TRF Limited Equipment 300 TPH StsckerResaimer | Location BINA ht No. (ATATA Entorprise) | client ORL BINA JobNo. 076162.00 By Port Yard Equipment Div__| Description _Contelitons> rg. No. _162-00-56.49002 | Date WRITE-UP ON OPERATION OF STACKER / RECLAIMER (PETCOKE) 1, Introduction ‘The rail mounted Slew able Stacker cum Reclaimer machine is used for handling limestone with following characteristics:~ Bulk Density --- 1,04 t/Cu. M, Grain Size Angle of Repose It travels through the maximum length of 255m across the stockpile (refer TRF civil information drawing 162 -00-08 1 2019). The machine is suitable for serving two parallel stockpiles, each on either side of the track rails. For pile configuration, refer GA of Stacker Recialmer bearing TRF Drawing No. 164 -00-00 1 6061C. Maximum height of stockpile shell be 6.00 Meters. at approx. 35° angle of repose. ‘The boom of the machine, used for both Stacking and Reclaiming with the help of flap gates, can luff up and down and slew through + 105°. 2. Modes of Operation from Equipment control point of view ‘There re the following modes to control machine operation: a. Local mode jis envisaged only for maintenance / testing Purpose of individual equipment. Operation will be possible from a Local Control Station (LCS) located near the motors /. drivesvof the individual mechanism. Operation in this mode is possible only If the Local / Remote switch on the respective LCS is selected in Local position. In this mode, only the equipment safely interlocks that are hardwired in the MCC or drive circuit are effective. Operations in this mode are generally without PLC. b. Remote mode shall always be selected during continuous ‘operation/positioning of the machine from operator's cabin. In Remote mode, both in Auto and Manual, ali operations shall be done from the touch screen, Long travel, Luff and slew motion shall be controlled through a joystick. In Remote mode, the operator has two options, viz. AUTO or MANUAL. The “AUTO/MANUAL’ mode is selected on the HMI. i. Manual mode primarily to be used for start-up functions and positioning. The operator cen select Manual mode from the HMI and operate the machine by starting one drive at a time in sequence. Safety and sequential interlocks for each Grive are provided in the PLC. In manual mode, there is no ‘automatic sequencing between the movements of different parts of the machine. In this mode, luffing, slew and long travel will be done with joy stick with interlock il. Auto mode is meant for continuous stacking or reclaiming operation. In automatic mode or AUTO mode, used during continued stacking or reclaiming operation, the sequence of operations is decided by the PLC based 162-00-control-PEANOILAd-dh-onsn-tonu0>-99-291 paypead St pte sed “2 ‘payempe 1 Bupyoe3S 40) YOYMS UH} PUB [9Ae. 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No. _ 182.00-55 4 6002 b. Direct feeding mode ‘On receipt of command from MHCR, machine operator selects Direct Feeding mode. For this operation the flap gate position is altered so that the material discharged from the tripper falls into the central chute of the stacker/reclaimer. €. Reclaiming mode The reclaiming operations will normally be started from one end of pile. Two (2) modes of reclaiming mode are envisaged, the block module mode and the benching mode end the Stacker cum Reciaimer shall be controlled as detailed in the following paragraph. Luffing operation will be guided by rotary cam limit switches. Block Module mode of reclamation In Block module mode, the reclaiming operation shall start from one end of ‘the stockpile. On Receipt of a request from the operator of the MHCR, the ‘machine operator will bring the equipment at one end of the coal stockpile; ‘postion the Boom in MANUAL mode by luffing up / down and or slewing the Boom. After positioning, he will inform MHCR operator Machine selected in mode and Ready to start at desired stockpile. On receiving this information, MHCR operator:will start the conveyor system with the yard Conveyor starting in the end, The machine receives the information Yard conveyor running. The machine operator can then start the Boom conveyor. The operator will then bring the:bucket wheel at suitable working position on stockpile from where he intends to start reclaiming. ‘The equipment will then be started in Auto mode, which will start the bucket wheel drive end the slew speed will get varied automatically through PLC software to maintain 2 constant reclaiming rate. After the materiel is recisimed from the first / starting block (measured by zero reading on the belt scale at the boom conveyor), the equipment will be advanced automatically to give a fresh cut for material reclamation by slewing operation and the process described above will continue. After a predetermined number of advancements to be set during commissioning at site (3-5, generally), the equipment will be traveled back to clear off the pile. The boom will be lowered end the equipment will be traveled back to clear off the pile, The boom will be lowered and the equipment will be moved forward So that it gets engssed with the next block for continuing with the reclaiming process. When material from ail the layers in a block is reclaimed, the operator, in Manual mode, treverses the Reclaimer back to clear off the pile, raises the boom and then moves the equipment forward for starting reclamation of the 162-00-contro|-write-up-PETCOKE-R-P>TRF Limited 8a Equipment 200TPHStstersecisimer | Location BINA ‘ht. No (ATATA Enterprise) | cient BORL Sia JobNo. 076 162-00 By sno Port & Yard Equipment Div__| pescription Contatti so Drg.No. _ 162.00.56 4 9902 _| Date organ, ext block. Process of reclamation is repeated till MHCR operator informs machine operator to Stop reclaiming Benching mode of reclamation ~ In the benching mode operation, the material will be reclaimed out of the stockpile starting from the top bench and by automatically controlled movement of the long travel drives (to maintain fixed reclaim rate) over the full length of the pile. This operation shall be carried out in the Auto mode. After full lenath of pile is reclaimed, the boom of the equipment will be slewed fo touch the material of the same bench and above mentioned procedure will be followed in reverse direction. After reciaiming the first bench, the boom is lowered to the next bench and the reclaiming process continued as described earlier. Reclaiming Rate Ingications will be provided on the operator’s console. General Permissive in Remote Mode: Ths general Starting Permissive for any movement of Stacker Reclaimer in Remote Mode under normal conditions are: ‘Transformer winding temperature not high 6.6 kV LBS ON 415V MCCB in MCC ON Emergency end limit switches for Long Travel, Slew and luff not actuated Wind Speed normal (Fault condition Is annunciated on CD - "Wind Speed High”) Boom not anchored Boom not on pile, detected by the level sensing probes systems are operational Em. Stop PS not actuated All drives in Remote mode 6. _ Interfaces with the MHCR: The machine PLC communicates with the stationary MHCR PLC through control Trailing cable . The signals that are exchanged for operation are as follows: From MHCR to machine PLC: | Select stacking Select reclaiming © Select Direct Feeding Iv. Stop machine . _® Yard conveyor running. 162-00-control-write-up-PETCOKE-R-PTi Location BINA JobNo, 07.6162.00 Drg.No._ 182.00-88 4 9902 TRF Limited Equipment 900 TPH StackerRectimer (ATATA Enterpiso) | citent ORL BINA ote sno otaian-12 Port & Yard Equipment Div | peseription Controle From Machine PLC to MHCR. Machine Healthy P/CS, B/SS on Tripper Portion of Yard Conveyor Healthy |. HT LBS on . Stacking Operation ON Reclaiming Operation ON |. Direct Feeding operation ON Stacking / Reclaiming Rate P/CS- Pull cord switch B/SS- Belt sway switch. 7. Emergency Stop: The mushroom head, lockable, rotate to release type Emergency Stop (E- stop) Stations are strategically located at different parts of the machine. Pressing this button gets the topmost priority of operation and stops the machine Irrespective Of the mode of operation. 162-00-control-write-up-PETCOKE-R-I se