Coal Stacker 2 New Cable Reeling Drive Project Report

Objective:

The main objective of this project is Procure and maintains a spare Cable Reeling Drive Motor for New
Yard Machines.

New Yard Machines CS-2, CR-2, CS-3 and CR-3 HT Composite Cable Reeling Drive System are equipped
with Stall Torque Motor of make M/s Auxema Stemman, Spain.

Cable Reeling Drive (CRD) system is the heart of Stacking & Reclaiming operations. It is very crucial to
maintain one spare motor for all machines in case of any breakdown. The existing motor with ventilation
fan costs too high and lead time is also high.

Proposal / Alternate Solution:

Alternative motor of the same type not readily available as it’s a specially designed Motor for our
application.

In this process M/s Electro Zavod has approached us and suggested a conventional solution. Their team
has visited our company and checked the existing Cable Reeling Application. They have designed an
alternative system (VFD application motor) which could meet our existing CRD applications and at a very
reasonable cost. The same proposal has been forward for the approval.

Summary of Project:

Design and Material Supply by M/s Electro Zavod (I) Pvt Ltd.

Automation by M/s Fuzi Electric India.

Equipment from the supplier:

CRD control panel with PLC and VFD, Local Control Station, 3-Phase Induction Motor 7.5kW with
encoder, DBR, Gear Box, Coupling and a Pedestal (for mounting Gear Box)

Progress of Work:

Preparatory work like Cable laying, LCS mounting, Drive Panel erection, Pedestal / basement preparation
have been carried out and made ready by 25-11-2020.

M/s Electro Zavod & Fuzi Electric India representatives arrived on 25-11-2020.

Control Panel wiring, Motor and Field inputs verified by Service Engineer and CRD PLC logic simulated
without coupling the motor to the Cable Reeling Drum.
After no load simulations trial operations with safety interlocks carried out by Service Engineer in
presence Electrical, Mechanical & Operations Team. Trial operations found satisfactory and machine
released for operations.

During Machine positioning for stacking operations it was found that Cable Reeling Drum shaft (between
the Gear Box coupling and Cable Reel Drum) got sheared. The exact reason for the damage is not clear
as there was no over tension on the Composite Cable. Cable guide also found skewed.

Damaged shaft has been replaced with new one and Cable guide has been repaired for smooth
functioning.

CRD operations trail run taken with some logic modifications. Trial run taken at Full Speed from parking
bay to the Center Pit with all safety interlocks.

All fail safe conditions with new CRD mechanism tested under the purview of OEM and found
satisfactory. Machine released for operations.

Coal Stacker-2 Old Cable Reeling Drive system

Coal Stacker – 2 New Cable Reeling Drive System