow”, at this moment, inspectors should be informed to check and handle. d. If dampers is ready, but the signals are not right, move cursor to click “damper position” button to make the procedure not check whether dampers are in right place.(after the flow operation is finished, the “damper position” state should be relieved without delay, and the forcibly fixed method should be used with great delicacy.) e. When the selected flow are right and in the very place, move cursor to start up the head of belt and other equipments according to the reverse coal flow direction, at this moment, the display will pop up the “control and state inquiry” window of these equipments, after the alarming ring sound three times, operate the startup button of equipments, start up the selected belt and equipments in correct order until the startup of the selected equipments are finished. In the process of startup, the following principles should be obeyed: (or it will not be started up) 2.3.6.3.7 a) Preset the position of damper, and then start up the belt feeder. b) Start up magnetic separator, and then start up belt feeder. c) Start up coal crusher, and then start up revolving roll picker. Observe the controlling display of operational signals and ammeter in host computer Page 132 of 160 in the process of startup, and make sure last belts have already started up, and then start next belt. 2.3.6.3.8 According to the firm operational flow to inform the materials piling and taking driver of dumper and bucket wheel machine to operate according to the ruled power. 2.3.6.3.9 If another flow need to started up to carry out “interlock manual control” operation. Repeat 2.3.6.3.3~2.3.6.3.9 operational procedure 2.3.6.4 The shutdown operation of “interlink manual control” 2.3.6.4.1 In the process of “procedural coal distribution”, when the sequential high coal level have been distributed, the upper display of host computer will pop up “ procedure distribution are finished” tooltip, at this moment, the procedure-control watchmen should inform the materials piling and taking driver of dumper and bucket wheel machine to shut down without delay. 2.3.6.4.2 When the procedure-control watchmen stop feeding coal or storing coal, inform the materials piling and taking driver of dumper and bucket wheel machine to shut down firstly. 2.3.6.4.3 After confirming it shut down, move cursor to stop the operational equipment in flow according to the ordinal coal flow direction, after the equipments shut down, the color of equipments in host computer will be changed from red to green: in the operational process of shutdown, the following principles should be obeyed. a. According to the length of belt feeder, calculate the stop time of belt, after confirming through the industrial TV monitoring display, shut down equipments. b. Shut down belt feeder firstly, and then shut down magnetic separator. c. Shut down revolving roll picker firstly, and then shut down coal crusher with delay. 2.3.6.4.4 Checking that equipments in shutdown flow have been shut down. 2.3.6.4.5 If it adopts parallel operation, after one-way equipments have been shut down, choose another way equipments according to 2.3.6.4.1 ~ 2.3.6.4.4 operational procedure. 2.3.6.4.6 After all of equipments shut down, move cursor to call out “main selected flow” display, choose the branch flow of shutdown, use cursor to eliminate the selected equipments, the color of host computer will be changed from green to blue. 2.3.6.4.7 Move cursor to press the “clear”, “clear distribution” button to make the procedure be in the initial state. 2.3.6.4.8 Move cursor to press the “neutral gear” button, cancel all of the coal handling and storing controlling method. 2.3.6.4.9 Before handing over to the next shift, we should record the accumulative count and overload time of every belt scale , and then calculate them. Page 133 of 160 2.3.6.5 The operation of “manual coal distribution” 2.3.6.5.1 Move cursor to call out “equipments maintenance” display, according to the maintenance and breakdown condition to set equipments maintenance, and according to the following condition to set plow maintenance (confirming the coal plowing is in the lift up position before setting) and maintenance bunker(confirming the tail bunker according to the setting of maintenance bunker) 2.3.6.5.2 Move cursor to cancel the “neutral gear” button, and then choose the coal handling mode is “procedural control” or “interlock”, and the coal distribution mode is “manual distribution”. 2.3.6.5.3 According to “procedural control” or “interlock” coal handling control mode to start up the coal handling flow. 2.3.6.5.4 Move cursor to call out “coal distribution display”, and then operate the manual falling and lift up button of coal plowing to make sure the plow of tail bunker in raw coal bunker fell. 2.3.6.5.5 According to the indicating condition of the coal level of host computer, use cursor to click “manual” control button of coal plowing, manually operate the falling and lift up of coal plowing to distribute coal. 2.3.6.5.6 Before finishing feeding coal, we should inform the materials piling and taking driver of dumper and bucket wheel machine to shut down, and adopt the “procedural control” or “interlock manually” controlling mode to shut down one by one. 2.3.6.5.7 Checking the selected equipments in “procedure shutdown” flow has already been shut down. 2.3.6.5.8 If it adopts paralleled operation, after one-way equipments have been shut down, choose another way equipments according to 2.3.6.2.1 ~ 2.3.6.2.4 or 2.3.6.4.1 ~ 2.3.6.4.4 operational procedure. 2.3.6.5.9 After all of equipments shut down, move cursor to call out “main selected flow” display, choose the branch flow of shutdown, use cursor to eliminate the selected equipments, and the color of host computer will be changed from green to blue. 2.3.6.5.10 Move cursor to click “clear”, “clear distribution” button, make the procedure return to the initial state. 2.3.6.5.11 Move cursor to click “”button to cancel the entire control mode of coal feeder and coal storage. 2.3.6.5.12 Before handing over to the next shift, we should record the accumulative count and overload time of every belt scale, and then calculate them. 2.3.6.6 Flow process Switching operation 2.3.6.6.1 The switch of coal supply equipments. Page 134 of 160 a. Shut down the equipments in original flow which need to be switched according to the ordinal coal flow direction. b. Cancel defunct equipments from the selected main flow. c. Rechoose equipments which will be switched, after finishing choosing, move cursor to click “flow switching” button in choosing window of branch flow equipments, if the upper display of host computer pop up” valid flow” tooltip, it indicates that the choice is right; if the display in host computer pop up a “wrong flow” tooltip, it indicates that the choice is wrong, and it needs to rechoose again until the display in host computer pop up “valid flow”. d. Start up the selected flow equipments according to the necessary operating mode. 2.3.6.6.2 8PA、8PB switchover a. Open the display of 8PA (8PB) CONTROL AND STATE. b. Click “ switching to 8PB(or 8PA)”,appear “8PA/B switching control” display; c. Click the “switch” button in“8PA/B switching control” display, it will turn out a red display “8PA is switching to 8PB……”, 8PB(or 8PA)start up automatically. 2.3.6.7 The observation and cautions in the operation of coal handling procedural control. 2.3.6.7.1 The observation and regulations of procedural operation. (1) Before the operation of procedural control, check and inquire the indication of current, coal level in coal bunker, system alarm, and the indication of anunicator window in equipments, pay attention to monitor the direction of damper. In order to understand the operational condition, and carry out production management and treatment disposal. (2) Observing that the coal quantity indicating value of belt scale are changing in rated range, and overload operation in equipments are not allowed absolutely. (3) When adopt the “procedural distribution” mode to feed coal, we should pay more attention to the signals of coal level in order to avoid the happening of overflow and lack of coal and make sure the coal distribution operate in normal state. (4) When the procedural control operates, if the equipments tripped, we should check whether equipments in this flow timely tripped in a interlock manner to coal supply equipments according to reverse coal flow direction, and then inform the drivers of ship unloaders and bucket wheel machine to stop working. If the interlock is abnormal, we should press the “emergency trip” button. After the equipments tripped, we must report to monitor to rechoose flow to start up in the condition of clearing of faults. (5) Checking whether the industrial tv monitoring display is in normal, inquire system alarm, when the fault signals are found, report to monitor without delay, Page 135 of 160 and then inform the maintenance workers to handle. (6) 2.3.6.7.2 When the procedural control operating, we should contact with workers on site in order to adjust the power and manage the production properly. The cautions of procedural control operation. (1) When the procedural control start up, we should monitor strictly the startup current and time of every equipment one by one, when the startup current overpass the needs of startup time, we can press the “emergency trip” button. (2) When the procedural control starts up, we should observe whether the startup procedures of equipments adapt to the set demands of flow. (3) When the procedural control start up, we should observe whether the color of equipments in monitoring display is normal, and observe whether the coal plowing in coal bunker adapt to the demands of “procedural coal distribution”, and the industrial TV monitoring display is normal. (4) When the procedural control start up, if one of equipments can not be started up or trip immediately after startup, we should find out the reasons of faults( inquire through the sound alarm and system faults), and then inform the workers on site to handle , report to monitor after confirming, and then we can rechoose the flow startup. (5) When one of flows or all of flows shutdown, we should check and confirm all of equipments in flow have already shut down, and the ammeter is in zero position. (6) After every shift work stop operating, and then check the variable reading of electrical belt scale. (7) After finishing feeding coal, operate manually every electrical T-pipe action two or three times, eliminate the coal in order to make sure the clear of electrical Tpipe. 2.3.6.8 If the following condition happen in the procedural control operation, shutdown immediately. 2.3.6.8.1 When human injury happen, when the accidents which threatened the safety of people and equipment happen. 2.3.6.8.2 Outbreak of fire in system. 2.3.6.8.3 When the belt is broken, the motor smoke, liquids spout oil and other fault happen 2.3.6.8.4 When sensor is ineffective, or coal blockage, heavy slippage and heavy off tracking and other heavy faults happen 2.3.6.8.5 The signals of belt heavy off tracking, heavy slippage, coal blockage enter PLC and they are not in shunt tripping. 2.3.6.8.6 The faults in system equipments do not trip or do not trip shuntly. Page 136 of 160 2.3.6.8.7 Coal crusher fault When the above faults in system shut down, the procedural control worker should contact with inspectors, handle it actively and cooperatively, and then use the monitoring system to monitor it in fixed point. When faults happen in controlling chamber or on site and it is too late to judge and handle, we can press “emergency trip”button, at this moment, PLC to system equipments send shutdown order, all of equipments will shut down immediately( the coal crusher will be shutted down with delay) 2.3.6.9 The common fault and treatment Fault phenomenon Belt overload Treatment 1.decide whether the follow-up belt should be shutted down according to the real condition. 2. check whether it is caused by more coal or other reasons 3. if it is caused by the former reason, inform the related workers to decrease the coal quantity; if it is caused by the latter reason, we should handle it according to the real condition Main equipments trip 1. confirm the definite reasons 2. inform the related personnel, the system will convert correspondingly Auxliary equipment trip 1. confirm the definite reasons 2. inform the related personnel, the system will convert correspondingly Belt emergency shutdown 1. contact with personnel on site to find out the specific condition and then dispose according to real condition 2. after disposing faults, reposite pulling switch. Belt deviation in first pole 1. remove deviated signals 2. inform personnel on site to allign according to deviated reasons. Belt deviation in second 1. inform personnel on site to find out the reasons of deviation pole 2. remove deviated protective equipment, and start up belt to allign without influencing safty. Relative-movement belt 1. stop belt immediately 2. inform personnel on site to find out the specific Page 137 of 160 reasons and dispose it. belt vertical slitting 1. inform personnel on site to confirm 2. inform maintennace disposal Unmovable damper 1. after the watchmen on site confirming that it can not be eliminated , inform the maintaining workers. Unmovable coal plow 1. Decide whether manual coal distribution or coal source cut-off should be carried out based on the coal level in coal silo. 2. After the confirmation made by operator, inform maintenance personnel for eliminating. Coal mill fault 1. stop the following belt machine immediately. 2. after the watchmen on site confirming that it can not be eliminated , inform the maintaining workers Startup failure Power fault 1. check reasons, if it can not handled, inform electrical maintaining workers. 1. check whether the power fuse is burnt. 2. inform the electrical maintaining workers to find out reasons Coal blockage 1. inform the watchmen to handle according to the specific condition. 2.4 Protection devices of coal handling system 2.4.1 The Formation of Protection Devices of Coal Handling System The formation of protection devices of coal handling system consists of the doublepole switch, two – throw pulling switch, relative-movement detector, speed detector, vertical slitting protective equipments, supersonic wave material level instrument, high and low coal level control instruments, materials flow detector and protective devices of downspouting blockage. 2.4.2 The Double-Pole Switch for Detecting Deviation State of Belt in Belt Conveyer. 2.4.2.1 Function: Through monitoring the deviation state of belt in belt conveyer to send out signals to realize the automatic alarm and shutdown function of belt deviation, this switch have double pole , one is used to alarm, the other is used to shut down 2.4.2.1 Work principle: The working process of the double-pole switch for detecting deviation state of belt in belt conveyer is that the belt touch the contact bar of switch to make it deviate, when it deviates to a the switch will send out alarm signals to control chamber to warn the supervisor on site to take some measures, when it deviates to ß, the switch will send out shutdown signals. Page 138 of 160 2.4.3 Two – Throw Pulling Switch 2.4.3.1 Function: Two-throw pulling switch is one of protective equipments which is used in emergency shutdown of belt conveyer on site. When the emergency happen, pulling switch anywhere on site can shut down it. 2.4.3.1 Work principle and structure features: This switch adopt moving cam wheel structure, when pulling the switch in one side or two sides simultaneously, the cam wheel can be driven and it also can send out shutdown signals and alarm signals simultaneously HFKLT2-Ⅱ-type two-throw pulling switch adopt manual reposition mode.(it refers that after the fault is removed) the controller needs to press downward reposition level so that this switch can be in normal-working state. 2.4.4 D H—Ⅲ Type Relative-Movement Detector 2.4.4.1 Function: D H—Ⅲ-type relative-movement detector is used to detect the relative-movement between belt and driving roller in the operation to avoid vicious events caused by relative-movement, it also can be used in the interlock startup, shutdown, lower speed braking and overspeed protect of belt conveyer which use more than one belt. 2.4.4.2 Work principle: DH—Ⅲ-type relative-movement detector is operating in this way: the belt drive contact wheel to make it reflect the real speed of belt, contact wheel drive transmission shaft of detector to make the inside speed relay work.. the work of relay mainly lies in the inside magnetic material which produce magnetic turning torque through rotating, it will drive moving fork to make the contact produce connecting or break signals 2.4.5 2.4.5.1 DH—S Type Speed Detector Function: DH—S-type speed detector can be used to detect the real time speed of belt in belt conveying working process, it also can be used to detect the real time rotating speed of countershaft in swirling equipment 2.4.5.1 Work principle: DH—S-type speed detector is operating in this way: the sensor head change the detected belt speed and rotating speed into pulse signals and send that into the controlling cabinet, the calculating circuit inside of controlling cabinet will count in unit time, and then make reasonable judgment comparing to the predicted belt speed and rotating speed. If it equals to the predicted belt speed and rotating speed or a little bigger than that, make the control relay absorb, at this time the operating speed of Page 139 of 160 belt is normal; If it is smaller than the predicted belt speed and rotating speed , make the control relay release, at this time the operating speed of belt is lost. 2.4.6 Vertical Slitting Protective Equipments of ZL Series 2.4.6.1 Function: Vertical slitting of belt is a vicious event, Vertical slitting protective equipments of ZL series is fit for the tearing protection of every specification and type sealing-type machine. 2.4.6.2 Work principle: Vertical slitting protective equipments of ZL series can be divided into two kinds: one is controlling cabinet and the other is sensor. The sensor is the detecting device of vertical slitting protective equipment. When the belt of belt conveyer presses B-type sensor during operation after pierced by materials, or when the trap door presses A-type sensor caused by the material blockage between the belt and chute discharging port, these two types of sensors will send signals to control box and send signals of alarm and auto-stop through control circuit. In this way, they function as protecting belt. 2.4.7 Supersonic Wave Material Level Instrument 2.4.7.1 Overview Supersonic wave material level instrument is a new-type measuring instrument for material which is controlled by computer. This equipment employs the return wave range finding theory, and makes use of supersonic wave to measure continuously material in material bunker without touching to supply several signal-type analogue for users Supersonic wave material level instrument can indicate the real-time material level of every bunker, high-level alarm, low-level alarm, overhigh level trip, and overlow level trip, additionally, it also can have networking digital communication with other computers. 2.4.7.2 The advantages and disadvantages of this instrument Ⅲ This instrument can be controlled by computer, the logic judging function is very good, meanwhile, it has the function of finding return wave automatically, window tracking, slow and variable output and etc. Ⅲ The setting of digital switch is convenient. Ⅲ It has AGC and PLL wave filter circuit, the resolving ability of signals is strong. Ⅲ Digital signal control is adopted between indicative cabinet and launching cabinet and it is separated by opto-coupler correctly and reliably, the anti-jamming ability is strong. Page 140 of 160 2.4.7.3 Ⅲ The detector is made by casting special silica gel, it has strong anticorrosive property and permissibility Ⅲ According to the practical experience of the using of material level gage, the inside of instruments is detected in cms, and the indicating analogue output are detected in dms, it is more reliable and practical. Work principle So far, the common-used ultrasonic material level gage has two structures. One of two-state detector structure which can collect and send separately, the other is onestate detector structure which can collect and send simultaneously. They are all using piezoelectric ceramic transductor to operate ultrasonic sending and collecting. When sending, use a electrical signals to stimulate piezoelectric ceramic transductor, and then piezoelectric ceramic transductor will send a series of ultrasonic signals, and this ultrasonic signals will be reflected when it meet material. When the reflected ultrasonic signals were received, it will be converted to electrical signals. Through measuring the time interval t from the ultrasonic sending and material receiving and calculate the distance between material surface and piezoelectric ceramic transductor, and then calculate the height the real material level. The formula is : H = L- 1 (331.13+0.6T)t 2 In the formula, H is material level height; L is material warehouse height(can be set); T is material warehouse temperature(tested by temperature sensitive pipe) t is the interval between supersonic emitting and receiving 2.4.8 MW—Ⅱ Type High and Low Coal Level Control Instruments 2.4.8.1 Function These controlling instruments are mainly used to detect the coal yard, coal bunker and the height of coal level in coal handling coal spouting in order to control automatically the coal handling quantity, simultaneously it also can be used to detect the water level and the height of other material level. 2.4.8.1 Work principle: High and low coal level detector are composed of controlling cabinet and electrode. The working method and electrical theory can be seen in picture one, the working process: when the coal in the coal bunker are in the low position, the electrode A send a signal to low coal level controlling circuit through detecting coal resistance to output binary of low coal level, when coal (or other materials) lift up to high coal level, the electrode B send a signal to high coal level controlling circuit through detecting coal Page 141 of 160 resistance. Output a high coal level binary. Thus, the detecting of high and low coal level are finished. 2.4.9 Materials Flow Detector of LL—ⅠSeries 2.4.9.1 Function: This product can be used as belt to conveying materials which used to detect the instantaneous state of material, the switch install in the inside of that, the binary output according to material flow condition. User can connect it to the controlling chamber in order to detect the material conveying state on site, it also can be used with sprinkler to realize the sprinkling function automatically when it has materials. 2.4.9.2 Work principle: LL—Ⅲtype material flow detector adopt cam and travel switch structure, there are one normally closed contact, four normally open contact in static state, the user can install according to demands, the user also can make use of four-group normally open contact to connect the indicator light, when the conveying material in belt are different, this detector deviate in different angle which means it has different indicator light, at this way the material conveying condition can be observed in controlling chamber. 2.4.10 Protective Equipments for LDM Series Downspouting Blockage. 2.4.10.1 Function: Downspouting Blockage protective equipments are used to inspect the downspouting blockage of belt conveying machine, when the downspouting are blocked, this detector can output the alarming and shutdown signals. 2.4.10.2 Work principle: This instrument adopt door-type structure, install on the wall of one side of downspouting. When the material in downspouting are in blocked state, the accumulated material leave pressure to the sidewall of downspouting, and then push outward the moving door of this equipments, when the moving door is deviated, and the turning angle equals to or bigger than controlled angle, it control the switch action in order to alarm the shutdown signals. If this signal will be connected to the controlling line of shaker which can realize the automatic shaking function when the equipments are in slight blocked state, when the blockage faults of downspouting are relieved, the moving door can be resetted and recovered. The structure of these two downspouting The moving doors of this instrument will install the sliding bearings to add the rotating reliability, the bearing adopt sealing measurement in order to adapt to the severe atmosphere. This equipments and the side wall of downspouting adopt elastic rubber to seal, that’s why the flexible and reliable action can be guaranteed, additionally, it also can be sealed entirely. Page 142 of 160 Appendix 1.2 Coal Delivery System Equipment Summary Drawings Table 1) Working drawing of coal delivery 2) Arrangement chart of coal loading system 3) A-A cross section arrangement chart of coal loading system 4) B-B E-E F-F cross sections arrangement chart of coal loading system 5) C-C D-D cross sections arrangement chart of coal loading system Page 143 of 160 1.2.1 Equipment General Arrangement and Installation Diagrams 1.2.1.1 Plant general arrangement drawing 1.2.1.2 Coal delivery process chart Page 144 of 160 1.2.1.3 Coal delivery system installation chart 1) Belt conveyor installation chart of Section C1 and C2 2) Belt conveyor and bucket wheel machine installation chart of section 3. 3) Belt conveyor installation chart of Section C7 Page 145 of 160 4) Belt conveyor installation chart of Section C4 and Section C5 5) Belt conveyor installation chart of Section C6 Page 146 of 160 1.2.2 Equipment Constructional Drawings 1.2.2.1 General drawing of ship unloader 1)general drawing of four-drum mechanism 2)general drawing of lifting mechanism Page 147 of 160 3)general drawing of crane traveling mechanism Page 148 of 160 1.2.2.2 General drawing of stacker reclaimer 1) General structural drawing of upper main engine Pylon Pull rod Cab Counterweight assembly Pull rod Support pivot Bucket mechanism wheel Bucket wheel boom rack Pitch oil cylinder Page 149 of 160 Slewing mechanism Counterweight stack 2)General structural drawing of bucket wheel Arc baffle Bucket Body Sliding chute Wheel drive 3) General structural drawing of traveling Distance between bearings Head device buffer Balance beam Rail clamping device Driven unit Rail sweeper Drive unit Driven unit Page 150 of 160 Tail device Driven unit Anchoring device Rail sweeper buffer 4) General structural drawing of rotation Slewing mechanism Driving device Three-row roller bearings Driving pinion Gear cover 5) General drawing of overhang adhesive tape holder Head redirection roller Belt Idler group Belt conveyor protection device Hammer take-up device Sweeper Pylon Driving device Transmission roller Support pivot Slewing mechanism 6) General drawing of rear bumper Tripper car Main tripper car Single-wheel non-drivenTripper car steel structure belt conveyor wheel bogie assembly mechanism Page 151 of 160 luffing Tripper car 1.2.2.3 Belt conveyor part 1.2.2.3.1 Drawing of supporting roller group 1) Troughed idler 2) Flat idler 3) Carrier troughing impact idler Page 152 of 160 4) Tilting straight roller group 5) Offset roller group 1.2.2.3.2 General drawing of heavy hammer take-up Page 153 of 160 1.2.2.3.3 General drawing of sweeper H-type P-type 1.2.2.3.4 General drawing of transmission drum 1.2.2.3.5 General drawing of actuating device Page 154 of 160 1.2.2.4 Chart series of ring hammer coal crusher 1) Fundamental diagram of coal crusher Back door Iron removal room Front door 2) Figure 1-coal crusher structure chart Surface alignment for Lower side door Page 155 of 160 3 Figure 2-coal crusher structure chart 4) Structure chart of coal crusher rotor Page 156 of 160 5) Steering schematic diagram of coal crusher rotor Back door Front door Screw cover Lower back door Sieve holes Lower side door tray 6) Coal crusher structure chart Supports Big hold things 7) Rotor drive diagram Oil filling holes Front part lubrication Page 157 of 160 1.2.2.5 General diagram of electronic belt conveyor scale Speed measuring sensor Belt conveyor Belt conveyor Force measuring sensor Secondary meter 1.2.2.6 Ripping motor Dust suction interface General drawing of bag filter Flat bag group Air fan Electrical valve Air suction inlet Page 158 of 160 air 1.2.2.7 General drawing of belt type iron remover 1.2.2.8 General drawing of sampler Page 159 of 160 1.2.2.9 Plough tripper 1) Out-of-service condition of plough tripper 2) Working condition of plough tripper Auxiliary plough cutter Page 160 of 160