Materi Training Coal Handling

Session 1
Introduction and Site layout of Coal Handling System
SESSION OBJECTIVE
Introduce the Facility.

Provide an overview of the CHEC Supply.
Introduction of the main equipment supplied.
Review the Coal delivery process
Identify the Design Standards & Codes applied.
CONTENT
1. Introduction and Overview
2. Project Equipment
3. Design Parameters
4. Ship Unloading
5. Material Handling & Ancillary Equipment
6. Stockyard
7. Screening & Crushing
8. Delivery
9. Standards, Codes & Manuals
1
1 Introduction and Overview
TJB Power Service (TJBPS)
Tanjung Jati B is a 2x660 MW coal fired Power station is situated at Desa Tubanan,
Kecamatan Kembang, Kabupaten Jepara, Central Java.
The two new stockpiles will be located to the left of the existing in the vacant
area adjacent.
2
This power plant is built on 150 Hectares of land right on the sea shore. Aerial view of the
plant shows it adjacent quiet villages and on the Java sea.
PLN - TJB are the lessee of the power station which was built By Sumitomo
Corporation.
The Tanjung Jati Coal Fired Power Station & supply sites currently have two units,
Units 1 and 2 designed to meet the fuel supply requirements of the existing power plant.
TJB power station has in excess of 500 personnel directly and indirectly employed at
this power station.
Both units went on commercial operation on 1st October 2006 and 1st November 2006
respectively. The power station supplies energy to the Java Madura - Bali 500 kV
distribution network.
The existing system has been identified to be upgraded to increase power production
and reliability. The expansion of Units 3 & 4 Power Plant systems is the result of
extensive reviews. The new site works will be independent of the existing power plants
and supply chains.
Upgrades consist of new wharf and ship unloading areas, conveyor systems
transporting fuel materials to new stockyards before processing, blending and storage
for the new power station units.
2 Project Equipment
Main Equipment Components are:
1. Ship Unloader
2. Conveyors, Trippers & Chutes
3. Transfer Towers and Structures
4. Stacker Reclaimers
5. Sampling Equipment
6. Screening & Crushing Equipment
7. Dust Collection and Suppression
8. Weightometers & Metal Detectors
3
The Coal Material Handling System Flow Diagram.
4
3 Design Parameters
GENERAL DESIGN CRITERIA
The coal handling system is based on the following design criteria:
The Berth can manage vessel sizes up to 70,000 DWT of oceangoing ships (Panamax
Type).
The Material Handling System can deliver 292.8 Metric TPH (burn rate of coal handling
system per one MCR mode)
Bulk density of 0.85 metric ton per cubic meter
Received coal size 150 mm x 0 mm
The coal handling system is designed to provide for the unloading, receiving, storing,
reclaiming, and crushing of coal at the stated design rates with ultimate delivery to 2 x
660 MW power units.
The coal handling system will be designed under the following conditions:
Unloading operation from vessels: 24 hours/day

Discharging operation to silos with 2 lines: 12 hours/day
Single line discharging operation to silos: 24 hours/day
The complete coal handling system will be possible to be operable for 24 hours/day.
The design of the coal handling system therefore has to take the nightly noise
limitations into account.
During the 24 hour per day ship unloading operation, two ship unloaders will be
operating at the same time, therefore, both lines of receiving conveyors and both
stacker/reclaimers will be operating simultaneously.
In addition, during the unloading operation either one or both reclaim lines to Unit 3 and
4 generation buildings will be operating when coal levels in the storage silos demand
fuel.
One plant feed line has the capacity to service the demand of both generating units.
During times of no ship deliveries, a single reclaim line operating approximately five
hours per eight-hour shift will supply the needs of both units operating at 80 percent
MCR.
The second stacker / reclaimer, crusher and reclaim line to the generation units will
serve as redundant equipment.
5
The ship unloader and stacker- reclaimer shall be capable of operating in wind speed
up to 20 m/s.
However the ship unloader and stacker- reclaimer shall be able to move to tie-down
location in a wind speed up to 30 m/s.
4 Ship Unloading Facility

SHIP UNLOADING
Coal will be delivered to the coal unloading dock aboard oceangoing vessels of up to
70,000 DWT class (Panamax type).
Two grab-type ship unloaders, each rated 1,500 MTPH (metric tons per hour), shall be
provided on the dock to unload the ships.
Both unloaders shall traverse on the same set of rails furnished by the Supplier.
Ship Unloader A can serve either Dock Conveyor 101A or Dock Conveyor 101B and
Ship Unloader B can serve either Dock Conveyor 101B or Dock Conveyor 101A.
The unloading operation shall be accomplished semi-automatically and/or manually by

using the controls in the operators cab.
SHIP UNLOADERS
Each ship unloader shall consist of a clamshell type bucket, mounted on a bucket
trolley.
The bucket trolley shall be mounted on a horizontal apron boom, at an elevated

position above a docked ship.
The apron boom shall be mounted to a traveling tower structure. The apron shall have
the capability of being raised from the horizontal operation position to clear the ship
structures.
Each tower shall consist of a mast and a 4-leg support structure, mounted on traveling
trucks at each corner leg.
The tower shall also support the inward extension of the apron boom, which is a fixed
runway.
The runway shall reach out to the rear of the tower. The apron boom and runway
components shall be box sections, with rails on the top side for the grab bucket trolley
travel.
Each tower shall also contain a hopper to receive the coal from the grab bucket
discharge. The hopper shall have a vibrating feeder at the lower discharge point. The
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feeder shall transfer the coal to impact tables, (2 impact tables for each unloader),
supporting the dock conveyor belts, which shall pass under the tower structure.
The operator is in an operators cabin. The cabin can travel along the underside of the
apron boom so the operator can position the cab for optimum viewing of the digging
and discharge operation.
The receiving system for the grab bucket shall be a 4-part rope arrangement for direct-
receiving operation. The 4-part ropes shall consist of two close ropes and two hold
ropes.
The close rope ends shall be anchored in the bucket. The hold ropes shall have pin
connections to the bucket for quick release and change of bucket.
Each unloader shall have approximately a 30 metric ton hoisting load (including grab
weight), scissors type, grab bucket. The grab bucket is able to lift a Caterpillar 910
loader, or equal, from the dock and place it in the ship to assist in cleanup.
The ship unloader has been designed to operate using the maximum outreach of 35
meters.
Included with each unloader shall be a dust-suppression system at the hopper grizzly
to minimize dusting and at the feeder discharge. An adjustable spill plate in front of the
hopper shall limit spillage of coal into the water. Spillage on the plate shall be dumped
back into the hopper by raising the spill plate
Access shall be provided on the machine for operator and maintenance personnel. An
elevator shall be included for access from dock level to the top of the hopper level, the
operators cab access area and the machinery house area.
The hold, close and trolley travel shall be operated by variable-speed drives. Power
shall be furnished by means of cable reeler. Control interface shall also be supplied by
the reel.
Each unloader shall include anchor brackets for tie-downs, shear pins, and anchor
bolts. The holding system shall include turnbuckles.
The end travel stops shall include fabricated brackets, bumpers located on the
unloaders, anchor bolts, and anti-collision system.
Ship unloader will be supplied with self contained dust suppression systems of the
atomized water sprays type at all transfer points.
Each unloader shall include a water tank for the dust suppression- and power/control
cable reel(s). Control cables shall be optical fibers.
Power and control junction boxes, water supply connection valve, communication
junction box, and required inserts shall be provided at the mid-point of travel for each
ship unloader.
5 Material Handling
COAL CONVEYING SYSTEM, CRUSHERS, AND DUST COLLECTORS
7
Conveyors shall be capable of starting and stopping when empty, partially loaded, or
fully loaded without slippage or damage to other components of the system.
Conveyors are complete with stringers, decking, support legs, idlers, conveyor belting,
skirt boards, belt seals, loading and discharge chutes, pulleys and shafts, drive units,
safety switches, and all other necessary appurtenances.
CONVEYORS 101 A & B
Conveyors 101A and 101B are to be uncovered to allow the ship unloaders to feed
their respective conveyors.
Each of Conveyors 101A and 101B is to be equipped with a Belt Magnetic Separator at
head end.
Conveyor 101A and 101B shall deliver coal to Conveyor 102A and Conveyor 102B at a
design rate of 1,500 Metric TPH via chute work respectively.
CONVEYORS 102 A & B
Conveyor 102A and 102B shall deliver coal to Conveyor 103A and Conveyor 103B at a
design rate of 1,500 MTPH via chute work respectively.
The transfer of coal is at Transfer Tower TT02
Belt weighers (or weightometers) are situated on each conveyor
CONVEYORS 103 A & B
Conveyors 103A and 103B shall be shall be supported at space of approximately 12

meters until the Conveyor reaches the shore. The supports will be at the same
elevation as the jetty.
Access to the walkway of Conveyors 102 and 103 shall be provided every 150 meters.
Conveyor 103A and 103B shall deliver coal to Conveyor 104 and Conveyor 105B at a
design rate of 1,500 MTPH via chute work respectively in Transfer Tower 103.
Before this transfer tower (on the Conveyors 103A and 103B) two As-Received
Sampling Systems shall be provided to take samples from both Conveyors 103A and
103B to verify quality of delivered coal respectively.
Diverter gates are provided in TT03 to allow for loading to either one or the other
conveyor. IE conveyor lines are interchangeable
CONVEYORS 104, 105 A & B
Conveyor 104 shall deliver coal to Conveyor 105B at Transfer Tower TT04. Conveyor
105B feeds the Reclaimer / stacker B at a design rate of 1,500 MTPH
Conveyor 105 is fed from TT03 at a design rate of 1,500 MTPH via chutework.
Conveyor 105A feeds the Reclaimer / stacker A at a design rate of 1,500 MTPH
The stackers and reclaimers have various modes of operation.
8
The output from these conveyors is a maximum of 1500 TPH once they have passed
the reclaimers / Stackers.
6 Stockyard
STACKERS / RECLAIMERS
All coal yard Stackers/ Reclaimers are rail mounted and designed to travel the full
length of the coal storage yard.
The Stacker/Reclaimers (A & B) can either stack coal onto the stockpiles or reclaim
coal onto their dedicated stockyard conveyor 105 (A or B).
CONVEYOR 106 A
Yard Conveyor 106A receives coal from Stacker/Reclaimer conveyor 105A.
The conveyor receives coal at Transfer Tower TT05.
Magnetic separators operate at this tower.
Diverter gates are in place at TT05 to alternate direct flow to either conveyor 106B or
106A
CONVEYOR 106 B
Yard Conveyor 106B receives coal from Stacker/Reclaimer conveyor 105B.
Diverter gates are in place at TT06 to alternate direct flow to either conveyor 106A or
106B
7 Screening & Crushing

CONVEYORS 107 A & B
Conveyor 106A and 106B shall deliver coal to Conveyor 107A and Conveyor 107B
respectively via chute work in the Crusher Tower.
Coal is delivered to the crushing building and then screened.
Screened material automatically passes to the discharge chutework. This chutework
also has diverter gates to allow loading to either conveyor
Oversize material is diverted to the Crusher equipment for resizing. Coal is then
delivered to the discharge chutework. This chutework also has diverter gates to allow
loading to either conveyor
SCREENING & CRUSHING
9
Belt Feeder A shall deliver coal from Conveyor 106A to Vibratory Screen (option:
Roller Screen) A
Belt Feeder B from Conveyor 106B shall deliver coal to Vibratory Screen (option:
Roller Screen) B.
The screens shall each divert the oversized (50-150 mm) coal to their respective coal
crushers.
The minus 50 mm shall be directed to either Conveyor 107A or 107B via chute work
and diverter gates.
CRUSHERS
Coal Crusher A and the through product of Screen A shall deliver the coal to
Conveyor 107A or 107B via chute work and diverter gate.
Coal Crusher B and the through product of Screen B shall deliver the coal to
Each crusher shall be designed to crush 800 MTPH of 150 mm x 50 mm to minus 50
mm.
Dust collection systems are in place on the Crushing buildings to limit dust emissions.
8 Delivery to Silos
CONVEYORS 107 A & B
Conveyor 107A shall deliver coal to Pipeline Conveyor 108A
Conveyor 107B shall deliver coal to Pipeline Conveyor 108B
Transfer occurs at Transfer Tower 107
Conveyor 107A and 107B shall each be equipped with a belt scale for equipment
control.
Conveyor 107A and 107B shall each be equipped with a Magnetic Separator.
A Coal Sampling device with two cutters shall be provided to take samples from both
Conveyors 107A and 107B
CONVEYORS 108 A & B

Pipeline Conveyor 108A shall deliver coal to Conveyor 109A at a design rate of 1000
MTPH via chute work.
Pipeline Conveyor 108B shall deliver coal to Conveyor 109B at a design rate of 1000
The transfer of coal shall be at Transfer Tower 108.
The pipeline conveyors traverse approx 300m over the existing plant facility, with a
horizontal curve.
CONVEYORS 109 A & B
10
Conveyor 109A shall deliver coal to Conveyor 110A at a design rate of 1000 MTPH
via chute work.
Diverter gates are in place in TT09 for loading of alternating conveyors as required.
This conveyor is a step vertical angled conveyor raising the coal approximately to a
height of 48m above ground level.
TRIPPER CONVEYORS
Tripper Conveyor 110A shall deliver the coal at a design rate of 1,000 MTPH to
motorized traveling Tripper A.
Tripper A shall traverse the required length of the Storage Silos delivering coal to any
of the storage silos.
Tripper Conveyor 110B shall deliver the coal at a design rate of 1,000 MTPH to
motorized traveling Tripper B.
Tripper B shall traverse the required length of the Storage Silos delivering coal to any
The silos shall be fitted with tripper seals to minimize dust emissions.
Coal dust collectors are installed to minimise dust pollution.
MATERIAL HANDLING GENERAL
All conveyors and transfer towers will be designed to permit easy access for bob cat
type equipment to clean up spillage that might occur beneath the conveyor structure.
Coal dust shall be controlled by wet dust suppression systems at all transfer towers.
Coal dust shall be controlled by dust collection systems at the crusher building and at
the storage silos.
A control system shall be included for the conveying system, ship unloaders, and
stacker / reclaimers by the Supplier.
Hoists shall be provided for all transfer towers for servicing conveyor drives and the
crusher structure for servicing the incoming conveyors, screens, samplers and the
crushers.
A rail system and hoists shall be provided for each unit for tripper equipment
maintenance. The hoist rail will be attached to the tripper gallery roof steel by others.
Hoists shall be arranged to lower equipment to the ground. The hoists shall be rated
to lift the heaviest piece of equipment.
The tripper area shall have a piped vacuum cleaning system for maintenance.
The elevated portion of conveyors shall be supported from open type trusses and
structural steel bents.
11
All conveyors shall be protected from the elements with conveyor hoods over the belt
portion of conveyor only except on portions of conveyors traversed by the ship
unloaders and the stacker / reclaimers and trippers.
Moving parts of equipment shall be readily accessible for inspection, lubrication, and
repair where necessary, and shall be protected from the flow of conveyed material.
However, moving parts of equipment shall also be guarded as required to protect
personnel during operation.
Expanded metal guards shall be furnished and installed at all nip-points or pinch-
points at conveyor pulley. Conveyors shall be of the rubber belt type.
Conveyors shall have a maximum inclination of 16 degrees.
Conveyor elevations shall be such that a minimum of 7.0 meters of clearance is
provided over all roads
9 Standards & Codes

CODES AND STANDARDS
The following international recognized standards and codes were used (but not limited to)
for the design of equipment as requested in the Main Tender Documentation:
Technical code for designing fossil fuel power plants (DL 5000-2000)
Technical code for Designing Coal Handling of Fossil Fuel Power Plant- Part 1: Coal
Handling System (DL/T 5187.1-2004)
Conveyor Equipment Manufacturers Association (CEMA)
The Anti-Friction Bearing Manufacturers Association (AFBMA)
Rubber Manufacturers Association (RMA)
ISO 5048 Continuous Mechanical Handling Equipment - Belt Conveyors with
Carrying Idlers - Calculation of Operating Power and Tensile (Conveyor Design).
ISO 5049 Mobile Equipment for Continuous Handling of Bulk Materials - Part 1: Rules
for the Design of Steel Structures (Machine Design Equivalent to FEM Std.)
BS 2573, Part-1 & 2
IS 13082
GB755; GB4208; GB12348; GB12351-90
GB/T 13384-92
REFERENCE MANUALS
Coal Handling Manuals

o (IM0401-1) Coal Handling System Table of Contents
12
o (IM0401-2) Coal Handling System General Description-0
Ship Unloader Manual
o (IM0401-3.1.1-1) Ship Unloader Erection & Commissioning Manual-1
o (IM0401-3.1.1-2) Ship Unloader Operation & Maintenance Manual-0
Conveyor Instruction Manual
o (IM0401-3.2-1) Conveyor Instruction Manual-0
Coal Crusher Manual
o (IM0401-3.6-1) Crusher Instruction Manual-0
Tripper
o (IM0401-3.7-1) Tripper Instruction Manual-1
13
Session 2
Coal Handling Process Flow
SESSION OBJECTIVE
Outline the Coal Process Flow

Review the Main Equipment supplied
CONTENT
1. System Purpose
2. System Process Flow
3. Project Equipment:
a. Ship Unloading
b. Conveyors
c. Stackers and Reclaimers
d. Screeners and Crushers
e. Pipe Conveyance
f. Silo Storage
g. Magnetic Separation
h. Coal Sampling
i. Coal Weighing
j. Dust Suppression
k. Coal Handling System Control
4. Technical Data
14
1 System Purpose
a. The purpose of the Coal Handling System is the off-loading of coal from ships and
the conveyance to the coal storage yard and the boiler bunkers.
b. The functions of the Coal Handling System are:
i. Unloading and conveying coal inside the power station.
ii. Stacking and reclaiming in the coal storage yards.
iii. Screening and crushing of raw coal.
iv. Weighing and sampling coal.
v. Removing metal from coal.
2 System Process Flow
15
3 Project Equipment
A: SHIP UNLOADING
Coal is delivered to the coal unloading dock aboard oceangoing vessels of up to
70,000 DWT class (Panamax type).
Two grab-type ship unloaders each rated 1,500 MTPH (metric tons per hour), operate
in conjunction with two jetty conveyors.
The cabin can travel so that the operator can position the cab for optimum viewing of
the digging and discharge.
The grab bucket is able to lift a Caterpillar 910 loader from the dock and place it in the
ship to assist in cleanup.
Each unloader has a cyclone tie-down system.
The two grab unloaders have 2-position diverter gates in their outlet chutes allowing
each unloader to feed coal at 1,500 MTPH to either jetty conveyor.
Ship loader elevation

with ship levels according to
tides and status of unloading.
16
B: CONVEYING: COMMON DETAILS
Access to the walkway of each conveyor is provided every 150 metres unless
otherwise specified.
Each conveyor is designed to carry 1,500 MTPH (Metric Tonnes Per Hour) from the
ship to the stockyard and 1,000 MTPH from the stockyard to the bunkers.
Dust suppression is provided at each transfer point unless otherwise specified.
CONVEYOR 101 (A & B)
The conveyors run most of the length of the jetty to receive coal for the complete
working travel distance of the unloaders and convey it to Transfer Tower TT101.
The conveyors are to be uncovered to allow the ship unloaders to feed their chosen
conveyors at 1,500 MPTH each.
When one unloader is operating, coal can be fed to either conveyor. When both
unloaders are operating, coal can be fed to both conveyors.
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uipped with a Belt Magnetic Separator at the head end.
o In TT101, conveyors 101 A and B feed conveyors 102 A and B respectively.
Each conveyor is equipped with a Coal Sampler and a Belt Weigher.
In TT102, conveyors 102 A and B feed conveyors 103 A and B respectively.

CONVEYORS 103 (A & B), 104, AND 105 (A & B)
17
In TT103, a diverter gate discharges conveyors 103 A and B to either conveyor 104
or stockyard conveyor 105 A.
In TT104, conveyor 104 feeds stockyard conveyor 105 B.
The stockyard conveyors 105 A and B each feed coal to their own slewing bucket
wheel travelling stacker/reclaimer at 1,500 MTPH. Alternatively, they can partially
pass 1,000 MTPH coal directly to transfer points at the other end of the stockyard.
C: STACKERS AND RECLAIMERS

Each stacker stacks the coal onto a short-term pile.
Coal from the short-term piles is spread to form long-term piles using scrapers and
bulldozers.
Stockyard elevation showing
travelling Stackers / Reclaimers
(NOTE 40 Angle of Repose)
18
Coal is reclaimed from the stockpiles by the bucket wheel stacker/reclaimer at
1,000 MTPH and then back onto the stockyard conveyors 105 A and B.
In TT105, conveyor 105 B can be diverted to either conveyor 106 A or B.
In TT106, conveyor 105A can be diverted to either conveyor 106 A or B.
Conveyors 106 A and B are designed for 1,000 MTPH each and feed the coal to the
Crusher Building to be screened and blended, providing a more consistent coal
supply to the power station and a more efficient operation.
19
D: SCREENING AND CRUSHING
In the Crusher Building, conveyors 106 A and B discharge through their own set of
Vibrating Screen and Crusher (Sets A and B respectively). Set A feeds conveyor
107 A or B; Set B feeds the other conveyor.
The minus 50mm sized product falls through the screen and is directed onto either
conveyor 107 A or B.
The oversize material (50-150mm) is directed by chute to be reduced in the crusher

to 50mm max and directed onto either conveyor 107 A or B.
Each crusher can crush 150mm x 50mm to minus 50mm at 800 TPH.
Dust collection systems in the building limit dust emission.
Sectional view of a
Screening and
Crushing Set
20
E: PIPE CONVEYANCE
CONVEYORS 107 (A & B) and PIPE CONVEYORS 108 (A & B)
Conveyors 107 A and B transfer the sized coal

to TT107 and feed the loading points of Pipe
Conveyors 108 A and B respectively.
The pipe conveyors 108 A and B transfer coal

through the existing power plant to TT108 and
onto normal belt conveyors 109 A and B.
Sectional view of the

Pipe Conveyor System
21
F: STORAGE
CONVEYORS 109 (A & B), 110 (A & B), AND SILO STORAGE
Conveyors 109 A and B transfer coal to TT109 and feed either conveyor 110 A or B
via a diverter gate.
Conveyors 110 A and B are mounted directly on top of the boiler bunkers of Units 3
and 4 and discharge via travelling trippers.
22
G: MAGNETIC SEPARATION
Magnetic separators are installed at the head of conveyors 101 (A & B), 105 (A & B),
and in the middle of conveyors 107 (A & B).
23
H: COAL SAMPLING
Coal sampling equipment is located at the head of conveyors 102 (A & B) and 107
(A & B).
I: COAL WEIGHING
Belt weighers (Weightometers) are located on conveyors 102 (A & B) and 107 (A
& B).
Weigh idlers are installed in the belt weighers frame.
24
J: COAL DUST SUPPRESSION
Dust suppression systems are fitted in the following areas:
o Transfer Towers (TT) 101, 102, 103, 104, 105, 106, 107, 108 and 109.
o Ship Unloader
o Stacker/Reclaimer
o Stockpile sprays
These systems reduce the dust nuisance by the addition of moisture together with a
special wetting agent. The spray bars are located at positions where the material
(coal) presents its greatest surface area.
Refer to the Dust Suppression Diagram overleaf.
K: COAL HANDLING CONTROL

The Coal Handling System is controlled from a control room located near the
stockyard. Its control extends from the ship unloader to the coal bunker and
includes the coal yard.
Programmable logic control (PLC) is adopted to perform programming control and

manual control.
Local pushbuttons are used for emergency stopping. Interlock and protective
devices are utilized.
The conveying control system includes sensors for belt speed, belt misalignment,
clogging in chutes/hoppers. Belt conveyors have pull cord switches.
The control system performs data acquisition and signal display. A control console
is installed in the coal control room.
The control mode for the stacker is semi-automatic and manual. Local pushbuttons
are used for emergency stopping.
Most the equipment for the coal plant is controlled from the control room.
Refer to diagram on next page for layout and schematic
25
Coal Dust Suppression Diagram
26
Coal Handling Control Layout
27
4 Technical Data
Material handled Coal
Density 0.85t/m3
Max lump size 150mm
Angle of repose 40 degrees
Grindability HGI 45
Moisture content refer to coal C
Capacity jetty to stockyard 1500t/hr

Capacity to boiler bunker 1000t/hr
Height of stockpile 15m
Stockyard capacity for 20 hours per day 60 days for 2 boilers
(when operating at BMCR per boiler).
Annual average temperature 27.0 C

Monthly average temperature 25.4 to 31.9 C
Design ambient temperature 40 C
Relative humidity 50 - 92%
Max. Wind Speed (at plant site +10m level) 21.0 km/h
Max. Monthly Average Wind Speed 15.5 km/h
Min. Monthly Average Wind Speed 9.7 km/h
5 Reference Manuals
CHEC Coal Handling Manuals
General Arrangement Drawings
o (F558S-M0101-01) COAL HANDLING SYSTEM FLOW DIAGRAM

o (F558S-M0101-02) LAYOUT OF COAL HANDLING SYSTEM
28
Day 2 Session 1
Introduction and Site layout of Coal Handling System
SESSION OBJECTIVE
Introduce the Facility.

Provide an overview of the CHEC Supply.
Introduction of the main equipment supplied.
Review the Coal delivery process
Identify the Design Standards & Codes applied.
CONTENT
1. Introduction and Overview
2. Project Equipment
3. Design Parameters
4. Ship Unloading
5. Material Handling & Ancillary Equipment
6. Stockyard
7. Screening & Crushing
8. Delivery
53
1 Introduction and Overview
BELT CONVEYORS
Belt conveyors are used for the controlled movement of various types of materials
on a horizontal, inclined or declined path.
Generally, belt conveyors transport material in linear form; when it is necessary to
change the conveying direction, several conveyors can be used together using
transfer stations to transfer the material from one conveyor to the next.
A conveyor belt (or belt conveyor) consists of two or more pulleys, with a
continuous loop of material - the conveyor belt - that rotates about them.
One or both of the pulleys are powered, moving the belt and the material on the belt
forward.
The powered pulley is called the drive pulley.
There are two main industrial classes of belt conveyors;
Those in general material handling such as those moving boxes along inside a
factory.
Those used in bulk material handling such as those used to transport industrial and
agricultural materials, such as grain, coal, ores, etc. generally in outdoor locations.
With strong adaptability to the conveying route and high flexibility, belt conveyors
are often the most practical and cost effective method of Materials Handling.
Belt Conveyors are used in various industries including; mining, port, chemistry,
light industry and petroleum.
In the materials handling industry there are several types of conveyor systems that
are used to convey materials.
Each system has their own unique abilities and requirements.
Conventional overland Belt Conveyors
Pipe Conveyors
Pocket Belts
The opposite diagram shows the different requirements that each belt can work
with as a guideline.
Overland conveyors generally consist of ground mounted conveyor frames.
This generally placed the belt approx 900-1200mm off the ground depending on
the belt widths, pulleys and gear box arrangement.
They are designed generally for long conveying distances of bulk materials.
Piped conveyor systems have the flexibility of horizontal and vertical movement on
tight curves.
Overland conveyors have limitation s according to the large radius required
generally in the area of 500m plus.
Piped conveyors have the added bonus of enclosing materials suppression dust
emissions and improving environmental conditions.
Their limitations come from the amount of material they can easily transport

54
Pouch Conveyors are different style of conveyance allowing highly flexible belts to
move in much smaller areas around corners and tight vertical changes.
They are driven by end pulleys and or individual wheel drives at the top of the
belts.
The belt is loaded by opening up the pouch belt and loading from above.
The pouch is then enclosed and suspended from above.
Pouch conveyors also have limitations currently and the y are mostly used in
pharmaceutical and light industry.

The belt consists of one or more layers of material they can be made out of rubber.
Some belts depending on their requirement can have steel mesh, wire rope or other
reinforcing material to make the belt stronger and more durable.
Material flowing over the belt may be weighed in transit using a beltweigher. Belt
Conveyors are used in self-unloading bulk freighters and in live bottom trucks.
Belt Conveyors use a continuous belt to transfer material.
The material being conveyed is carried by the top surface of the belt.
Belt conveyors can take materials from one point or several different points, can
also unload materials to several points or working areas.
The longest belt conveying system in the world is in Western Sahara. It is 100 km
long, from the phosphate mines of Bu Caa to the coast south of El - Aauin.
The longest conveyor system in an Airport is the Dubai International Airport
baggage handling system at 92km. It was installed by Siemens and commissioned
in 2008, and has a combination of traditional belt conveyors and tray conveyors
The longest single belt conveyor runs from Meghalaya in India to Sylhet in
Bangladesh. It is about 17 km long and conveys limestone and shale at 960 tons/hr,
from the quarry in Indiato a cement factory in Bangladesh (7 km long in India and
10 km long in Bangladesh).
Belts can be moved at varying speeds according to the requirements of each
project.
Features of Belt Conveyors include;
Reliable, continuous operation
Low operating cost
Low maintenance
Low demand for energy consumption
Minimal damage to the conveyed material
Good climbing performance
Conveyor systems can be fully automated
Belt conveyors usually consist of the following components;
Conveyor Belting generally consisting of a continuous belt, that is spliced through
mechanical and thermal processes call vulcanisation
A singular drive pulley at one end.
A tail pulley
A gravity Take up pulley and counterweights or a screw tightening unit to place
tension in the belting to allow for the belt to adequately traverse the conveyors.
Carry Idlers designed to assist the belt in moving along the conveyor
Training Idlers designed to assist the belt in correct alignment.

Return idlers designed to allow the belt to move freely on the underside of most
conveyors which is unloaded
55
Impact idlers to allow for materials to be placed onto the conveyor belt allowing
flows from other conveyors or chute works to impact the belt with minimal bouncing
and damage occurring.
Head Discharge area.
Tail Area
Some conveyors can be covered with dust covers to remove problems with dust.
General guards around all idlers and pulleys to remove the dangers of getting arms,
hands, clothing and tools caught in the belt.
Scrapers to assist in cleaning the belt and decrease damage.
Conveyors need to be supported on steel frames to allow for the machinery to be
situated securely.
The framing allows for all the idlers, pulleys, drives and belt to attach to the frame.

Frames can be designed according to each site requirements. Many frames come
in modules attached to the ground at relatively low heights to allow for maintenance.
Frames can also be designed to span great distances according to the site.
They can be elevated at heights with no decrease in the conveyor operations.
2 Project Equipment
Main Equipment Components are:
1. Ship Unloader
2. Conveyors, Trippers & Chutes
3. Transfer Towers and Structures
4. Stacker Reclaimers
5. Sampling Equipment
6. Screening & Crushing Equipment
7. Dust Collection and Suppression
8. Weightometers & Metal Detectors
56
The Coal Material Handling System Flow Diagram.
57
3 Design Parameters
GENERAL DESIGN CRITERIA
The coal handling system is based on the following design criteria:
The Berth can manage vessel sizes up to 70,000 DWT of oceangoing ships
(Panamax Type).
The Material Handling System can deliver 292.8 Metric TPH (burn rate of coal
handling system per one MCR mode)
Bulk density of 0.85 metric ton per cubic meter
Received coal size 150 mm x 0 mm
The coal handling system is designed to provide for the unloading, receiving,
storing, reclaiming, and crushing of coal at the stated design rates with ultimate
delivery to 2 x 660 MW power units.
The coal handling system will be designed under the following conditions:
Unloading operation from vessels: 24 hours/day

Discharging operation to silos with 2 lines: 12 hours/day
Single line discharging operation to silos: 24 hours/day
The complete coal handling system will be possible to be operable for 24 hours/day.
The design of the coal handling system therefore has to take the nightly noise
limitations into account.
During the 24 hour per day ship unloading operation, two ship unloaders will be
operating at the same time, therefore, both lines of receiving conveyors and both
stacker/reclaimers will be operating simultaneously.
In addition, during the unloading operation either one or both reclaim lines to Unit 3
and 4 generation buildings will be operating when coal levels in the storage silos
demand fuel.
One plant feed line has the capacity to service the demand of both generating units.
During times of no ship deliveries, a single reclaim line operating approximately five
hours per eight-hour shift will supply the needs of both units operating at 80 percent
MCR.
58
The second stacker / reclaimer, crusher and reclaim line to the generation units will
serve as redundant equipment.
The ship unloader and stacker- reclaimer shall be capable of operating in wind
speed up to 20 m/s.
However the ship unloader and stacker- reclaimer shall be able to move to tie-down
location in a wind speed up to 30 m/s.
4 Ship Unloading Facility

SHIP UNLOADING
Coal will be delivered to the coal unloading dock aboard oceangoing vessels of up
to 70,000 DWT class (Panamax type).
Two grab-type ship unloaders, each rated 1,500 MTPH (metric tons per hour), shall
be provided on the dock to unload the ships.
Both unloaders shall traverse on the same set of rails furnished by the Supplier.
Ship Unloader A can serve either Dock Conveyor 101A or Dock Conveyor 101B
and Ship Unloader B can serve either Dock Conveyor 101B or Dock Conveyor
101A.
The unloading operation shall be accomplished semi-automatically and/or manually

by using the controls in the operators cab.
SHIP UNLOADERS
Each ship unloader shall consist of a clamshell type bucket, mounted on a bucket
trolley.
The bucket trolley shall be mounted on a horizontal apron boom, at an elevated

position above a docked ship.
The apron boom shall be mounted to a traveling tower structure. The apron shall
have the capability of being raised from the horizontal operation position to clear the
ship structures.
Each tower shall consist of a mast and a 4-leg support structure, mounted on
traveling trucks at each corner leg.
The tower shall also support the inward extension of the apron boom, which is a
fixed runway.
59
The runway shall reach out to the rear of the tower. The apron boom and runway
components shall be box sections, with rails on the top side for the grab bucket
trolley travel.
Each tower shall also contain a hopper to receive the coal from the grab bucket
discharge. The hopper shall have a vibrating feeder at the lower discharge point.
The feeder shall transfer the coal to impact tables, (2 impact tables for each
unloader), supporting the dock conveyor belts, which shall pass under the tower
structure.
The operator is in an operators cabin. The cabin can travel along the underside of
the apron boom so the operator can position the cab for optimum viewing of the
digging and discharge operation.
The receiving system for the grab bucket shall be a 4-part rope arrangement for
direct- receiving operation. The 4-part ropes shall consist of two close ropes and
two hold ropes.
The close rope ends shall be anchored in the bucket. The hold ropes shall have pin
connections to the bucket for quick release and change of bucket.
Each unloader shall have approximately a 30 metric ton hoisting load (including
grab weight), scissors type, grab bucket. The grab bucket is able to lift a Caterpillar
910 loader, or equal, from the dock and place it in the ship to assist in cleanup.
The ship unloader has been designed to operate using the maximum outreach of 35
meters.
Included with each unloader shall be a dust-suppression system at the hopper

grizzly to minimize dusting and at the feeder discharge. An adjustable spill plate in
front of the hopper shall limit spillage of coal into the water. Spillage on the plate
shall be dumped back into the hopper by raising the spill plate
Access shall be provided on the machine for operator and maintenance personnel.
An elevator shall be included for access from dock level to the top of the hopper
level, the operators cab access area and the machinery house area.
The hold, close and trolley travel shall be operated by variable-speed drives. Power
shall be furnished by means of cable reeler. Control interface shall also be supplied
by the reel.
Each unloader shall include anchor brackets for tie-downs, shear pins, and anchor
bolts. The holding system shall include turnbuckles.
The end travel stops shall include fabricated brackets, bumpers located on the
unloaders, anchor bolts, and anti-collision system.
Ship unloader will be supplied with self contained dust suppression systems of the
atomized water sprays type at all transfer points.
Each unloader shall include a water tank for the dust suppression- and
power/control cable reel(s). Control cables shall be optical fibers.
60
Power and control junction boxes, water supply connection valve, communication
junction box, and required inserts shall be provided at the mid-point of travel for
each ship unloader.
5 Material Handling
COAL CONVEYING SYSTEM, CRUSHERS, AND DUST COLLECTORS
Conveyors shall be capable of starting and stopping when empty, partially loaded,
or fully loaded without slippage or damage to other components of the system.
Conveyors are complete with stringers, decking, support legs, idlers, conveyor
belting, skirt boards, belt seals, loading and discharge chutes, pulleys and shafts,
drive units, safety switches, and all other necessary appurtenances.
CONVEYORS 101 A & B
Conveyors 101A and 101B are to be uncovered to allow the ship unloaders to feed
their respective conveyors.
Each of Conveyors 101A and 101B is to be equipped with a Belt Magnetic

Separator at head end.
at a design rate of 1,500 Metric TPH via chute work respectively.
CONVEYORS 102 A & B
at a design rate of 1,500 MTPH via chute work respectively.
The transfer of coal is at Transfer Tower TT02
Belt weighers (or weightometers) are situated on each conveyor
CONVEYORS 103 A & B

Conveyors 103A and 103B shall be shall be supported at space of approximately
12 meters until the Conveyor reaches the shore. The supports will be at the same
elevation as the jetty.
Access to the walkway of Conveyors 102 and 103 shall be provided every 150
meters.
Conveyor 103A and 103B shall deliver coal to Conveyor 104 and Conveyor 105B at
a design rate of 1,500 MTPH via chute work respectively in Transfer Tower 103.
Before this transfer tower (on the Conveyors 103A and 103B) two As-Received
Sampling Systems shall be provided to take samples from both Conveyors 103A
and 103B to verify quality of delivered coal respectively.
61
Diverter gates are provided in TT03 to allow for loading to either one or the other
conveyor. IE conveyor lines are interchangeable
CONVEYORS 104, 105 A & B
Conveyor 104 shall deliver coal to Conveyor 105B at Transfer Tower TT04.
Conveyor 105B feeds the Reclaimer / stacker B at a design rate of 1,500 MTPH
Conveyor 105 is fed from TT03 at a design rate of 1,500 MTPH via chutework.
Conveyor 105A feeds the Reclaimer / stacker A at a design rate of 1,500 MTPH
The stackers and reclaimers have various modes of operation.
The output from these conveyors is a maximum of 1500 TPH once they have
passed the reclaimers / Stackers.
6 Stockyard
STACKERS / RECLAIMERS
All coal yard Stackers/ Reclaimers are rail mounted and designed to travel the full
length of the coal storage yard.
The Stacker/Reclaimers (A & B) can either stack coal onto the stockpiles or reclaim
coal onto their dedicated stockyard conveyor 105 (A or B).
CONVEYOR 106 A
Yard Conveyor 106A receives coal from Stacker/Reclaimer conveyor 105A.
Diverter gates are in place at TT05 to alternate direct flow to either conveyor 106B or
106A
CONVEYOR 106 B
Yard Conveyor 106B receives coal from Stacker/Reclaimer conveyor 105B.
Diverter gates are in place at TT06 to alternate direct flow to either conveyor 106A or
106B
62
7 Screening & Crushing

CONVEYORS 107 A & B
respectively via chute work in the Crusher Tower.
Coal is delivered to the crushing building and then screened.
Screened material automatically passes to the discharge chutework. This chutework
also has diverter gates to allow loading to either conveyor
Oversize material is diverted to the Crusher equipment for resizing. Coal is then
delivered to the discharge chutework. This chutework also has diverter gates to allow
loading to either conveyor
SCREENING & CRUSHING
Belt Feeder A shall deliver coal from Conveyor 106A to Vibratory Screen (option:
Roller Screen) A
Belt Feeder B from Conveyor 106B shall deliver coal to Vibratory Screen (option:
Roller Screen) B.
The screens shall each divert the oversized (50-150 mm) coal to their respective coal
crushers.
The minus 50 mm shall be directed to either Conveyor 107A or 107B via chute work
and diverter gates.
CRUSHERS
Coal Crusher A and the through product of Screen A shall deliver the coal to
Coal Crusher B and the through product of Screen B shall deliver the coal to
Each crusher shall be designed to crush 800 MTPH of 150 mm x 50 mm to minus 50
mm.
Dust collection systems are in place on the Crushing buildings to limit dust emissions.
8 Delivery to Silos
CONVEYORS 107 A & B
Conveyor 107A shall deliver coal to Pipeline Conveyor 108A
Conveyor 107B shall deliver coal to Pipeline Conveyor 108B
Transfer occurs at Transfer Tower 107
Conveyor 107A and 107B shall each be equipped with a belt scale for equipment
control.
63
Conveyor 107A and 107B shall each be equipped with a Magnetic Separator.
A Coal Sampling device with two cutters shall be provided to take samples from both
Conveyors 107A and 107B
CONVEYORS 108 A & B

Pipeline Conveyor 108A shall deliver coal to Conveyor 109A at a design rate of 1000
The pipeline conveyors traverse approx 300m over the existing plant facility, with a
horizontal curve.
CONVEYORS 109 A & B

Conveyor 109A shall deliver coal to Conveyor 110A at a design rate of 1000 MTPH
via chute work.
Diverter gates are in place in TT09 for loading of alternating conveyors as required.
This conveyor is a step vertical angled conveyor raising the coal approximately to a
height of 48m above ground level.
TRIPPER CONVEYORS
Tripper Conveyor 110A shall deliver the coal at a design rate of 1,000 MTPH to
motorized traveling Tripper A.
Tripper A shall traverse the required length of the Storage Silos delivering coal to any
Tripper Conveyor 110B shall deliver the coal at a design rate of 1,000 MTPH to
motorized traveling Tripper B.
Tripper B shall traverse the required length of the Storage Silos delivering coal to any
The silos shall be fitted with tripper seals to minimize dust emissions.
Coal dust collectors are installed to minimise dust pollution.
MATERIAL HANDLING GENERAL

All conveyors and transfer towers will be designed to permit easy access for bob cat
type equipment to clean up spillage that might occur beneath the conveyor structure.
Coal dust shall be controlled by wet dust suppression systems at all transfer towers.
Coal dust shall be controlled by dust collection systems at the crusher building and at
the storage silos.
64
A control system shall be included for the conveying system, ship unloaders, and
stacker / reclaimers by the Supplier.
Hoists shall be provided for all transfer towers for servicing conveyor drives and the
crusher structure for servicing the incoming conveyors, screens, samplers and the
crushers.
A rail system and hoists shall be provided for each unit for tripper equipment
maintenance. The hoist rail will be attached to the tripper gallery roof steel by others.
Hoists shall be arranged to lower equipment to the ground. The hoists shall be rated
to lift the heaviest piece of equipment.
The tripper area shall have a piped vacuum cleaning system for maintenance.
The elevated portion of conveyors shall be supported from open type trusses and
structural steel bents.
All conveyors shall be protected from the elements with conveyor hoods over the belt
portion of conveyor only except on portions of conveyors traversed by the ship
unloaders and the stacker / reclaimers and trippers.
Moving parts of equipment shall be readily accessible for inspection, lubrication, and
repair where necessary, and shall be protected from the flow of conveyed material.
However, moving parts of equipment shall also be guarded as required to protect
personnel during operation.
Expanded metal guards shall be furnished and installed at all nip-points or pinch-
points at conveyor pulley. Conveyors shall be of the rubber belt type.
Conveyors shall have a maximum inclination of 16 degrees.
Conveyor elevations shall be such that a minimum of 7.0 meters of clearance is
provided over all roads
9 Standards & Codes

CODES AND STANDARDS
The following international recognized standards and codes were used (but not
limited to) for the design of equipment as requested in the Main Tender
Documentation
Technical code for designing fossil fuel power plants (DL 5000-2000)
Technical code for Designing Coal Handling of Fossil Fuel Power Plant- Part 1: Coal
Handling System (DL/T 5187.1-2004)
Conveyor Equipment Manufacturers Association (CEMA)
The Anti-Friction Bearing Manufacturers Association (AFBMA)
Rubber Manufacturers Association (RMA)
ISO 5048 Continuous Mechanical Handling Equipment - Belt Conveyors with
Carrying Idlers - Calculation of Operating Power and Tensile (Conveyor Design).
65
ISO 5049 Mobile Equipment for Continuous Handling of Bulk Materials - Part 1: Rules
for the Design of Steel Structures (Machine Design Equivalent to FEM Std.)
BS 2573, Part-1 & 2
IS 13082
GB755
GB4208
GB12348
GB/T 13384-92
GB12351-90
REFERENCE MANUALS
Coal Handling Manuals

o (IM0401-1) Coal Handling System Table of Contents
Ship Unloader Manual
o (IM0401-3.1.1-1) Ship Unloader Erection & Commissioning Manual-1
o (IM0401-3.1.1-2) Ship Unloader Operation & Maintenance Manual-0
o (IM0401-3.2-1) Conveyor Instruction Manual-0
Coal Crusher Manual
o (IM0401-3.6-1) Crusher Instruction Manual-0
Tripper
o (IM0401-3.7-1) Tripper Instruction Manual-1
66
Day 2 Session 2
Introduction to belt conveyor main parts
SESSION OBJECTIVE
Introduce the main part of the conveying system

Identify various components of the conveyor and their functions
CONTENT
1. Conveyor Overview
2. Gearbox & Motor
3. Pulleys
4. Belts
5. Idlers
6. Belt Scrapers and Ploughs
7. Conveyor Skirts
8. Belt Tensioning
9. Alarms & Trips
10. Dust Covers
11. Belt Weighers
12. Belt Samplers
13. Reference Manuals
67
1 Conveyor Overview.
This graphic represents a 3D model of a conveyor system comprising a nominal sized belt,
drive pulley with motor and gear box, Counter Weight frame (gravity Take Up), idlers and
frames, return idlers and some basic framing.
This graphic represents a 2D model of a conveyor system comprising a nominal sized belt,
drive pulley with motor and gear box, Counter Weight frame screw unit), idlers and frames,
return idlers and some basic framing.
68
Gear box and motor
The motor and gear box can be individual based systems or one entire unit.
This is designed upon the performance criteria, system requirements, spare parts
and overall functionality.
The Shaft of the drive pulley sits in the gear box mounting. The shaft is supported
on two side bearings to remove vertical weight loading onto the shaft and gear box.
The motors are usually controlled via a PLC control system and electrically driven.
Cabling to support all the elements runs back to a central control and distribution
area
Pulleys
69
The drive shaft and bearings are supported on the structural steel structure.
The pulley shafts are housed in bearings which allow free rotation of the shaft.
Drive shafts and pulleys can range in size
Shafts come in a variety of materials, including Stainless steel.
They are highly machined for tolerances and correct operation
Pulley diameters are designed to incorporate the high tensions placed on to them
from the drive units and belts.
Pulleys are made from a range of materials including mild steel. Tubular sections
are used when in correct sizes.
Pulleys are also lined according to the clients requirements either with rubber
lagging, ceramic materials or other specifications. This increases the wear life and
belt life.
Belts
Belting comes in many forms and can be tailored to suit each conveyor
profile to the engineers/designers specifications.
70
71
Belt Idlers
9. Belt idlers come in a range of varying configurations to suit the belt configurations,
product being conveyed and the principal requirements.
10. Generally the carry idlers are troughed.
11. This means the edges are raised on nominal angles.
12. This allows for the product to be heaped and prevent spillage of the material.
13. Mobile Limestone Grab Crane
Idlers come in different forms to suit different needs.

Plain carry idlers are generic idlers that allow for general conveying.
Impact idlers as the name suggests allows for the idlers to be under impact loads
from the loading area of the conveyor.
The idlers are fitted with rubber or steel idlers depending upon the requirements.

72
Return Idlers
Return idlers come in various forms depending upon their use.

Flat return idlers are generally a single or multiple roller configuration with no
inclination.
These units do not allow for tracking of the belt.
Special flat roller training idlers are required at certain lengths along the return side
of the belt.
V-Return idlers allow the belt to keep some of the troughed form that the carry side
idlers undergo.
These allow for minor belt tracking and if required can be used in conjunction with
V-Return training idlers.
Return idlers come in various forms depending upon their use.
Flat return idlers are generally a single or multiple roller configuration with no
inclination.
These units do not allow for tracking of the belt.
Special flat roller training idlers are required at certain lengths along the return side
of the belt.
V-Return idlers allow the belt to keep some of the troughed form that the carry side
idlers undergo.
These allow for minor belt tracking and if required can be used in conjunction with
V-Return training idlers.
73
Training Idlers
Training idlers for the return and carry sides of the conveyor belt used for tracking
the belt into correct alignment.
The training idlers can be situated along the conveyor as required.
Idlers can come in various angles to suit the overall carry side and return side idler
characteristics.
Belt scrapers and Ploughs
Scrapers and Ploughs are used to keep the conveyor belts clean and avoid excess
material being deposited on pulleys and other machinery.
They are situated at various sections along the belt.
Typically conveyors have scraper units mounted at the head pulley, drive pulley, tail
units and be at changes of belt interaction with pulleys.
Excess material is either deposited into small chutes, on the ground or to diverted
away from the main machinery.
74
Conveyor Skirts
Skirts are designed to allow for loaded material to be contained on the conveyor
belt near the chute area.
Generally skirts are supported on the main structural frame with angle framed arms
and straight guides.
Guide are generally made from mild steel, but can be made from stainless steel
where required for abrasion purposes.
Belt Tensioning
Gravity take up Units (GTUs) are designed to place the conveyor belt in tension.
This allows the belt to be straight between the carry idlers whilst carrying material
removing sag from in between.
The sag induced impact loads into the carry idlers and causes excess damage.
The tension in the belt also assists in the drive pulley maintaining traction and
preventing slipping, which damages the belt.
Screw take up units can also be used in lieu of GTUS.
They consist of a screw mechanism over a couple of meters that tighten the belt.
These are usually only found in smaller conveyor belt system.
Hydraulically driven rams can also act as tensioning elements.
They gain tension by lengthening the belts.
75
Alarms and Trips

Alarms are used on the conveyor systems when certain events occur, such as
blockages, overloading, belt tracking issues and motor failures.
The alarms are usually PLC controlled in some cases have the automatically
response to cut power to the conveyor system to limit damage to the conveyor and
its surrounds.
Dust Covers
Dust Covers area elements that can be used to present wind blown dust occurring
from the conveyor system.
They are usually attached to the main part of the conveyor structural frame and
enclose the belt entirely.
Belt covers can be made of light steel, plastics, sheet metal or similar products.
76

Belt covers can come in a variety of sizes to suit the clients needs.
Covers can be made strong enough to resist wind, cyclonic and typhoon loadings.
Covers are considered an environmental solution for wind blown dust.
Belt Weighers
Belt weighers are property units designed to be integrated with conveyors to measure the
weight of the transported material for an accurate tonnage and loading rate.
Weighers consist of idlers that are pressure loaded at known distances, with electronic
control devices measuring belt speed and weights, allowing for easy and accurate
readings.
77
Coal Samplers
Belt samplers are designed to allow for conveyed material to be sampled without
the need for stopping the conveyor system.
The system generally consists of a sampling arm which obtains material form the
belt without disturbing the main flow of the belt.
Belt samplers are designed to allow for conveyed material to be sampled without
the need for stopping the conveyor system.
The system generally consists of a sampling arm which obtains material form the
belt without disturbing the main flow of the belt.
Magnetic Sampler
Magnetic samplers are used to assist in the removal of metal particles within the
conveyed product.
Many types of magnets separators exist. Each will have their own disposal system
of the collected metal material.
Non removal of metal materials in elements such as coal used for fuel purposes on
the power plant, could lead to permanent damage and in correct fuel burning.
78
REFERENCE MANUALS
For Detailed technical Information refer to:
Gear Motor Instruction Manual

(IM040251)GearmotorInstructionManual0
Belt Weigh Scale Manual
(IM040255)BeltWeighScaleInstructionManual0
(IM04013.21)ConveyorInstructionManual0
79
XLCD1200 TRIPPER & DIVERTER GATE
SESSION OBJECTIVE
Introduce the tripper
Introduce the diverter gate
CONTENT
1. Introduction
2. General Description
3. Maintenance
4. Reference
184
PART 1: TRIPPPER
This section covers the basics of a traveling tripper.
There are two types of traveling trippers used within the coal handling system:
1. The stock yard stacker tripper.
This tripper is attached to the stacker/reclaimer machine and is covered in the

sessions of Day 4.
2. The traveling trippers above the storage silos on conveyors CV 110 A & B.
The tripper is designated the XLCD1200 tripper and is a purpose built unit
commonly used in the coal storage systems of thermal power plants
XLCD1200 tripper is a conveyer belt unloading piece of equipment.
It can accomplish unloading of coal conveyer belts automatically.
The tripper is designed with a reduction in environmental pollution ,and is fitted

with Dust Collection and Suppression equipment to further reduce pollution
185
The XLCD1200 tripper is composed of the following:

A traveling propulsion system
A manual operators driving platform
An electric diverter chute
An incline trailing conveyor
Rail clamping apparatus
Bend pulleys
Dust collector
Cable reel and electrical control system.
The XLCD1200 tripper is used to unload coal from the conveyer belt of CV110 to
the coal bunker of Units 3 & 4.
The tripper runs the full length of the conveyer belt, it can discharge incrementally
or discharging at a fixed point.
The tripper is controlled by the PLC system and can operate either manually or on
an automatic system.
The XLCD1200 Tripper Unit (Under Construction)

186
The XLCD1200 tripper has 6 wheels to reduce the point loads on the rail. The stress of
support is spread more uniformly along the conveyors above the silos.
The two front wheels are the driving wheels which can propel the unit along both directions
of the conveyor.
The tripper needs more power to drive against the direction of the conveyor movement.
The dust collector (blue) is mounted close to the discharge so that any light fugitive dust
can be captured and dropped back into the material stream.
The electrical and control panel has its power supplied via a trailing cable reeler. The
realer automatically manages the tension and position of the supply cable along the
conveyor.
The XLCD1200 tripper has a hinged tail-car and driving platform is to make sure there is
normal contact between all wheels and rail, this gives the tripper added flexibility
Rail Clamping device

This device is to ensure that the tripper does not accidentally move while not in use.
187
The function of the hydraulic rail clamping apparatus is to clamp to the rail under the
force of springs when the trippers power is off.
The clamp has a secondary feature in that it assists the guide rollers to avoid
derailing accidents by providing lateral stability.
Tripper guide wheels
The function of the directive wheel is to guide the tripper when it is traveling.
The wheels minimize excess loads on the flanges of the main wheels. The axial loads are
generated by wind and discharge forces.
Tripper Tail Section
188
The tripper tail section or belt lift section is designed to manage the belt as it rises to the discharge
position.
The tripper tail is designed as short as possible to minimize the travel length of the
supporting conveyor system. The maximum preferred angle is 15 degrees.
During start up of the conveyor additional belt tensions will tend to lift the belt up off of the
trailing tail stock section. Additional holds down wheels are installed to reduce the lift and
associated wind forces on the belt.
189
MAINTENANCE
Lubrication Chart
Lubrication part Lubrication

Lubricating oil Remarks
name interval
36 months According to
instruction
1 Flender reducer Work over CLPCC
provided by
8 hours everyday Manufacturers
36 months According to
Lubricating
Motor and gear instruction
2 Work over grease
bearing provided by
DIN51818
8 hours everyday Manufacturers
250C~500C
DB-25 According to
Hydraulic rail instruction
3 12 months GB2536
damping device provided by
HL-10 Manufacturers
DIN51524
Bearings of wheel
group
Bearings of Synthesis of Ca-

lubricating
Filling volume
guide wheel grease
4 6 months bearing case
Bearings of press SH/T0372- room 1/32/3
wheel 92
Bearings of bend
pulley
Synthesis of Ca-
Filling volume
lubricating
5 Electric flap bearing 6 months bearing case
grease
room 1/32/3
SH/T0372-92
Comments Lubrication interval can change according to actual situation.
190
PART 2 DIVERTER GATES
Diverter gates are used extensively in the bulk material processing industry:
Its primary function is to direct the flow of material to various processing circuits.
191
It also can regulate the amount of flow to various circuits, and to isolate circuits for
maintenance.
The single blade diverter, commonly know as a flop gate, is custom built to fit each
individual application. The unit features:
Heavy-duty construction
Abrasion-resistant steel blade
Elastomer Seals
Outboard bearings
Various sizes, angles of diversion, actuation styles, and materials of construction.
The electro-hydraulic push rod type applies to the gate actuation to push or pull the
gate to a position.
Hydraulics is generally used to generate the large forces required to reliably hold
the diverter or gate.
The proportional control is usually PLC or computer control and is generally used in
blending processes.
Manual over ride mechanism are also provided.
192
Order Malfunction Cause of Malfunction Ways of Removal

Number
1 The pistol rod can 1.the electric engine fails to turn 2.no 1.to examine the electric
be turned oil is added, 3.the oil is too dirty, the circuit
pilot-controlled check valve is
blocked, 4.the pressure the fluid 2.to fully fill the hydraulic oil
valve adjusts is too small. 3.to dismantle the rod and
clean it
4.to debug it according to

the regulations.
2 The pistol rod can 1. the oil is too dirty, 1. to change the oil and use
only be turned in the coal oil to remove the
one direction 2. the pilot-controlled check valve is impurities
blocked,
2. to clean the jumper valve
3.the check valve isnt strictly sealed.
3. to do the steady filtration
of the hydraulic oil.
3 There is oil leakage The seal components of the oil pump To change the seal
between the axial skeleton gets broken components
electric engine and
the engine base
4 There is oil leakage The axis YX seal components on the To change the seal
between the pistol pistol rod is broken components
rod and the front
end cover
For Detailed technical Information refer to:
XLCD1200 Tripper Instruction Manual
193
Day 9 Session 1
ELECTRICAL SYSTEM INTRODUCTION
SESSION OBJECTIVE
Overview of electrical system

Outline of electrical equipment
CONTENT
1. System Overview
2. Electrical System Voltages
3. Electrical Components Layout
4. Electrical Equipment Description
5. References
240
1 System Overview
The electrical system be designed serves for the coal handling plant of unit 3&4 . It
be controlled and monitored through the PLC from the Central Control Room(CCR).
Four electrical houses in the CHS.
-TTG (Transfer Tower/Tripper Gallery Electrical House)
-RA(Crusher Building Electrical House )
-CE(Coal Yard Control/Electrical House)
-CJE(Coal Unloading Jetty Electrical House)
Six power circuits (10 kV )to coal handing medium voltage switchgears.
The 3kV switchgear be fed from the 10kV board via transformers.
Motors >= 150 kW be powered by 3 kV. Motors < 150 kW and other electrical
consumers be powered by 380 V.
At least one set of 220V DC system be placed in each electrical house
Single Line Diagram
241
2 Electrical System Voltages

System Voltages:
10kV ac (HV) Distribution Voltage Site wide.
3kV ac (HV) Distribution Voltage Stacker/Reclaimers.
380V ac (LV) Standard Distribution Voltage.
220V ac Single Phase Volatge.
24V dc PLC IO Volatge.
220Vdc Tripping Supply Voltage (for HV Switchgear)
3 Electrical Equipment Layout

Site Electrical Equipment Layout Plan
CJE
CE
TTG
RA
242
TTG Electrical Equipment Layout
RA Electrical Equipment Layout
243
CE Electrical Equipment Layout
CJE Electrical Equipment Layout
244
4 Electrical Equipment Description

High Voltage (HV) Distribution Switchboards
Type ABB
UniGear ZS1, 40KA.
Used for switching

and circuit protection
of feeders to
field switchboards.
VB:VD4-12
VC:VSC/P7- 400A
Control Voltage:DC 220V
Isolation and Locking of Breaker.
Circuit breaker can be racked in/out manually and electrically.
Electrical Equipment Description
Isolation and Locking of Breaker.
Electrical Equipment Description
Tripping supply system 220V dc.
Type PZDWK, by China Huadian Engineering Co. Ltd.
Transformers
BS9-M-2500/10-3, BS9-M-3200/10-3 and SCR10-800/10-3 for 3kV.
Nneutral points be grounded
through resistors.
Cooling method be of ONAN.
SCB10-250/10, SCB10-1000/3 and SCB10-800/3 for 380V.
Neutral points be grounded directly.
245
HV Distribution Transformers
Type ABB pad mount:
Oil type Hermetically Sealed.
Dry type RESIBLOCK design.
Fault Protection:
High Temperature Alarms.
Gas Pressure Alarms.
Refer ABB Transformer manual.
HV System - Neutral Earthing Resisters

Rating of 400A for 10sec.
Type ZZH-3.15-4.6, by XI AN Xiangrui Electric Apparatus

Manufactory Co. Ltd.
Creates Lower fault levels, reduces electrical equipment damage if a

fault occurs on the HV system.
380V Motor Control Centres (Switchboards)

Type MZS by China Huadian Engineering Co. Ltd.
Breakers: E2N/E1N, 50KA
MMCB Type: T2S
Control Voltage
CB: DC220V
MCB: AC220V.
Withdrawable.
Indoor Only application.
Site Switchboards;
No. 1 TTG.
No. 2 RA
No. 3 CE
No. 4 CJE
Drive Isolation & Locking.

246
Drive Isolator Handle.
Controls/Automation Equipment
VSDs;
Type ABB ACS800 Stacker/Reclaimers.
Type Siemens Simovert Ship Unloaders.
PLC System;
Type AB Control Logix5000 - Stacker/Reclaimers, Coal Handling

Plant.
Type (Schneider) Modicon Concept Ship Unloaders.
HMI System
Type AB Stacker Reclaimers.
Type WINCC Ship Unloaders.
Type GE iFIX Coal Handling Plant Central Control.
247
5 References Manuals
Links to Instruction manuals.
Transformer OEM Instruction Manual
(IM0401-3.1.3-16 Instruction Manual
HV Switchbaord OEM Instruction Manual
(IM0401-4-2) Instruction Manual
LV Switchbaord OEM Instruction Manual
PLC Instruction OEM Manual
(IM0401-5.1-4) OEM Instruction Manual
248
Day 9 Session 2
CONTROL SYSTEM DESCRIPTION
SESSION OBJECTIVE
Review of control system

Describe and outline the operating functions
CONTENT
1. System Overview
2. Control System Architecture
3. Operating Description
4. Operating Functions
5. Equipment Operating Functions
6. References Manual
249
1 System Overview
The Control System contains
Central Control Room Computers
3 x Operator (HMI/SCADA) Stations
1 x Engineering Work Station (for PLC access)
2 x Coal Yard Management (HMI/SCADA) Stations
Computers are Windows XP in English Language
Switchroom PLC Cabinets x 4
Jetty Electrical House
Coal Yard Control/Electrical House
Crusher Building Electrical House
Tripper Gallery Electrical House
Fibre Optic cable links to Ship Unloaders & Stacker/Reclaimers.
This system control equipments include

11 control cabinets,
19 belt conveyors,
2 vibrating screens,
2 coal crushers,
22 chute vibrators,
10 diverted gates,
2 disc magnetic separators,
4 belt magnetic separators,
4 belt weighers,
2 traveling trippers,
and 3 dust collectors.
250
2 Control System (Network) Architecture
Site Equipment Layout
3 Operating Description
The coal handling control system is a dedicated system for control and monitoring
for the coal handling (feed in of fuel) system of the power plant.
251
The coal handling system is used for the unloading, storage, feed and distribution of
coal for power plant by coordination with coal unloading, stacking system and
reclaiming to provide coal for TJB power plant units 3 & 4.
Equipment Interlocking includes:
2 x Ship Unloaders.
2 x Stacker/Reclaimers.
2 x Sample Stations.
This equipment has dedicated (local) control systems that interface with the Coal
Handling control system (CHCS) for interlocking controls.
The CHCS may assist operators to monitor and analyse service conditions (further
diagnostic information will be available at the local displays).
Conveyor/Belt Interlock Conditions:
Start Interlocking
Conveyors can be started according to reverse direction of coal flow,

i.e. CV101 can only be started when CV102 is running.
Stop Interlocking
Under normal conditions, the conveyors may be stopped according to

the direction of coal flow. If a belt is abnormally stopped, all belts
before it are stopped.
T-Damper (Diverter Gate) Interlocking
The Tee can move forward and backward only when the conveyor
along its reverse direction of coal flow is stopped, i.e. SWT801 must
be operated only when CV803A conveyor is stopped.
After the system is put into operation, this should increase;
Production safety,
Reliability of the power plant,
Reduce the labor requirements,
Improve the working conditions, and
Provide automation management.
The system has three main process flow options:
Stacking Process
252
Ship unloader to the coal yard, combined with the coal unloading
system, the coal handling system shall convey the coal from jetty to
the coal yard for storage through the coal stacking and reclaiming
system.
Reclaiming Process
From coal yard to coal bunker, combined with the coal stacking and
reclaiming system, the coal handling system may convey the coal
stored in coal yard to coal bunker, this process flow has the coal
mixing function
Through Process
Ship unloader to coal bunker, combined with the coal unloading

system, coal stacking and reclaiming system. The coal handling
system directly conveys the coal from jetty to the coal bunker. And this
process flow has the coal mixing function
Operating Description
All process flow options have several optional routes the coal can follow.
Coal Stacking Routes (Prefix of letter D)

[Ship Unloader to Coal Yard]
D1
SU801A -> CV801A > CV802A > CV803A -> CV805A -> SKR805A ->
Coal Yard.
253
D2
SU801A -> CV801A > CV802A > CV803A -> CV804 -> CV805B ->
SKR805B -> Coal Yard.
D3
SU801B -> CV801B > CV802B > CV803B -> CV805A -> SKR805A ->
Coal Yard.
D4
SU801B -> CV801B > CV802B > CV803B -> CV804 -> CV805B ->
Operating Description
D5
SU801A -> CV801B > CV802B > CV803B -> CV805A -> SKR805A ->
Coal Yard.
D6
SU801A -> CV801B > CV802B > CV803B -> CV804 -> CV805B ->
D7
SU801B -> CV801A > CV802A > CV803A -> CV805A -> SKR805A ->
Coal Yard.
D8
SU801B -> CV801A > CV802A > CV803A -> CV804 -> CV805B ->
Feed Coal Routes (Prefix of letter M)

[Coal Yard to Trippers (Storage Bins)]
M1 SKR805B -> CV805B -> CV806B -> VS801B -> CR801B -> CV807A ->
CV808A -> CV809A -> CV810A -> TRP810A.
M2 SKR805B -> CV805B -> CV806B -> VS801B -> CR801B -> CV807A ->
CV808A -> CV809A -> CV810B -> TRP810B.
M3 SKR805B -> CV805B -> CV806B -> VS801B -> CR801B -> CV807B ->
CV808B -> CV809B -> CV810B -> TRP810B.
254
CV808B -> CV809B -> CV810A -> TRP810A.
M5 SKR805B -> CV805B -> CV806A -> VS801A -> CR801A -> CV807A ->
CV808A -> CV809A -> CV810A -> TRP810A.
M6 SKR805B -> CV805B -> CV806A -> VS801A -> CR801A -> CV807A ->
CV808A -> CV809A -> CV810B ->TRP810B.
M7 SKR805B -> CV805B -> CV806A -> VS801A -> CR801A -> CV807B ->
CV808B -> CV809B -> CV810B -> TRP810B.
CV808B -> CV809B -> CV810A -> TRP810A.
M9 SKR805A-> CV805A -> CV806B -> VS801B -> CR801B -> CV807A ->
CV808A -> CV809A -> CV810A -> TRP810A.
M10 SKR805A -> CV805A -> CV806B -> VS801B -> CR801B -> CV807A ->
CV808A -> CV809A -> CV810B -> TRP810B.
M11 SKR805A -> CV805A -> CV806B -> VS801B -> CR801B -> CV807B ->
CV808B -> CV809B -> CV810B -> TRP810B.
M12 SKR805A -> CV805A -> CV806B -> VS801B -> CR801B -> CV807B ->
CV808B -> CV809B -> CV810A -> TRP810A.
M13 SKR805A -> CV805A -> CV806A -> VS801A -> CR801A -> CV807A ->
CV808A -> CV809A -> CV810A -> TRP810A.
M14 SKR805A -> CV805A -> CV806A -> VS801A -> CR801A -> CV807A ->
CV808A -> CV809A -> CV810B -> TRP810B.
M15 SKR805A -> CV805A -> CV806A -> VS801A -> CR801A ->CV807B ->
CV808B -> CV809B -> CV810B -> TRP810B.
M16 SKR805A -> CV805A -> CV806B -> VS801A -> CR801A -> CV807B ->
CV808B -> CV809B -> CV810A ->TRP810A.
Feed Routes from Ship Unloader (Prefix of letter X)

[Ship Unloaders (through) to Trippers (Storage Bins)]
X1 SU801A -> CV801A > CV802A > CV803A -> CV805A -> SKR805A - >
CV805A -> CV806B -> VS801B -> CR801B -> CV807A -> CV808A -> CV809A ->
CV810A -> TRP810A.
X2 SU801A -> CV801A > CV802A > CV803A -> CV805A -> SKR805A >
CV805B -> CV806B -> VS801B -> CR801B -> CV807A -> CV808A -> CV809A ->
CV810B -> TRP810B.
255
CV805A -> CV806B -> VS801B -> CR801B -> CV807B -> CV808B -> CV809B ->
CV810B -> TRP810B.
CV805B -> CV806B -> VS801B -> CR801B -> CV807B -> CV808B -> CV809B ->
CV810A -> TRP810A.
CV805A -> CV806A -> VS801A -> CR801A -> CV807A -> CV808A -> CV809A ->
CV810A -> TRP810A.
X6 SU801A -> CV801A > CV802A > CV803A -> CV805A -> SKR805A >
CV810B -> TRP810B.
CV805A -> CV806A -> VS801A -> CR801A -> CV807B -> CV808B -> CV809B ->
CV810B -> TRP810B.
CV810A -> TRP810A.
X9 SU801A -> CV801A > CV802A > CV803A -> CV804 -> CV805B -
>SKR805B -> CV805B -> CV806B -> VS801B -> CR801B -> CV807A -> CV808A -
> CV809A -> CV810A -> TRP810A.
X10 SU801A -> CV801A > CV802A > CV803A -> CV804 -> CV805B ->
SKR805B -> CV805B -> CV806B -> VS801B -> CR801B -> CV807A -> CV808A ->
CV809A -> CV810B -> TRP810B.
SKR805B -> CV805B -> CV806B -> VS801B -> CR801B -> CV807B -> CV808B ->
CV809B -> CV810B -> TRP810B.
>SKR805B -> CV805B -> CV806B -> VS801B -> CR801B -> CV807B -> CV808B -
> CV809B -> CV810A -> TRP810A.
>SKR805B -> CV805B -> CV806A -> VS801A -> CR801A -> CV807A -> CV808A -
> CV809A -> CV810A -> TRP810A.
SKR805B -> CV805B -> CV806A -> VS801A -> CR801A -> CV807A -> CV808A ->
CV809A -> CV810B -> TRP810B.
256
SKR805B -> CV805B -> CV806A -> VS801A -> CR801A -> CV807B -> CV808B ->
CV809B -> CV810B -> TRP810B.
SKR805B -> CV805B -> CV806A -> VS801A -> CR801A -> CV807B -> CV808B ->
CV809B -> CV810A -> TRP810A.
X17 SU801B -> CV801B > CV802B > CV803B -> CV805A -> SKR805A->
CV810A ->TRP810A.
CV810B -> TRP810B.
CV810B -> TRP810B.
CV810A -> TRP810A.
X21 SU801B -> CV801B > CV802B > CV803B -> CV805A -> SKR805A ->
CV810A -> TRP810A.
CV810B -> TRP810B.
CV810B -> TRP810B.
CV810A -> TRP810A.
X25 SU801B -> CV801B > CV802B > CV803B -> CV804 -> CV805B ->
SKR805B -> CV805B -> CV806B -> VS801B -> CR801B -> CV807A ->
CV808A -> CV809A -> CV810A -> TRP810A.
SKR805B -> CV805B -> CV806B -> VS801B -> CR801B -> CV807A ->
CV808A -> CV809A -> CV810B -> TRP810B.
257
SKR805B -> CV805B -> CV806B -> VS801B -> CR801B -> CV807B ->
CV808B -> CV809B -> CV810B -> TRP810B.
SKR805B -> CV805B -> CV806B -> VS801B -> CR801B -> CV807B ->
CV808B -> CV809B -> CV810A -> TRP810A.
SKR805B -> CV805B -> CV806A -> VS801A -> CR801A -> CV807A ->
CV808A -> CV809A -> CV810A -> TRP810A.
SKR805B -> CV805B -> CV806A -> VS801A -> CR801A -> CV807A ->
CV808A -> CV809A -> CV810B -> TRP810B.
SKR805B -> CV805B -> CV806A -> VS801A -> CR801A -> CV807B ->
CV808B -> CV809B -> CV810B -> TRP810B.
SKR805B -> CV805B -> CV806A -> VS801A -> CR801A -> CV807B ->
CV808B -> CV809B -> CV810A -> TRP810A.
3 x Operating Modes
Auto
Equipment starts and stops automatically according to the selected

route.
(Remote) Manual
Enables independent start/stop control of equipment via function keys

on the HMI/SCADA system.
Local Manual
Enables control of equipment by use of the field mounted local control

stations.
Primary use for Maintenance & Commissioning.
[Auto & (Remote) Manual are the preferred modes]
4 Operating Functions
258
Auto Mode - Starting:
Under auto mode, the conveyors will automatically start and stop according
to the specified route.
If the route is selected and verified, the diverter gates shall be switched to
the relevant position automatically to enable the coal feed along the specified
route.
Once diverter gates are switched to the correct positions, and verify check
passed, starting of the route is achieved by pressing the sequence start
button.
Equipment will be started in order, according to the sequence of reverse

coal flow.
Prior to starting each belt conveyor, the local alarm (Siren) horn will sound to warn
personnel nearby for 20 seconds before the belt conveyor starts running.
Auto Mode - Stopping:
To Stop the route, press the sequence stop button.
The field equipment will be stopped according to the specified delay

sequence along the direction of coal flow.
During the normal operation, when any faults occur, the PLC system will
immediately trip all process equipment from the point-of-failure along the
reverse direction of coal flow, and give an alarm indication on the
HMI/SCADA operator stations.
Emergency Condition! to stop at any time.
Press the EMERGENCY STOP button on the HMI/SCADA workstation with

mouse or press the EMERGENCY STOP button on operator console to
stop all equipment immediately.
Tripper Control Modes (Manual & Auto):
Auto (Coal Distribution) Mode;
Bins are able to be set to Not Available for the case when being
repaired or unavailable. For this case the unavailable bin is removed
from the sequence.
Residual Coal Distribution:
The control system calculates the capacity of the residual coal

of the bins, if the set-point has been reached, the system will
automatically stop reclaiming coal from the Jetty or Coal yard.
High Level Alarm:
259
During distribution, if any bin reaches a high level, an alarm is

given, and the bin is removed out of the automatic coal
distribution sequence, the tripper then moves to next bin.
Manual Mode:
The operator may start/stop the equipment one by one via the workstation,
under manual mode.
The equipment may be started one by one only according to the correct
sequence.
If the equipment is initiated to start in the incorrect order (out of the correct
sequence), the system will inform the operator by a pop up error message on
the HMI/SCADA screen.
Local Mode:
The field operator may start/stop the equipment from the local control panels
(LCPs) when selected in Local.
SC2 Conveyor
Local-Remote Switch.
SC3 Conveyor Brake

On-Off Switch.
SB1 Conveyor Stop button.
SB2 Conveyor Start button.
SB3 Emergency Stop button.
SB4 Horn button.
Limestone Control - Local Mode:
The field operator may start/stop the limestone conveyor from the local LCP
when selected in Local.
SC2 Conveyor
Local-Remote Switch.
A Ammeter,
Motor Current.
SBG Stop Indicator,

[Green when Stopped].
SBG Stop button.
260
SBR Start Indicator,

[Red when Stopped].
SBR Start button.
Tripper Control Modes (Manual & Auto):
Manual (Coal Distribution) Mode;
The tripper can be manually set (by the operator via the HMI/SCADA
screen) to fill any of the Bins (Bunkers).
The Bin Levels are shown on the HMI/SCADA screen, and alarm
occurs if the level gets too low.
[if running in manual mode and a bin level gets low, the operator needs to set the
tripper to that bin, to allow filling of the empty bin]
Auto (Coal Distribution) Mode;
Control Mode selected by operator via HMI/SCADA.
Cyclic adding of coal into the bins occurs following low level signal
indications of any bins.
The adding of coal into bins occurs in sequence according to a

specified order.
Tripper will move and distribute coal to the next bin when currently
filled bin reaches high level.
Automatic skip function:
Bins are automatically skipped that have high and/or high-high

levels, also if the bin(s) are being repaired (bunker not
available).
5 Equipment Operating Functions

Conveyors:
Local Mode
Local mode is selected by the remote-local switch being set to local

at the local control station.
Operated (Start/Stop) only by the local Control Panel.
Remote Mode
261
Remote mode is selected by the remote-local switch being set to

remote at the local control station.
Operated (Start/Stop) by the HMI/SCADA Screen.
Starting is interlocked, by the PLC system (by the down stream

equipment being feed by the conveyer).
Ship Unloaders (SU101A & SU101B):
Controlled by Onboard Control System.
Connects to Coal Handling Plant PLC System for process interlocking.
Communication by hard wired and Modbus signals.
Stacker/Reclaimers:
SR805A & SR805B
Controlled by Onboard Control System.
Connects to Coal Handling Plant PLC System for process interlocking.
Communication by hard wired and ControlNet signals.
Vibrating Screens (Local & Remote Modes)
Local;

Remote;


Stopping;
60sec delay used to avoid coal jamming
If a fault occurs, up stream equipment is stopped.
Coal Crushers (Local & Remote Modes)
Local;
262

Remote;


Stopping
60sec delay used to avoid coal jamming
If a fault occurs, up stream equipment is stopped.
Diverter Gates (Local & Remote Modes)
Local Mode

Operated only by the local Control Panel.
Remote Mode

Operated by the HMI/SCADA Screen.
Starting is interlocked, by the PLC system
[Diverter gates fitted with sensors to confirm position of gate, ensures selected
position as part of route sequencing]
263
Control System Instruction Manuals
PLC Hardware Manual
PLC Programming Manual
HMI Programming Manual
PLC User Manual
Control System Operation Manual-0
Control System Operation Manual-1
Control System Maintenance Manual-0
264
Day 9 Session 3
CONTROL SYSTEM DESCRIPTION
SESSION OBJECTIVE
Brief explanation on running the system
CONTENT
1. System Descriptions
2. Process Descriptions
3. Menu Descriptions
4. Plant Information
5. References manual
265
1 System Descriptions
To start the system:
Click the iFIX 4.0 icon on the windows
desktop to open the HMI/SCADA software.
The default (first) screen to appear is the

Overview screen.
HMI/SCADAOverviewScreen
SystemMenu
The system menu has the following main pages;
Overview
Process
Conveyor (4 off)
Water
Dust
Electric (Power Distribution)
System Descriptions
Screen(Drive)Colours
Red Running
266
Green Stopped (and Healthy [Not Faulted])
Grey Not Available
Red-Yellow [Flashing] Invalid Condition
Yellow - Drive Failed (Faulted)
Blue Equipment Selected (in process selection)
General
Buttons:
Auto / Manual buttons are grayed out when the item is selected in that
mode.
Status
The status (circle) indicator is in red, when that state is active,

otherwise indicator is shown as green.
System showing item in Manual Mode.
SystemLogon
Initially a user is not logged onto the system when first started, Click Change
User button.
267
Changingtheoperator(User)
To change the user, click Change User button.
On the pop up window, click Log Out to log the current user out.
Enter new Username & Password and click Logon to logon to the system as
the new user.
[Note: the logout and logon buttons are the same, the button changes name
with the logging out of a user]
ExitingtheHMI/SCADASystem
Click the EXIT button at the bottom left.
If the operator is authorized to exit the system, the iFIX system is

automatically closed, otherwise, an error dialog box pops up.
2 Process Descriptions
StackingProcess
Autostackingprocess(fromjettytocoalyard)
SU801A-CV801A-CV802A-CV803A -CV805A-SKR805A
Step (1) - First Stage:
The CCR operator will request the operator of ship unloader SU801A to
preset the diverted gate of ship unloader SU801A manually to the seaside.
Then click the ship unloader SU801A icon on the OVERVIEW screen. A
SU801A window pops up. The following figure indicates ship unloader
SU801A in the remote, Auto, and A side (seaside state).
Auto stacking process (from jetty to coal yard)
Step (2) - Route Selection:
Click the equipment in the process you want to start on the OVERVIEW
screen or the CONVEYOR1-2 sub screen, and set each to AUTO mode.
The following figure indicates a screen where conveyor CV801A is clicked

and the CV801A window is popped up. Select AUTO for CV801A. After
your selection, AUTO button is grayed out. The same procedure may be
fulfilled to select AUTO state for other conveyors and auxiliary equipments.
268
Auto stacking process (from jetty to coal yard)
Step (3) - Selecting a process:
Select SKR805A, CV805A, CV803A, CV802A, CV801A, SU801A on

PROCESS screen. The selected equipment is changed to blue. All other
equipments that have not been selected still appear in green.
Click STCK of SKR805A. A dialogue box pops up, on which you should
reconfirm whether SKR805A will be selected. Click OK to select stacking.
After STCK is selected, SKR805A changes to blue and the RCLMR button
is grayed out. If you want to cancel stacking, re-click STCK button. A
CANCEL SKR805A STCK dialogue box pops up. Select OK to cancel
stacking. After executing, SKR805A changes to green and RCLMR button
change to previous color.
The following figure shows the process equipment SKR805A, CV805A,

CV803A, CV802A, CV801A, and SU801A have been selected.
Step (4) Checking a Process:
After the process is selected, you should press the CHECK button on the
process screen. The diverter gates in the selected process are automatically
switched to the pre-selected process route. If all diverted gates in the
selected process have been switched to the right position, the system
automatically pops up a SRA STCK READY OK message to the operator.
After the correct message appears, you may start the process. Click the
Start Process icon on the overview screen, and according to prompt
information to solve the matter.
If the selected process is incorrect, an error prompt appears after you press
the CHECK PROCESS button.
269
Step (5) Starting a Process:
Click the START STCK button of SKR805A process on the OVERVIEW

screen.
When the stacking operation of the Stacker/Reclaimer A starts, the system

will then automatically start all the selected primary process equipment one
by one in the correct sequence.
The system will automatically, and in an interlocking manner, start all

auxiliary equipment (e.g. magnetic separators, sprayers and samplers etc.).
All started equipment change to red based on the feedback of the equipment
started.
Step (6) Stopping a Process:
Click the STOP STCK button of SKR805A process on the OVERVIEW

screen.
The system will automatically stop all selected primary process equipment
one by one in the correct sequence (according to the direction of coal flow).
After the primary process equipment have stopped, the relevant auxiliary
equipment be automatically stop according to the process logic.
All stopped equipment will change to green based on feedback of the

equipment status.
Manualstackingprocess(fromjettytocoalyard)
Step (1) First Stage:
The CCR operator will request the operator of ship unloader SU801A to
preset the diverter gate of ship unloader SU801A manually to the seaside.
The CCR operator clicks the ship unloader SU801A icon on the OVERVIEW
screen, then SU801A window pops up.
The CCR operator clicks the MANUAL button to switch to manual mode.
The AUTO button appears, and the MANUAL button is grayed out.
The indication lamp MANUAL turns red, and indication lamp AUTO turns
green.
Step (2) Setting up:
Click the equipment in the process to start on the OVERVIEW screen or the
CONVEYOR1-2 sub screen, and set to MANUAL mode.
270
The following indicates a screen where conveyor CV801A is clicked and the
CV801A window is popped up. Select MANUAL for CV801A. After selection,
the MANUAL button is grayed out.
The same procedure may be followed to select MANUAL mode for other
conveyors and auxiliary equipment.
Step (3) Starting:
Click SKR805A icon, to pop up a dialogue box, on which you click the STCK
START button to start the stacker.
After SKR805A running, SKR805A icon changes to red.
The CCR operator may start the other equipment one by one in sequence
(according to the reverse direction of coal flow).
All started equipment will change to red based on the feedback of the
equipment.
[Note: Interlocking of equipment will prevent equipment being started in the wrong
order]
Step (4) Stopping Stacking:
Click the equipment icons one by one in the process (according to the
direction of coal flow).
With each item, a dialogue box pops up, on which you click the Stop button
when to stop the equipment (and stacking).
After all equipments has stopped, the stacking process is finished.
All stopped equipment will change to green based on feedback of the

equipment status.
OtherProcesses
The select, start and stop of other process routes, follow the same
instructions as per the stacking system.
The Processes are:
Stacking Process (Previous Description)
Reclaiming Process (Reclaimer to Tripper)
Mix Reclaiming Process
(Allows 2 Reclaimers to feed one Tripper)
Through Process
271
(Ship Unloader directly to feed Tripper)
(Allows 1 Reclaimers and 1 ship Unloader to feed one Tripper)
These can be started and stopped by both the Auto or manual methods.
Only different methods involved within the Processes will be discussed.
ReclaimingProcessTripperSelection
Autoreclaimingprocess(SUorYardtobunker)
Step (1) [Condition prior to start]
Selection of the boiler(s) needs to be made
Select 1 boiler or 2 boilers (to which coal will be distributed)
If only 1 boiler selected
Then selection of unit 3 or unit 4 is required.
For selecting the tripper mode, use the tripper pop up window selected by
clicking Travelling Tripper icon
ion the overview screen.
Figure showing pop up
Tripper TRP810A in
Auto mode,
To 1 boiler,
set to Unit 3.
Step (2)
The tripper requires to be enabled (selected from pop up)
Set any Bins to Bypass as required.
If Bin A, or Bin F, or Bins A/F, or Bins A/B, or Bins E/F are in Bypass,
then the Auto Reclaim process can be executed.
Set any Bins to Stand By as required.
A minimum of 1 and a maximum of 3 can be selected.
Bypassed Bins are displayed as Red in the Bypass icon.
CoalBlendingProcess
MixingcoalonReclaimingProcess
(Allows 2 Reclaimers to feed one Tripper)
272
Route selection:
SKR805A-CV805A-CV806A-VIBNA-CRSHRA-CV807A-CV808A-
CV809A-CV810A-TRP810A
SKR805B-CV805B-CV806A-VIBNA-CRSHRA-CV807A-CV808A -
CV809A-CV810A-TRP810A
It is the same process as reclaiming process (from coal yard to coal

bunker): SKR805A-CV805A-CV806A-VIBNA-CRSHRA-CV807A-CV808A-
CV809A-CV810A-TRP810A except that SKR805B and CV805B are added
to the process.
Mixing coal on reclaiming process can be switched to pure reclaiming

process. And vice versa.
MixingcoalonThroughProcess
(Allows 1 Reclaimers and 1 ship Unloader to feed one Tripper)
On PROCESS screen, selecting SKR805A Bucket diversion, SKR805B

Bucket reclaim coal, and selected mixed coal state as shown below, and at
the same time finishing the selection of other belt. (Select SKR805A Bucket
diversion, also with the choice of the bucket wheel stacking state, because
the pile material is a part of diversion)
Input SKR805A Bucket diversion output value, for example, setting 400 tons
/ hour of diversion output value to SKR805A (diversion output range 350--
650 tons / hour)
In the MAIN screen, starts SKR805A diversion process (this time reclaiming
process can not be started)
The figure above SKR805A, the following DISTR shows distribution output of
400 tons / hour, and SRA shows stacker/reclaiming has the output of 800
tons / hour. And SKR805B Bucket no value under the SRB, indicating
SKR805B not running.
When the diversion program starts, and SKR805A Bucket adjusted diversion
output = 400 tons / hour, SKR805A Bucket will return a confirmation signal to
the control room. Only after this signal is returned, the operator can start the
reclaiming process of SKR805B
Below SKR805B running, reclaiming output of 600 tons / hour
Diversion and the reclaiming programs running, you can stop any one or all
of the processes.
Stop diversion process, the reclaiming process is running however
Stopping the reclaiming process

273
The system restore the initial state
If the process starts again mixed coal, the steps are the same.
SKR805B divided material, SKR805A reclaiming
SKR805B finishes the diversion, diversion output value is the same as

setting value
SKR805B return signals that shows the setting value and the diversion
output value are equal, then SKR805A reclaiming output of 600 tons / hour
In the main screen to start SKR805A reclaiming process
After reclaiming process starts, SKR805A will follow the setting output of 600
tons / hour.
Stopping reclaiming process
Stopping the whole process
WaterSpraysatTransferStations
ForManualcontrolofwatersprays:
Click the MANUAL button, at this time, dust suppression is in the manual
mode.
The CCR operator may manually start or stop any dust suppression solenoid
valve.
The following figure illustrates WATER2: CONVEYOR DUST

SUPPRESSION SYSTEM screen in the manual state.
AutoMode:
To select Auto mode, click the Auto button.
At any conveyor other than CV805A/CV805B, the dust suppression (head

and tail) will start after the corresponding conveyor is running and the
material flowing signal is confirmed.
CV805A & B Head End Sprays;
The dust suppression is started at a delay of 2 seconds after CV805A/B and

CV806A/B (or CV804) conveyors are running and the material flowing signal
is confirmed.
CV805A & B Tails End Sprays;
274
The dust suppression is started at a delay of 2 seconds after CV805A/B and

CV803A/B conveyors are running and the material flowing signal is
confirmed.
WaterSpraysatCoalYard
ManualMode
For Manual control of water sprays, click the MANUAL button, this
allows individual start/stop of sprays.
Equipment interlocking is still in operation in this mode.
Setting of the spray time and cycle time is required to be set in this
mode, (Click Set parameter button).
AutomaticMode
For Auto control of water sprays, click the AUTO button, this allows
automatic start/stop of all yard sprays.
The sprays are opened one by one in order, for a preset time, until the
yard cycle is completed.
The system stops once all sprays have been cycled or there is a drop
in water pressure (low pressure).
HMI/SCADAscreenofyarddustsuppression
Shown in the manual state.
WaterSpraysatCoalYardWaterPumps
For the yard sprays to operate the water pumps P802A and/or P802B need
to be running.
The pumps can be run in either manual or auto modes.

275
Pumps can run provided pond low level has not been reached.
Manual Mode
Pumps can be started/stopped manually.
Pumps set to Manual mode, require water supply valve (SV802A/B) to

be opened 120sec prior to starting pump.
If outlet pressure becomes low, the second pump can be manually

started.
On stopping the supply valve will automatically close after a delay of 6

seconds.
Auto Mode
Pumps (a pump) are started automatically.
Pumps set to Auto mode, require water supply valve (SV802A/B) to

be opened, the pump will start 120sec after.
The spray program sequence starts automatically after a pump is

detected as running.
Pumps set to Auto mode, require water supply valve (SV802A/B) to

be opened 120sec prior to starting pump.
If outlet pressure becomes low, the second pump will automatically be

started.
If outlet pressure is low for too long (even if 2nd pump), the sprays,
pumps and supply valves will automatically stop.
Water Supply valve (W809): Closes on high-high pond level, and

Opens on low pond level.
DustSuppression
DustCollectorsDC901Crushers,DC902&DC903Bunkers.
Two screens available Dust 1 and Dust 2, selected from a popup from the
bottom menu icon Dust of main screen.
Manual Mode
Select manual mode from on the screen or the popup, this also sets
dampers to manual mode.
Dust Collector and Dampers can then be manually started and

stopped.
276
In case of an equipment emergency shutdown, the dust collector

immediately shuts down and its corresponding electric damper is
closed at a delay of 60 seconds.
Auto Mode (Crushing)
In Auto mode, the DC901 will automatically start after CV806A/B,

Screen VS801A/B and CV807A/B are running and the corresponding
dampers will open.
When the equipment is stopped, the corresponding damper is closed

after a delay of 60 seconds.
The dust collector stops after a delay of 5 minutes.
Auto Mode (Bunkers)
In Auto mode, if CV810A/B is started the corresponding dust collector

DC902/DC903 will automatically start depending on where the trippers
TRP810A/B are located.
When the tripper is filling a bin (bunker) the corresponding damper will
open, dampers at other bins will be closed.
As the tripper moves on to the next bin, the previous damper (at that
bin the tripper was) closes after a delay of 10 seconds.
When the conveyors CV810A/B are stopped the corresponding dust

collector is stopped after a delay of 5 minutes.
During the dust collector run down time, the dampers W918/W926 are
opened.
Screen showing bunker dust collectors (in Auto mode)
277
ElectricalMonitoringSystem
The electrical monitoring system for supply power includes four stations
JETTY STATION, TRIPPER STATION, COAL YARD STATION and

CRUSHER STATION
The medium voltage system includes two display screens, and six display
screens for the low voltage system
Only Qualified Electrical personal should operate (open/close) the circuit

breakers
3 Menu Descriptions
PopUpMenu
Ship Unloader
Menu Descriptions (Pop Up)

278
Stacker/Reclaimer
Tripper
Crusher
Coal Sampler
Water Spray Solenoid
Dust Collector / Air Damper
Belt Weigher
Magnetic Separator
Diverter Gate
Vibrating Feeder
DCSMenu
Displays communication between the plant (central) control system and the
remote machines.
For central control room control select PLC CNTRL
Status indicators show machine Permits, Running and Faults.
Click DCS menu button to get to screen.
4 PLANT INFORMATION
ThesystemprovidesInformation,suchas
Events Information
Trending
279
Alarms Information
Reporting Information
To go to either of the information pages, select the appropriate menu button

from the bottom of the screen.
Events
An event list can be obtained by making selections in the drop down boxes, and
selecting either .
Two Types of queries can be made:
Time Enquiry - Events between 2 times, start & finish.
Tag Inquiry - All events related to a tag.
280
Trends
Trends are added to the screen by using the drop down box and pressing the Add
button.
Trends can also be deleted if other trends want to be added.

Alarms
The alarm screen shows all active alarms; unacknowledged and acknowledged
alarms.
Unacknowledged alarms are shown as flashing, to acknowledge the alarm, right

click with mouse and click Acknowledge.
If an alarm turns off that has been acknowledged, and turns back on again, it will
start flashing.

281
Reporting
The reports are selecting by the desired report and pressing the create button.
Daily and Monthly reports are available for each type of report (topic).
The report topics are:
Storage Coal
Elec. Energy
Boiler Use & Crusher
Control System Instruction Manual
282

Materi Training Coal Handling

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Materi Training Coal Handling

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Session 1

Introduction and Site layout of Coal Handling System

Introduce the Facility.

Main Equipment Components are:

The coal handling system is based on the following design criteria:

Bulk density of 0.85 metric ton per cubic meter

Received coal size 150 mm x 0 mm

Unloading operation from vessels: 24 hours/day

4 Ship Unloading Facility

The unloading operation shall be accomplished semi-automatically and/or manually by

The bucket trolley shall be mounted on a horizontal apron boom, at an elevated

CONVEYORS 101 A & B

CONVEYORS 102 A & B

The transfer of coal is at Transfer Tower TT02

Belt weighers (or weightometers) are situated on each conveyor

CONVEYORS 103 A & B

Conveyors 103A and 103B shall be shall be supported at space of approximately 12

CONVEYORS 104, 105 A & B

7 Screening & Crushing

SCREENING & CRUSHING

CONVEYORS 108 A & B

CONVEYORS 109 A & B

MATERIAL HANDLING GENERAL

9 Standards & Codes

Coal Handling Manuals

Coal Handling Process Flow

Outline the Coal Process Flow

b. The functions of the Coal Handling System are:

i. Unloading and conveying coal inside the power station.

ii. Stacking and reclaiming in the coal storage yards.

iii. Screening and crushing of raw coal.

iv. Weighing and sampling coal.

v. Removing metal from coal.

2 System Process Flow

Each unloader has a cyclone tie-down system.

Ship loader elevation

Dust suppression is provided at each transfer point unless otherwise specified.

CONVEYOR 101 (A & B)

o In TT101, conveyors 101 A and B feed conveyors 102 A and B respectively.

CONVEYOR 102 (A & B)

Each conveyor is equipped with a Coal Sampler and a Belt Weigher.

In TT102, conveyors 102 A and B feed conveyors 103 A and B respectively.

In TT104, conveyor 104 feeds stockyard conveyor 105 B.

C: STACKERS AND RECLAIMERS

CONVEYOR 106 (A & B)

In TT105, conveyor 105 B can be diverted to either conveyor 106 A or B.

In TT106, conveyor 105A can be diverted to either conveyor 106 A or B.

The oversize material (50-150mm) is directed by chute to be reduced in the crusher

Dust collection systems in the building limit dust emission.

Conveyors 107 A and B transfer the sized coal

The pipe conveyors 108 A and B transfer coal

Sectional view of the

Weigh idlers are installed in the belt weighers frame.

Dust suppression systems are fitted in the following areas:

Refer to the Dust Suppression Diagram overleaf.

K: COAL HANDLING CONTROL

Programmable logic control (PLC) is adopted to perform programming control and

Refer to diagram on next page for layout and schematic

Capacity jetty to stockyard 1500t/hr

Annual average temperature 27.0 C

CHEC Coal Handling Manuals

o (IM0401-2) Coal Handling System General Description-0

General Arrangement Drawings