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 2315M coal fired power plant project in PACITAN, Indonesia. It is only suitable for the
operation of the coal handling system of the 2315M 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

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 Type Relative-Movement Detector....................................................................................138

2.4.5

DHS 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 Type High and Low Coal Level Control Instruments......................................................140

2.4.9

Materials Flow Detector of LLSeries..........................................................................................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

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 stackerreclaimer and main workshop is double. C-1C2c-3c-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

3550

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

Base distance

16

Rated lifting weight of grabber

32

Gravity weight of grabber

13

Grabber capacity

19

Max outer distance

25

Max inner distance

14

Page 7 of 160

Lifting scope above the roller

23

Lifting scope under the roller

10.5

Cab outer distance

25

Cab inner distance

14

Ship unloader moving scope

~170

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

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 80030 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 operators 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 computers 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

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

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 donts 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 drivers 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 theres 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 drivers cab firmly to the sidewalk.

2.1.1.1.3.4

Energization
Press the light indication button on the right ganged platform in the drivers cab. If the
indication light is bright, the operation of the drivers cab is effective. If the operation is
effective at other place formerly and wants to be transferred to the drivers 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

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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 value1000automatically 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 its 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
value1000automatically. 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
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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

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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
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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 cant 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

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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 SB816button
SB817button 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 cabs 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 operators 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 operators 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 (2315MW) 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 40slewing 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: 0.81.2t/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

Slewing unit
Slewing radius: 40m
Slewing speed: 0.020.12r/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: 6300mm
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

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

Boom conveyor
Length of boom conveyor 41.9m
Rated conveying capacity 1500t/h
Belt width x belt speed: 1400mm x3.15m/s
Idler diameter: 133mm
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-
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: 0.10.2(MPa)

Page 31 of 160

Power cable reeler device

Cable specification: 6000V, GKFB-3x35+3x16/3Pmm
Cable cross-section dimensions: 71.8mmx31.3mm

Reeler device
Cable specification : 380VYEFBG-24x2.5mm2+2x4Gmm 2
Cable cross-section dimensions: 99mmx19mm

Transfer chute
Electrical thrustor DT30050-20II

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, operators
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
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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 630 drive wheel bogie assembly, 630 non
driven wheel bogie assembly, equalizer, rail clamps (hydraulic spring type), anchoring
device, rail cleaner, end buffer, pin roll, block and pivot etc. 630 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.

11

8
10

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.

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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.

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.

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 .

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

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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. 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/COS, 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/COS, if it is within 60~70, should be 60.

Rotary layer reclaiming

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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

Do all the preparations before startup of the stacker reclaimer;

Check the HV switch panel is energized and observe the indicating gauge and
ON/OFF indicator;

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 10A HV electrical panel
in the electrical room and in the 21 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 11 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

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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 11 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 10A HV electrical panel.
(4) HV feedback circuit of the 10B HV electrical panel.

b.

LV room
(1) 11 LV electrical panel: LV power circuit.
(2) 12 LV electrical panel: PLC main station and auxiliary control circuit.
(3) 13 LV electrical panel: control circuit for the crane travel mechanism, cable
drum, and rail clamping device.
(4) 14 LV electrical panel: control circuit for the slewing, lifting, water spraying,
intermediate section hopper damper, and bucket wheel guide through.
(5) 14 LV electrical panel: control circuit for the bucket wheel, boom belt,
auxiliary trailer alternation, and trailer belt.

c.

Operator cab

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1. 21 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. 22 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. 23 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;

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(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 10A 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 10b 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.
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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
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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

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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.
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(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
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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.

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(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.

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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
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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

Noticethe 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.
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(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

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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

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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

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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

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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 commanders 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.

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(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 theres 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
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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

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(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 cant 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 cant be used to extinguish fire on motor
When theres 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,
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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 operators 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 Drivers 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.

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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

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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.

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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

The
belt
adjustment
appropriate.

tension
is
not 2

is

not 1

Adjust
tension.

the

replace
belt

Replace it.

Check and
the line.

The generator has fault.

Repair the generator.

The wiring is not good.

The starting switch is

not good.

Check and
the line.

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.

The connector leaks oil.

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.

Wash the oil filter or

replace it again.

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.

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

The engine cannot start 1

(the swirling starter has
already been used).
2
3

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.

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

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

200500kW

No less than 1h

Above 500kW

No less than 2h

Remark: The condition that motor is restarted after less than 1 hours continuous
operation or after more than 1 hours 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
speedr/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-1214 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 20-30of 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.

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

1Adjust 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-X

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

0.0150.25

50150

adjustable

adjustable

0.0150.25

25100

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

300200

50

Y112M-4

4 KW

HJC0403

400300

150

Y132M-6

5.5 KW

HJC0404

400400

150

Y200L2-6

22 KW

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)
3850

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

0.0150.25

50150

adjustable

adjustable

Sample collector
Page 106 of 160

1.1

UDY1.1XW4/43

Ty

Number

CubageLi
tre

Power
(KW)

25

0.75

pe
SC-R6

2.2.9.2.6

Drive Device
Brake Motor Reducer

Coal returning equipment (bucket elevator)

Hoisting Height

2.1628.16 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 1.111/17
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

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:

36062090mm (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 linear160400

Driven pulley

steel linear160400

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:

Coal-returning equipment (bucket elevator)

Bucket elevator type:

TD-100-00

Output:

0-4m /h

Bucket width:

100mm

Bucket capacity :

0.16L

Buckets pitch:

200mm

Belt speed

1.4m/s

Drive pulley:

400

Driven pulley:

316

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 runsfeeder runsbeginning 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

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

Model

LJT-12

Supply voltage

230V10%

Whole machine power

20W

Adaptive relative humidity

85% 40

Adapt ambient temperature

-10 - 40

Page 118 of 160

50HZ

Particle size

<400mm

Material character

60%

Adaptive belt speed

0.8 - 4.0m/s

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

2.2.12.3

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

Metal in the coal

can
still
be
detected
and
make the alarm
sound.

Too low detector sensitivity.

Re-adjust.

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.

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

124150

380V
50Hz

JZF-6

6-8

YZO-21-4

0.4

1450

500

130170

380V
50Hz

JZF-10

8-10

YZO-31-4

0.75

1450

800

130170

380V
50Hz

JZF-11

10-12

YZO-41-4

1.1

1450

1000

130170

380V
50Hz

JZF-15

15-25

YZO-51-2

2.2

3000

1200

156180

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 reducerimpeller 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 motors 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 phenomenonand

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 leaders orders.

c.

Startup the main electric motor, and at this moment, the adjusting
operating machine should in a low-speed positionand 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.

After the main impeller startupthe moving TV can be start upand 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 coulters 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 rods 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 0from 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 24V15%, 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.

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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

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

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

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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 2.3.6.3.32.3.6.3.9 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

8PA8PB switchover
a.

Open the display of 8PA (8PB) CONTROL AND STATE.

b.

Click switching to 8PBor 8PA,appear 8PA/B switching control display;

c. Click the switch button in8PA/B switching control display, it will turn out a red
display 8PA is switching to 8PB, 8PBor 8PAstart 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 tripbutton, 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 , 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-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 Type Relative-Movement Detector

2.4.4.1

Function:
D H-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-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

DHS Type Speed Detector

Function:
DHS-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:
DHS-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

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.

The setting of digital switch is convenient.

It has AGC and PLL wave filter circuit, the resolving ability of signals is strong.

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

The detector is made by casting special silica gel, it has strong anticorrosive
property and permissibility

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+0.6Tt
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 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 LLSeries

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:
LLtype 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, thats 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

1general drawing of four-drum mechanism

2general drawing of lifting mechanism

Page 147 of 160

3general 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

2General 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

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