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Samson Brochure
Samson Brochure
Samson Brochure
Contents
Contents:
The Samson Concept _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _4 The Samson Solution _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _5
Receiving Unit _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _6-7 Controlled Rate Feeder _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _8-9 Storage and Pasteurisation _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _10-11 Body and Entry Designs _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _12 Under Floor Options _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _13 Dust and Fume Control _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _14-15 Head Chutes and feeders _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _16-17 Drive Systems _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _18-19 Instrumentation _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _20
Electric Controls _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _21 Special Applications _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _22 Ship Loading and Stacking _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _23
x Above Ground Installation x Minimum Civil Works x Large Holding Capacity x Receives Direct from Tipping Truck or Shovel x Fast Truck Tipping x Controlled Discharge x Compact Installation x Handles Wet and Sticky Materials x No Risk of Material Bridging x Handles Dry and Dusty Materials x Minimum Dust Generation x Efficient - Low Energy Consumption x Flexibility in Location x Easily Re-Located x Excellent Maintenance Access x Minimum Spillage x Reduced Housekeeping Costs x Clean and Hygienic x Robust and Reliable x Minimum Operating Costs x Minimum Project Cost
4
The unique Samson wide belt design with steel apron bar technology offers the strength of an apron feeder with clean operation. The section through the Samson body shows the wide belt construction with vertical hopper sides. Since the material depth is low compared to the belt width virtually any bulk material may be handled without risk of bridging. Trapezoidal apron bars support the load through to the conveyor chain rollers with the conveyor belt riveted above the steel apron bars to seal the load within the Samson body. Since the conveyor chains are always outside the material flow chain wear is drastically reduced and inspection made easy. Close contact flexible rubber side seals mounted outside the loaded area prevent side spillage even when handling granular and free flowing materials such as cement clinker. In addition to the side seals the conveyor belt has a raised edge to contain any dust particles passing the main seals. In the event of a total seal failure any spilled material may flow through the ventilated side pressing clear of the return belt preventing damage to the conveyor chains and apron bars. Optional ball or plain bearing chain rollers support the load reducing frictional losses minimising power consumption. Positive conveyor chain drive prevents slippage and allows high torque transmission within compact dimensions.The conveyor chain system eliminates belt tracking problems and the need for any belt tension to transmit the drive. Robust construction designed to absorb impact loads from tipping trucks or loading shovels with generous safety margins for long life and reliable operation. A wide range of conveyor chain options are available from 380 to 3200 kN. rupture strength selected to suit each application.
Side seals
Chain rollers
Double apron bars showing conveyor belt line coincident with chain boller centre
5
Compared to a traditional underground pit for receiving bulk materials from trucks the Samson offers major advantages.
Flexibility:
No excavation is required and only the minimum of civil works, generally the Samson may be simply bolted to a flat concrete slab foundation. Since the Samson may be installed completely above ground maintenance access is much improved and housekeeping made easy. Even for fixed installations the Samson remains portable since the unit may be easily relocated for future plant development and therefore investment risk is minimised.
Environmentally Friendly:
The wide belt system allows fast truck discharge with minimum dust generation since the material is drawn from the truck body in a controlled stream minimising particulate separation, compared to conventional pits or hoppers the material fall is significantly reduced and as a result dust generation is minimised.
Mobility:
For absolute flexibility the Samson may be fully mobile on pneumatic tyres for use as a feeder in mining or port applications in conjuction with overland conveyors, mobile stackers and shiploaders.
6
The Samson receiving unit may be used in applications where the discharge rate may be controlled by a secondary feeder or conveyor system. With the Samson empty material is received from the tipping truck direct to the Samson entry and conveyed forward by the Samson belt. When the first truck is emptied and the Samson is fully loaded the material is discharged from the Samson head to the ongoing conveyor or feeder equipment. As the next truck manoeuvres into position ready to tip the material is continually moved forward along the Samson body as the Samson discharges leaving space at the entry. The next truck then discharges to the empty Samson entry and the process is repeated. In this manner the Samson discharges on demand to the process system using a feeder or extractor conveyor to control the flow rate. This system may be used effectively to provide fast truck unloading whilst allowing the on-going conveyors to be sized according to the process demands thus minimising the cost and energy requirements of the installation as a whole. To regulate the Samson discharge a level probe is required in the Samson head chute linked to the belt drive system to interrupt the discharge on the high level signal, see page 21. The receiving unit principle is ideal for applications where the truck deliveries are infrequent and therefore the Samson may be fully emptied between each delivery. Alternatively, where the ongoing conveyors may be of high capacity allowing the Samson to be quickly discharged between loads.
Material is received to the Samson entry and drawn into the Samson body
7
The Samson receives as-dug brick clay discharging via a belt feeder to the process system including a B&W troughed belt conveyor installation. Holding capacity - 25 tons
The Samson receives salt discharging to an inclined conveyor using the conveyor as an extractor to regulate the material flow to the silo storage system. Holding capacity - 40 tons
The Samson receives aggregates for a quarry process plant discharging to an overland conveyor.The conveyor acting as an extractor to control the feed rate to the main installation. Holding capacity - 30 tons
8
The Samson Feeder uses a levelling blade at the discharge to regulate the material flow to the ongoing conveyors providing a closely controlled discharge rate. In this manner the discharge rate is directly proportional to the Samson belt speed providing the ideal solution where high handling rates are required. In addition, since the Samson conveying rate is directly proportional to the belt speed and bed depth the use of the levelling blade system permits an increased receiving rate. At the Samson entry the material bed depth is significantly greater than at the discharge and therefore the receiving rate is greater than the discharge rate by a ratio of typically up to 5 : 1. For example if the ongoing conveyors will handle 200 t.p.h. the Samson may receive at up to 1000 t.p.h. allowing very fast truck discharge... A receiving rate of 1000 t.p.h. will unload a typical 30 ton truck in less than 2 Minutes. As the first truck tips and moves away the second truck may manoeuvre directly into position, during this operation the Samson moves the load forward rapidly to expose the entry section ready to take the next truck load with minimum delay.The Samson provides a continuous regulated output using the buffer holding capacity to maintain the output between truck deliveries. For really fast truck tipping with Zero-Wait-Time the high capacity entry version as illustrated opposite allows the complete truck contents to be received within the Samson entry section. Typically in mining application this arrangement may accept trucks up to 100 tons capacity with a Samson holding volume of up to 300 tons of live material. The design of the blade is critical to both shear and lift the material to avoid excessive load to the apron bars, conveyor chain and drive system.
High capacity entry
Levelling blade
9
The Samson receives as-dug aggregates providing a controlled rate feed to an overland conveyor. This machine is skid mounted and may be repositioned within the quarry to suit the production requirements. In addition a Grizzly Screen is provided at the Samson discharge to remove oversize material.
The Samson receives limestone from dump trucks providing a controlled rate feed to an overland conveyor.
In the bottom two illustrations a Samson receives clay from loading shovels or dump trucks. In this case the Levelling blade also shears the large lumps to a manageable size.
10
The Samson system provides the ideal solution for the live storage of wet and sticky sludges down to 20 % dry solids content.
Travelling plough
Twin Receiving Units mounted external to the main storage building discharging to Kleen-Line design extractor conveyors
Shown above the Samson storage unit with twin Samson receiving units mounted outside the main building. Material is delivered from the receiving units to the storage system via a B&W belt conveyor system including a travelling plough unit to distribute the material along the full length of the Samson body. To prevent material bridging in the Samson after prolonged storage the tapered body section expanding towards the outlet to guarantee reliable discharge with the option of negative angle side walls for extremely cohesive materials.
11
Twin 40 ton capacity pasteurisation units Illustrated below the Samson pasteurisation unit based on the storage unit principle but in this case loaded at the tail section by a fixed conveyor. Material is loaded to the stationary Samson belt from the overhead conveyor, when the load level reaches a preset height a probe engages the Samson drive and the material is moved forward until the probe is clear, this operation continues until the Samson is fully loaded over a timed period allowing the material to cure within the Samson body. Capacities up to 300 tons may be provided in these formats. Twin Samson storage units with plough distribution conveyors
12
Two basic alternative designs are available using either a straight or deflected chassis arrangement. The straight pattern design is ideal for applications receiving from loading shovels or where an increased vehicle ramp is permitted for truck loading applications. The deflected chassis offers improved holding capacity with the minimum vehicle access ramp height and offers improved clearance where dissimilar materials are handled without cross contamination. Where free flowing materials are handled the deflected chassis design allows the material to stabilise on the horizontal section before being elevated to the discharge. For applications where road truck only deliveries are required the standard parallel entry is the most economical solution. Where larger dump trucks are used or for loading shovel applications where an increased capacity is required the flare entry is the preferred solution. The flared entry gives greater vehicle alignment tolerance offering faster truck unloading and easier vehicle manoeuvring for high capacity applications. Combining the flared entry and deflected chassis design significantly increases the entry volume to further reduce truck tipping time. The flared entry is available in various constructions using 6 mm, 12 mm or 20 mm thick steel plate sections to suit the working environment. Various standardised widths of flared entry are available, typically 4.0, 4.5, 5.0 or 6.0 metres in width. Optional stainless steel body panel construction for handling food stuffs or aggressive materials. Deflected chassis design Straight chassis design
13
The wide belt Samson principle allows underfloor installation with the absolute minimum of excavation handling even wet and sticky materials without risk of bridging.
Sub-Floor Installation:
The installation shown here handles biomass fuels within a power generation plant and incorporates a disc screening unit with a Samson sub-screen conveyor below.The primary Samson feeder unit incorporates a levelling blade to control the feed rate to the screen. A total of twelve Samson units were used forming the main raw materials reception facility for the power station. In this application the wide belt Samson design offered the ideal solution for handling this wet and sticky material..
Sub floor feeder shown with disc screen and sub-screen conveyor
14
The unique receiving action of the Samson draws material from the truck in a controlled stream and requires the minimum of dust control equipment. For environmentally sensitive applications a range of enclosures are available to contain any minor dust generation within the Samson body. The partial enclosure is generally extended to the inclined section only and provides control of dust generated at the discharge from the Samson to the ongoing conveyor. A full enclosure provides excellent dust control both at the tipping point and discharge and may be extended around the receiving section for machines fitted with a flared entry. Reverse Jet or shaker type dust filters may be supplied, mounted to the enclosure roof, and provided with an access platform for maintenance of the filter unit. For most applications the profiled steel enclosure is the preferred choice offering a permanent solution with good appearance and generally eliminates the need for any additional building enclosures. For extremely sensitive applications the enclosure may be extended around the vehicle, forming a tipping booth for absolute security. The profiled steel system comprises a fabricated steel frame bolted direct to the Samson side plates and clad externally in plastic coated steel sheet with flashings and cappings to prevent rain ingress. For temporary or mobile applications the flexible PVC covers provide a reasonable level of dust control with minimum cost and weight. In applications handling obnoxious materials such as sewage sludge odour control vents may be provided for connection to a centralised odour control system.
Flexible PVC cover fitted to steel frame over the inclined section only
Full profiled steel enclosure extended around the Samson flared entry
15
Twin Samsons with partial enclosures and flexible entry curtains handling coal
Twin Samsons with full enclosures and dust extraction handling kaolin
16
A comprehensive range of discharge chutes and feeder equipment is available designed specifically to suit the handling characteristics of individual materials. Centralising Chutes may be used with reasonably free flowing materials delivering to a conveyor either in-line with the Samson or at an angle. Parallel Chutes are ideal for handling wet and sticky materials or where the ongoing conveyor or feeder may be positioned at 90 degrees to the Samson. Various types of feeder system may be employed to suit the requirements of each applications as illustrated herein.
B&W kleen-line belt feeder with parallel chute handling cement clinker
Parallel chute discharging to B&W inclined conveyor handling steel works slag
B&W troughed belt feeder with parallel chute handling brick clay
17
B&W kleen-line belt feeder discharging to a bucket elevator handling damp sand
Centralising chute with in-line vibro feeder discharging to B&W inclined conveyor
Vibro feeder discharging to a B&W steep angle conveyor handling talc raock
18
The Samson drive comprises a shaft mounted gear unit as illustrated with the option of a standard worm gear for hydraulic drives, a helical worm for electric drives or for special applications a flange mounted helical/bevel gear may be supplied. Gear units may be installed singly on either the left or right sides or for very high performance applications tandem hydraulic drives may be fitted with a gear unit on each side of the head shaft. The Flender range of worm or helical gears have been chosen for their robust construction and proven long term reliability. The Cooper split roller bearing is a high precision design with high load capacity. The bearing is split into sections allowing simple installation and easy replacement without disturbing the main drive gear unit. Hydraulic drive
Drive Systems
Shaft mounted worm gear with hydraulic motor drive showing the drive sprocket and cooper split roller bearing
Drive Systems
Hydraulic Drives:
19
L B D A C
High performance hydraulic drive with electric motor and axial piston hydraulic pump including load sensing
For most applications the hydraulic drive system is the preferred option providing automatic torque control and soft starting with the ability to stop/start at high frequency using a solenoid control valve to interrupt the drive to the Samson conveyor. This is G particularly important when the Samson is used as a receiving unit, see page 21 describing the operation of the head chute probe in this application. F In the majority of applications the Samson will be subject to high impact loads with the opportunity for overloading, in these situations the hydraulic drive system absorbs the drive shock and allows precise setting of the drive torque to prevent damage to the driving gear in the event of extreme overload. Load Sensing is an integral element in the hydraulic drive, in the event of high load levels within the Samson body the hydraulic pressure and flow are automatically regulated to keep the power demand within preset limits preventing overload of the main electric motor/pump drive unit. Using this system the drive motor may be sized to suit the normal machine operation without fear of stalling in the event of short term overload, thus minimising power usage.The load sensing feature may also be used to regulate the Samson output by automatically reducing the belt speed as the load level increases to maintain a partially regulated discharge rate. All hydraulic systems include comprehensive filtration equipment and protection systems.The hydraulic relief valve provides ultimate protection for the drive and hydraulic equipment, this system reacts instantaneously to extreme overload situations by limiting the torque transmission capacity and thus protecting the drive unit and conveyor chains. As a further benefit the hydraulic drive system provides simple local speed control by varying the flow rate to the hydraulic motor.This system may be expanded to include an electrical interface allowing remote setting of the Samson discharge rate using a 4-20 m signal interface.
20
Instrumentation
F D
A G H
K E
Terminations:
The complete instrumentation system may be linked direct to the Samson local control cabinet or may be supplied prewired to a central junction box for remote control applications.
Electrical Controls
21
The Samson is offered with a range of control options ranging from basic manual control to fully automatic unattended operation: System 1 The entry level system comprising a standard motor starter and Isolator mounted to a cabinet for the control of the electric motor only. In this option the belt drive start/stop is controlled only using the manual rotary speed control valve. Generally only applicable to mobile equipment where an operator will be on station to control the machine manually. No instrumentation interfaces are available with this option. System 2 Access doors For applications where the Samson will be supplied with a solenoid valve to control the belt with press buttons for belt start/stop. This equipment may be interfaced to the head chute level detector only, not suitable for other instrumentation. Generally used for basic fixed plant for infrequent use where a local operator will be on station to control the machine. System 3 A comprehensive system which may be used with the full range of instruments listed permitting automatic unattended operation with full interface connections to the associated plant including voltfree connections to remote control systems. Switched Local and Remote control options are provided plus status indication for all instrumentation and drives. This system may be further extended to include a PLC with remote communication module to interface with the clients main plant control system.
Special Applications
Belt weigher
Samson receiving unit handling steel works slag from trucks and shovels with belt weigher interface
Levelling blade
Roll crusher
Samson receiving unit handling steel works slag from trucks and shovels with belt weigher interface
23
The ability of the Samson to receive virtually any bulk material direct from tipping trucks without the need for large ramps or underground pits opens new opportunities for mobile Stackers and Shiploaders. These applications demonstrate the flexibility offered by the Samson solution.The projects shown here would not have been possible except for the unique benefits of the Samson.
The B&W Stormajor as shown above comrises a Samson receiving unit with a radial outloading boom mounted to a common chassis as a single mobile machine
Twin independent mobile Samsons loading to a B&W mobile Shiploader handling cereals
The B&W Stormajor loading sand to Rhine barges from a river berth
Multi feed point mobile Samson used with a B&W mobile Shiploader handling cereals
Great-Britain
B&W Mechanical Handling Ltd. Lancaster Way, Ely, Cambridgeshire CB6 3NP Tel.: +44-1353-665001 Fax: +44-1353-666734 e-mail: sales@bwmech.co.uk www.bwmech.co.uk AUMUND Ltd. Ryton House, 7 Lane Head Ryton,Tyne & Wear NE40 3NA Tel.: +44 - 191 - 413 8077 Fax: +44 - 191 - 413 6379 e-mail: aumund.uk@mcmail.com
Germany
AUMUND Foerdertechnik GmbH Saalhoffer Str. 17 47495 Rheinberg Tel.: +49 - 2843 - 72 0 Fax: +49 - 2843 - 6 02 70 e-mail: aumund@aumund.de www.aumund.com LOUISE Foerdertechnik GmbH & Co. KG Saalhoffer Str. 17 47495 Rheinberg Tel.: +49 - 28 43 - 925-5 Fax +49 - 28 43 - 925 600 e-mail: louise@louise.de www.louise.de SCHADE Lagertechnik GmbH & Co. KG Dorstener Str. 360 44653 Herne Tel.: +49 - 2325 - 58 74-0 Fax +49 - 2325 - 58 74 74 e-mail: info@schade-lagertechnik.de www.schade-lagertechnik.de
France
AUMUND France S.A.R.L. 53, rue d`Hauteville 75010 Paris Tel.: +33 - 1 - 42 46 72 72 Fax: +33 - 1 - 42 46 72 74 e-mail: aumund@aumund.fr AUMUND Polska Representative Office ul. Lektorska 34 G 44-210 Rybnik Tel.: +48 - 32 - 42 63 211 Fax: +48 - 32 - 42 63 201 e-mail: aumund@post.pl AUMUND Contracting AG Lwenstr. 55, P.O. Box 8023 Zrich Tel.: +41 - 1 - 215 68 68 Fax: +41 - 1 - 215 68 70 e-mail: info@aumund.ch www.aumund-contracting.com AUMUND AG Ober Altstadt 32a, P.O. Box 6301 Zug Tel.: +41 - 41 - 710 10 82 Fax: +41 - 41 - 710 42 02 email: info@aumund.ch
Poland
Swizerland
Brazil
AUMUND Ltda. Rua do Rocio, 220-5, andar - Conj. 52 Edif. Atrium - VI. Olimpia CEP-04552-903 So Paulo, SP Tel.: +55 -11 - 3046 4800 Fax: +55 -11 - 3046 4801 e-mail: aumund@aumund.com.br AUMUND Corporation 2300 Windy Ridge Parkway Suite 150S Atlanta, GA 30339 Tel.: 1 - 770 - 226 - 95 78 / 80 Fax: 1 - 770 - 953 - 48 44 e-mail: sales@aumundusa.com AUMUND Engineering Private Ltd. 2nd Floor, Lakshmi Neela Rite Choice Chambers 9, Bazulla Road,T.Nagar Chennai - 600 017 Tel.: +91 - 44 - 815 60 48 Fax: +91 - 44 - 815 60 46 e-mail: aumund@vsnl.com AUMUND (China) Representative Office Room 909, East Ocean Center, No. 24A Jian Guo Men Wai Street Chao Yang District Beijing 100004 - P.R. CHINA Tel.: +86 - 10 - 65 15 58 13 / 14 Fax: +86 - 10 - 65 15 58 15 e-mail: aumund@public.bta.net.cn
USA
India
P.R. China
www.bwmech.co.uk