TECHNICAL TRAINING

Chennai Radha Engineering works (p) ltd

KICTPPL, OPERATION
 Day to Day Issues

 Defects are not raising on time

 Not returning work permit on time

 Repeated defects and problems

 Unable to issue work permit on time

 Fine dust

© Chennai Radha Engineering Works (P) Ltd.

 Defects are not Raising on Time
 No proper Trainings
 Awareness to be given

 Negligence of operators

 No Interaction

 Not completing defects on time

 No Awareness about Defects & Breakdowns

 Insist all operators to raise defects in registers daily

 Check weather the defects are raised in every shifts

 Discuss all the defects in daily meeting

 Appreciate the person who raising more defects & Valid points in meetings
© Chennai Radha Engineering Works (P) Ltd.
Not Returning the Work Permits on Time

 Time Bound should be fixed for every work

 Continuous follow ups by operation department

 Explaining the operational difficulties

 Self evaluation to be done for every work whether the permits returned
in correct time or not.

 If the permits getting delay alternative routes to be changed for

receipt/bunkering
 Appreciate if the permits returned in time
© Chennai Radha Engineering Works (P) Ltd.
 Repeated Defects/Problems

 Giving Enough time to complete the maintenance task

 Ensuring the quality of work

 Ensure the job completed as per SMP

 Making awareness to all about the operation difficulties if it repeats

© Chennai Radha Engineering Works (P) Ltd.

Unable to issue work permit on time

 The next day's work plan should discuss in todays Inter

 Department Meeting and the same to be followed Strictly.

 Inform Electrical Department to increase man power in MCC during the

peak hours
 Stop the Routes which going under permit before the Maintenance arrives
& arrange work permits earlier

 Fill the Bunkers as per Bunkering Schedule

 list of Pending permits to be Analyzed on daily basis

 All Pending permits to be Analyzed & root cause to be identified and

© Chennai Radha Engineering Works (P) Ltd.
 Fine Dust

 Spray Water before Unloading /Reclaiming.

 Giving High severity for leakages

 Scheduled water sprinkling in coal yards

 All Rain guns should be in Availability and timer to be set for
auto spraying
 DE & DS System to be utilized Effectively

 DE& DS system to be interlocked

© Chennai Radha Engineering Works (P) Ltd.

SAFETY DEVICES
There are Safety Switches for conveyor and material
handling plant. These are the specially developed field
mounted enclosures with added safety features.
Some of the Safety Switches in our plant are as follows:
1. BELT SWAY SWITCH (BSS)

The switch allows smooth

running of the conveyor and
protects it from damages by
over swaying which can occur
due to uneven loading of
material, worn out idler roller
bearings etc. Belt sway
switch is also known as Run
Off Switch
2. PULL CHORD SWITCH (PCS)

Pull cord switch also known

as Rope Operated Emergency
switch is used as a safety
switch to stop the conveyor
belt in case of an emergency.
It is also known as pull switch
cord
3. ZERO SPEED SWITCH (ZSS)
Electronic Speed Monitor is used
to monitor speed of conveyors,
crushers, rolling mills, agitators,
mixers, stirrers, screw conveyors,
and other industrial machinery.
This device actuates relay
contacts at preset speed. Using
these contacts desired control
action such as zero speed
protection/ under speed
protection/ over speed
protection can be achieved.
4. CHUTE JAM SWITCH

To sense the material

jamming in a compact chute
in feeding hoppers.
If it is not present there are
chances that there will be
coal accumulation and can
damage the conveyor belt.
5. LIMIT SWITCH

A limit switch is a switch operated

by the motion of a machine part
or presence of an object.
They are used for control of a
machine, as safety interlocks, or
to count objects passing a point. 
6. EMERGENCY-STOP (E-STOP)

An Emergency stop or e-
stop, is a safety mechanism
used to shut off a device in
an emergency situation in
which it cannot be shut down
in the usual manner. 
SCRAPPERS & ITS FUNCTION :

TYPES : 1. Internal Scrapper

2. External Scrapper
3. Diagonal Scrapper
4. V Scrapper
5. Counter Weight Scrapper

FUNCTION : A Scrapper is used to clear the material coming in Belt

WHAT IF SCRAPPER IS ABSENT??

If there is no Scrapper installed on a Belt there will be coal accumulation in the

Conveyor Route. It will require additional Man Power to clean the material.
SEQUENCE OF STARTING CONVEYOR PATH :

1. HOOTER HONKS
If the Hooter doesn't honks inform it to Control Room. There are chances
people working on the Route and will get informed and move to a Safe
place.

2. HT (HIGH TENSION) MOTOR STARTS

3. HYDRAULIC MOTOR STARTS

Its work is to circulate the oil from fluid coupling to Radiator Fan.

4. RADIATOR FAN STARTS

Its work is to cool Hydraulic Oil.

5. FLUID COUPLING
A fluid coupling is a simple mechanical device that connects a prime
mover, typically a squirrel cage motor, to a driven machine.

6. GEAR BOX (REDUCTION)

It reduces the speed and is used for speed control.
HOW TO START A CONVEYOR MANUALLY
1. Ensure the status of the concerned conveyor from control room.
2. If the status is healthy switch off the first three pole MCB (Miniature
Circuit Breaker).
3. Give the clearance to control room to start HT motor and hydraulic &
radiator motor.
4. If its double drive motor should switch off MCB in both the coupling
panels to start the conveyor manually.(M1 & M2)
5. Unlock the handle and rotate it in clock wise direction to scoop out &
rotate it in the opposite direction to scoop in. After scoop in inform to
control room then stopped the system.
 SAFETY PRECAUTIONS FOR PAYLOADER, EXCAVATOR &
HYDRA OPERATORS :
PAYLOADERS :

The first thing to keep in mind when operating a front end loader, as with any
heavy equipment, is safety. Be mindful of obstacles on the work site and always
wear your safety equipment.

When operating a front end loader, be sure that you raise and lower the bucket
slowly. Don’t jerk it. And when you turn, make sure you allow for some extra
space because it doesn’t turn on a dime.

If you see people nearby, don’t swing or dump your load.

When you carry a load in the bucket, keep your bucket low to the ground, but
don’t scrape the ground with it. And, finally, never carry a person in the bucket.
That’s a good way to get someone injured.
EXCAVATOR OPERATORS :
Ensure a suitable clearance for ‘tail swing’ behind and around the
machine – danger area should be barricaded

Method of alerting driver/operator if anyone must enter into the

work radius must be established, i.e. signals, radio, etc.

Bucket or load should never be slewed directly over personnel

Vehicles should be loaded from the side or rear and material should
not be dropped from excessive height

Appropriate PPE should be given to the operator

Avoid contact with overhead and underground power-lines

 KEY RESPONSIBILITY OF ON BOARD SUPERVISOR :
To provide adequate personal protective clothing and gears, such as safety
helmet, safety shoes and safety harness to workers employed.

Worker should report any defects of equipment or any hazardous situation to a

responsible person.

The inclination of the gangway to water level should not exceed 55 degrees.

Hatch covers and beams should be of robust construction and made from sound
materials, and maintained in good states of repair and any faults should be
brought to the notice of the master or officer in charge of the vessel.
 Chennai Radha
LIST OF MAJOR EQUIPMENT :- Engineering works (p) ltd.

SL.NO EQUIPMET CAPACITY NO OF EQUIPMENT

1 SHIP UNLOADER CREAM= 2750 TPH 2 NO'S

2 STACKER CUM RECLAIMER STACK=5500 TPH

PEAK RECLAM = 4500 TPH 3 NO'S

3 RAPID LOADING SYSTEM SYSTEM CAPACITY - 4500 TPH

SILO CAPACITY - 875 T 2 NO'S

CONVEYOR BC-1A/1B, BC-2A/2B, RATED = 2750 TPH

4
BC-3A/3B, BC-4A/4B 8 NO'S
5 CONVEYOR BC-5, BC-6, BC-7 RATED = 5500 TPH 3 NO'S

6 RATED = 4500 TPH

CONVEYOR BC-8A/8B, BC-9A/9B,
BC-10A/10B, BC-11A/11B 08 NO'S
7 BOOM CONVEYOR RATED = 5500 TPH 3 NO'S
8 BELT FEEDER RATED = 2750 TPH (MAX) 2 NO'S
STOCK PILE LENGTH TOTAL NO OF EQUIPMENT
STOCK PILE 1-625 Mtr. TOTAL NO SUL 2 NO'S
STOCK PILE 2-645 Mtr. TOTAL NO SCR 3 NO'S
STOCK PILE 3 & 4-630 Mtr. TOTAL NO RLS 2 NO'S
STOCK PILE 5 & 6-605 Mtr. TOTAL NO CONVEYOR 24 NO'S
  TOTAL NO BF 2 NO'S
  TOTAL NO TOWER 8 NO'S
 Chennai Radha
EQUOPMENT TECHNICAL DETAILS :- Engineering works (p) ltd.

TECHNICAL DATA KICTPPL

SL.NO LOCATION CAPACITY BELT SPEED BELT TYPE BELT LENGTH BELT WIDTH MOTOR K/W LOAD CURRENT
1 BC-1A 2750 TPH 4 M PER SEC NYLON FABRIC 504.5 M 1600 MM 250 K/W 28 AMPS
2 BC-1B 2750 TPH 4 M PER SEC NYLON FABRIC 504.9 M 1600 MM 250 K/W 28 AMPS
3 BC-2A 2750 TPH 4 M PER SEC NYLON FABRIC 131.1 M 1600 MM 315 K/W 34.5 AMPS
4 BC-2B 2750 TPH 4 M PER SEC NYLON FABRIC 133.7 M 1600 MM 315 K/W 34.5 AMPS
5 BC-3A 2750 TPH 4 M PER SEC NYLON FABRIC 142.2 M 1600 MM 250 K/W 28 AMPS
6 BC-3B 2750 TPH 4 M PER SEC NYLON FABRIC 140.5 M 1600 MM 250 K/W 28 AMPS
7 BC-4A 2750 TPH 4 M PER SEC NYLON FABRIC 157.9 M 1600 MM 180 K/W 20 AMPS
8 BC-4B 2750 TPH 4 M PER SEC NYLON FABRIC 155.4 M 1600 MM 180 K/W 20 AMPS
9 BC-5 5500 TPH 4.9 M PER SEC NYLON FABRIC 725.8 M 2000 MM 1120 K/W 122 AMPS
10 BC-6 5500 TPH 4.9 M PER SEC NYLON FABRIC 735.6 M 2000 MM 1120 K/W 122 AMPS
11 BC-7 5500 TPH 4.9 M PER SEC NYLON FABRIC 707.2 M 2000 MM 1120 K/W 122 AMPS
12 BOOM-1 5500 TPH 4.9 M PER SEC NYLON FABRIC 53.2 M 2000 MM 250 K/W 360 AMPS
13 BOOM-2 5500 TPH 4.9 M PER SEC NYLON FABRIC 53.2 M 2000 MM 250 K/W 360 AMPS
14 BOOM-3 5500 TPH 4.9 M PER SEC NYLON FABRIC 53.2 M 2000 MM 250 K/W 360 AMPS
15 BC-8A 4500 TPH 4.75 M PER SEC NYLON FABRIC 277.4 M 1800 MM 450 K/W 49.5 AMPS
16 BC-8B 4500 TPH 4.75 M PER SEC NYLON FABRIC 276.6 M 1800 MM 450 K/W 49.5 AMPS
17 BC-9A 4500 TPH 4.75 M PER SEC NYLON FABRIC 123 M 1800 MM 315 K/W 34.5 AMPS
18 BC-9B 4500 TPH 4.75 M PER SEC NYLON FABRIC 118.9 M 1800 MM 315 K/W 34.5 AMPS
19 BC-10A 4500 TPH 4.9 M PER SEC NYLON FABRIC 242.3 M 1800 MM 1120 K/W 122 AMPS
20 BC-10B 4500 TPH 4.9 M PER SEC NYLON FABRIC 242.3 M 1800 MM 1120 K/W 122 AMPS
21 BC-11A 4500 TPH 4.75 M PER SEC NYLON FABRIC 27.6 M 1800 MM 180 K/W 20 AMPS
22 BC-11B 4500 TPH 4.75 M PER SEC NYLON FABRIC 27.6 M 1800 MM 180 K/W 20 AMPS
23 SILO-1 875 T NOT REQ NOT REQ HEIGHT-59 M NOT REQ
24 SILO-2 875 T NOT REQ NOT REQ HEIGHT-49 M NOT REQ
25 SUL-1(GRAB) 52.5CBM PER HOUR 2750 MT NOT REQ HEIGHT-67/84 NOT REQ
26 SUL-2(GRAB) 52.5CBM PER HOUR 2750 MT NOT REQ HEIGHT-67/84 NOT REQ    
27 SUL-1(BF) 2750 TPH(MAX) 1 METER PER SEC NYLON FABRIC 8.7 M 2400 MM 90 K/W 160 AMPS
28 SUL-2(BF) 2750 TPH(MAX) 1 METER PER SEC NYLON FABRIC 8.7 M 2400 MM 90 K/W 160 AMPS
 Chennai Radha
BYPASS PATH DETAILS :- Engineering works (p) ltd.
 Chennai Radha
STACKING PATH DETAILS :- Engineering works (p) ltd.
 Chennai Radha
RECLAIMER PATH DETAILS :- Engineering works (p) ltd.
 SKILL MAPPING
KICTPPL
CREWPL
SKILL MATRIX
DEPARTMENT: OPERATION DESIGNATION: FIELD OPERATOR REVISION DATE: 24-05-22
5 4 3 2 1
Expert Advanced Proficient Application Basic
Minimum Skills required for the Position (Has to be Expert at it ( Knows theory & ( Knows theory & ( Knows theory but (Just to have a brief
) practical and able to practical both) not practical) Overview)
train / teach others)
Leader Right Fit Emerging Developing Dormant
SKILL-1 Technical/Functional Knowledge 5
SKILL-2 Equipment Maintenance Operation 4
SKILL-3 Coordination skills 5
Learning Strategies,Writing Skills & Inter
SKILL-4 5
departmental skill
SKILL-5 Safety Awareness & 5S 5

© Chennai Radha Engineering Works (P) Ltd.

 TRAINING CALENDER
KICTPPL
CREWPL
TRAINING CALENDER
DEPARTMENT: OPERATION DESIGNATION: FIELD OPERATOR REVISION DATE: 24-05-22
SL NO NAME OF THE TRAINING SKILL DURATION FACULTY NOS TO BE COVERED TRAINING PLANNED DATE
1 General safety rules 5 1 DAYS HOD 38 1-Jun-22
2 Occupational health hazards 5 1 DAYS HOD 38 2-Jun-22
3 Use of appropriate PPE's at work place 5 1 DAYS HOD 38 3-Jun-22
4 Slip, trip & fall 5 1 DAYS HOD 38 4-Jun-22
5 Monsoon safety precautions 5 1 DAYS HOD 38 5-Jun-22
6 Hand & finger safety 5 1 DAYS HOD 38 6-Jun-22
7 Causes of accident 5 1 DAYS HOD 38 7-Jun-22
8 Basic fire safety 5 1 DAYS HOD 38 8-Jun-22
9 Permit to work system 4 1 DAYS HOD 38 9-Jun-22
10 Safe use of sharp tools 4 1 DAYS HOD 38 10-Jun-22
11 Rake Pre loading and Post loading Activities 4 1 DAYS HOD 38 11-Jun-22
12 Behaviour based safety 3 1 DAYS HOD 38 12-Jun-22
13 UA/UC & Near-miss & reporting 3 1 DAYS HOD 38 13-Jun-22
14 On Board Activities 3 1 DAYS HOD 38 14-Jun-22
15 Working at height 2 1 DAYS HOD 38 15-Jun-22
16 Isolation & use of LOTO 2 1 DAYS HOD 38 16-Jun-22
17 Safety in cleaning & housekeeping 2 1 DAYS HOD 38 17-Jun-22
18 Conveyor safety 1 1 DAYS HOD 38 18-Jun-22
19 Safe working with rotating equipment 1 1 DAYS HOD 38 19-Jun-22
20 Use of safety & safety switches in conveyor system
1 1 DAYS HOD 38 20-Jun-22
21 Conveyor SOP 1 1 DAYS HOD 38 21-Jun-22
22 SUL SOP 1 1 DAYS HOD 38 22-Jun-22
23 SCR SOP 1 1 DAYS HOD 38 23-Jun-22
24 RLS SOP 1 1 DAYS HOD 38 24-Jun-22
25 Belt Feeder SOP 1 1 DAYS HOD 38 25-Jun-22
26 Aux Equipments (MD/MS/SPRINKLER/DSS/FIRE1 HYDRENT) 1 DAYS HOD 38 26-Jun-22
MONTHLY SKILL TEST 27-Jun 30-Jun

© Chennai Radha Engineering Works (P) Ltd.

 QUESTIONARRIES

© Chennai Radha Engineering Works (P) Ltd.

  
 

THANK YOU
© Chennai Radha Engineering Works (P) Ltd.