Contents

Preface ...........................................................................................................................................0
1 Coal Handling System Overview........................................................................................1
2 Equipment and Control.......................................................................................................2
2.1 Control Scope ....................................................................................................................2
2.2 Components of Programmed Control System....................................................................2
2.3 Major Ways of Coal Feeding and Storing ...........................................................................2
2.4 Interlock Principle Between Each Equipment of System With Centralized Control ............4
2.5 Operation Ways of Centralized Control ..............................................................................4
2.6 Centralized Control Operation............................................................................................4
2.7 Monitoring Items and Precautions During Operation........................................................10
2.8 Common Failures and Solutions for Centralized Control System.....................................10
3 Coal Unloading and Coalyard Equipment ........................................................................12
3.1 Gantry Crane....................................................................................................................12
3.2 Bucket Wheel Stake and Reclaimer .................................................................................18
3.3 Double Beam Crane.........................................................................................................41
3.4 Wiper................................................................................................................................50
4 Equipment of Coal Feeding System.................................................................................53
4.1 Belt Conveyor...................................................................................................................53
4.2 Vibrating Feeder...............................................................................................................58
4.3 Ring Hammer Coal Crusher .............................................................................................60
4.4 Natural Cooling Belt Type Magnetic Separator ................................................................63
4.5 Electronic Belt Scale ........................................................................................................66
4.6 As-fired Coal Sample Device ...........................................................................................68
4.7 Low Noise and Anti-blockage Devices .............................................................................71
4.8 Plough Tripper..................................................................................................................72
4.9 Bag Filter..........................................................................................................................74
5 Sprinkler and Flushing Hose Reel of Coal Yard ...............................................................77
5.1 Sprinkler ...........................................................................................................................77
5.2 Flushing Hose Reel ..........................................................................................................77
6 Troubleshooting of Coal Unloading, Storage and Conveying ...........................................79
6.1 Principle of Troubleshooting .............................................................................................79
6.2 Emergency Shutdown ......................................................................................................79
6.3 Solutions of Auxiliary Power Supply Interruption ..............................................................79
6.4 Precautions and Handling of Wet Coal in Rainy Season..................................................80
6.5 Precautions and Adjustments of Conveying High Dust Concentration Coal .....................80
Appendix Flow Chart of Coal Convey System ..........................................................................81

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Operation Manual Vol.1–5A Coal Handling Operation Manual

Preface
This Operation Manual is based on equipment operation specification and relevant drawing
provided by coal handling system equipment manufacturers in Indonesia Aceh 2x110MW
Coal-fired Power Plant Project. It is only suitable for operating coal handling equipment in
2x110MW Coal-Fired Power Plant Project.
This manual should be modified and completed on the basis of practical experience in
equipment commissioning, operation and maintenance. If there exist conflicts, base on the
scheme given by operators modulate on site.
Protection set value of every piece of equipment involved in this manual will be added after
commissioning on site.

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Operation Manual Vol.1–5A Coal Handling Operation Manual

1 Coal Handling System Overview

The task of coal handling system is to unload coal from coal transporting barge at coal
unloading dock of power plant, and convey the coal to coal yard and handle the coal
to required size that are easy to be fired in boiler and convey coal to front bunker of
boiler. At coal unloading dock, this unit is equipped with two portal-type clamshell
cranes to conduct unloading task.
The capacity of this coal yard is about 235,000 tons that two units can use for 60 days.
It is 10m high. Coal storage capacity in dry coal shed is based on the coal need of two
units for 10 days. It is about 38 000 tons. The pile is 8m high. The shed is 136m in
length and its span is 33.35m.
The dry coal shed is equipped with two portal-type clamshell cranes, each of them is
31.5m in span, has 5 m3 grab capacity and 10 tons payload capacity. The coal from
dock is unloaded into dry coal shed by belt conveyor and single-side plough type
material unloader equipped at the side of dry coal shed. To coordinate with bridge
type grab crane to work, two grab buckets is equipped inside the dry coal shed. Under
each grab bucket is setting a vibration coal feeder, through which the coal is given to
belt conveyor of coal feeding system.
To ensure safety in operation of belt conveyor, every section of belt conveyor of coal
handling system is equipped with protection devices, such as two-direction pulling
switch,, two-grade misalignment switch, slippage switch and speed detector.
Open-air coal yard is equipped with one cantilever bucket wheel stack & reclaimer,
whose arm length is 25m, rated stacking capacity is 800t/h and rated reclaiming
capacity is 200t/h. The cantilever bucket wheel stack & reclaimer is used to stack or
reclaim in open-air coal yard.

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2 Equipment and Control

2.1 Control Scope
Such as gantry crane, vibration coal feeder, belt conveyor, bucket wheel stack and
reclaimer, belt iron remover, single plough-type unloader, bi-side plough-type unloader,
sampling device, electrical three-way damper, coal crusher, wiper, motor-driven
three-way valve.
2.2 Components of Programmed Control System
Coal handling program control system consists of three parts: programmable logic
controller system, main computer monitor and control system and CCTV system.
2.3 Major Ways of Coal Feeding and Storing

a) Coal from coal transporting barge all goes to coal silo or dry coal shed. As shows
in the Figuure 2-1

Figure 2-1
1-coal carrier 2-ship unloader (1/2) 3-plough-type material unload
4-dry type shed 5-bucket stack & reclaimer 6-coal silo

b) Coal from coal transporting barge goes through coal feeding system directly and
enters coal bunker, the left of which goes to coal yard or dry coal shed.

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Figure 2-2
1-coal carrier 2-ship unloader 3- dry coal shed 4-bucket wheel 5-coal yard
6-coal-plough 7-coal bunker 8-coal crusher 9-coal crusher
c) Coal grabbed by portal-type clamshell crane from dry coal shed goes through
coal feeding system and then enters coal bunker.

Figure 2-3
1-dry coal shed 2-double girder crane 3-vibration coal feeder A 4-vibration
coal feeder B 5-coal crusher A 6- coal crusher B 7-coal bunker
d) Bucket wheel stack & reclaimer gets coal from coal yard. The coal goes through
coal feeding system and then into coal bunker.

Figure 2-4
1-coal yard 2-bucket wheel 3-C10 belt conveyor 4-coal crusher A 5- coal
crusher B 6-coal plough 7-coal bunker
The operation types described before are the main classifications of coal handling
system operation. There will be more operation ways by changing belt type conveyor
with A, B of equipment.
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2.4 Interlock Principle Between Each Equipment of

System With Centralized Control
Under normal circumstances, start up equipment accord with reverse direction of coal
stream and shut down equipment accord with the coal stream direction. If individual
fails, shut down relevant equipment immediately accord with reverse direction of coal
stream. Equipment after the trouble equipment is still running so as to avoid or reduce
the possibility of coal blockage in system and accident expanding.
2.5 Operation Ways of Centralized Control
a) Centralized programmed control operation
It refers that after operation way is selected, startup and shutdown commands
come from central control room, then the selected equipment starts up and shuts
down in a group based on the set process flow.
b) Interlock manual operation
Interlock manual controlled by upper computer requires manual startup the
equipment accord with reverse direction of coal stream and manual shutdown
accord with the coal stream direction. To startup and shutdown signals cannot
meet interlock relation; systematic main computer would ignore them. In the
operation process, if a piece of equipment fails, solutions of trouble shouting are
the same with programmed control.
c) Unblock manual operation
In interlock manual operation and programmed control, every piece of equipment
is interlocked. In unblock manual operation, the whole system will break interlock
relation and any piece of equipment will be started up and shut down. It is
abnormal operation and not allowed to operate with load. It is suitable in
individual equipment commissioning and calibration.
d) Local manual control operation
Every piece of equipment can apart away from programmed control by changing
PROGRAMMED CONTROL and LOCAL switches in control room or on local
operation box. Start up or shut down equipment one to one directly. The whole
system has no interlock condition when starts up. It is used in single equipment
commissioning and calibration. It also used for emergency coal feeding when
upper computer breaks down.
2.6 Centralized Control Operation
2.6.1 Check before Operation
2.6.1.1 Seriously consult shift record, be aware of shutdown and operation of the equipment
comprehensively and accurately. Inform personnel on site to do static check of the
equipment at his position completely.
2.6.1.2 Assure the main computer is at working state.
2.6.1.3 Check to see if all equipment in flow-process is in shutdown state.
2.6.1.4 Check if coal level indicator and high coal level indicator of every coal bunker display
normally. Then assure if the indication result is suitable for the actual condition. If
there is doubt, inform personnel to collate.
2.6.1.5 Check if every communication tool is complete.

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2.6.2 Preparation Before Operation

2.6.2.1 Assure that change-over switch REMOTE and LOCAL is switched to REMOTE.
(Including every controlled equipment on site or in control room)
2.6.2.2 Assure that master power supply switch is on. If it closes, start up upper computer.
2.6.2.3 Inform drivers of gantry crane, bucket wheel or double girder crane to be ready to
work.
2.6.2.4 Contact personnel on site. If all preparations before startup are done and receive the
reply to start up, then programmed control startup operation can be performed.
2.6.3 Control Mode
2.6.3.1 Startup and Shutdown of Program Control
a) Startup of Program Control
1) Move the cursor and click to disable NEUTRAL button. When COAL
FEEDING is selected as the main process, select PROGRAM CONTROL as
the way to feed coal and PROGRAM BLEND to blend coal. When COAL
STOCK is selected as the main process, select PROGRAM CONTROL as
the way to feed coal.
2) Move the cursor and click ZERO CLEAR button and then the BLEND
CLEAR button to set the program in the initial state.
3) Move the cursor to trun to the MAIN PROCESS display. Based on the
operation mode, select one bypass process among the eight processes and
the bypass process selection window will be popped up in the display.
4) Move the cursor along the way coal flows to select equipment that needs to
be started up. On the master computer, the equipment selected changes
from blue to green.
5) After the selection, if there is EFFECTIVE PROCESS information popped up
on the upper part of the master computer display, the selected process is
correct but if there is WRONG PROCESS information popped up, the
process selected is wrong and it needs to be reselected until EFFECTIVE
PROCESS information popped up.
6) After the popping up of the EFFECTIVE PROCESS, move the cursor and
click PRESTART button and the sound device will inform the operator on
duty: the damper of the selected process is properly positioned. As to the
condition of PROGRAM BLEND, the device will inform: the coal plough at
the end of the raw coal bunker falls down while the other ploughs are up.
After several seconds, the properly positioned damp changes to red and
there appears signal of the properly positioned plough. On the upper part of
the master computer display, it pops up the STARTUP PERMISSION
information and sends out voice announcement.
7) If there is no positioned signal for the damper or no signal for the dropping
and rising of the plough, the sound device announces DAMPER JAMMED or
PLOUGH JAMMED. At this time, inform the patrol personnel to check or
repair the damper or plough.
8) If the damper is properly positioned while the damper signal suggests
otherwise, move the cursor and click DAMPER POSITION SET button to set
the program to skip the checking of damper. Then click ZERO CLEAR button

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and PRESTART button in order and there will pop up STARTUP

PERMISSION information on the upper part of the master computer display
and voice announcement will be sent out as well. (When the process is over,
it should release the state of DAMPER POSITION SET button in time. This
method to force the damper in its place should be used with caution.)
9) After the appearance of the STARTUP PERMISSION signal, move the
cursor and click PROGRAM STARTUP button. In a direction contrary to the
coal flow, equipment of the selected process starts up with time in delay. The
EFFECTIVE PROCESS button and STARTUP PERMISSION button
disappear at the time when the last equipment completes startup. The color
of started equipment changes from red to green on the main computer.
10) Based on requirements of the process selected and startup mode, properly
order the driver of the double beam crane or bucket stacker and reclaimer to
output according to the regulations and conduct the startup operation.
11) If it needs to run both the routes, another route can only be started after the
first route is normally run and its operation should accord with the above
procedures.
Notes: the equipment selected changes from blue to green. In operation, the
equipment turns to red and when there is malfunction, it sends out
malfunction flashing. In the state of PROGRAM STARTUP and STARTUP,
the alarm bells along the line runs automatically.
b) Shutdown of Program Control
There are two ways of PROGRAM CONTROL shutdown
The first is that the program stops feeding coal automatically in the process of
coal feeding.
The second is that the operators on duty stops feeding or stocking coal.
1) Program automatic stop feeding coal during coal feeding
In the process of PROGRAM CONTROLLED COAL BLEND, after the
sequenced high level coal blend is completed, the PROGRAM BLEND
COMPLETE information pops up on the upper part of the master computer
display. At the same time, along the direction of coal flows, the process
selected automatically stops from the coal sources with time in delay. When
it is stops, operators on duty should timely inform the driver of double beam
bridge type crane or bucket wheel stacker and reclaimer to stop.
2) Operators on duty to stop feeding or stocking coal
Before the operators on duty stopping feeding or stocking coal, the driver of
double beam crane or bucket stacker and reclaimer should be ordered to
shut down firstly. When that shutdown is confirmed, move the cursor and
click PROGRAM SHUTDOWN button. In the popped up SELECT COAL
SOURCE STOP window of the upper computer, select the coal source that
should be stopped.
Move the cursor and click CONFIRM button, from the coal source,
equipment in operation automatically shuts down along the direction coal
flows with time in delay. After the shutdown, equipment on the master
computer changes from red to green.
Check to ensure all the equipment of the selected PROGRAM SHUTDOWN
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process is indeed shut down.

If both the routes are in operation, it should shut the first route and then take
the above procedures to shut down another route.
After shutting down all the equipment, move the cursor and call out the MAIN
PROCESS display. Select the shutdown bypass process and click off all the
equipment selected. On the computer, the equipment changes from green to
blue.
Move the cursor and click ZERO CLEAR and BLEND CLEAR button to reset
the program to the initial state.
Move the cursor and click NEUTRAL button to cancel the selection of all
control modes of coal feeding and coal stocking.
Record and calculate the total number of every belt scale and the
overloading time before shifting.
2.6.3.2 Manual startup and shutdown via interlock
a) Manual startup via interlock
1) Move the cursor and click to disable NEUTRAL button. When COAL
FEEDING is selected as the main process, select MANUAL INTERLOCK as
the way to feed coal and PROGRAM BLEND to blend coal. When COAL
STOCK is selected as the main process, select MANUAL INTERLOCK as the
way to feed coal.
2) Move the cursor and click ZERO CLEAR button and then the BLEND CLEAR
button to set the program in the initial state.
3) Move the cursor to call out the MAIN PROCESS display. Based on the
operation mode, select one bypass process among the eight processes and
its corresponding selection window is popped up in the display.
4) Move the cursor along the way coal flows to select equipment that needs to
be started up. On the master computer, the equipment selected changes from
blue to green.
5) After the selection, if there is EFFECTIVE PROCESS information popped up
on the upper part of the master computer display, the selected process is
correct but if there is WRONG PROCESS information popped up, the process
selected is wrong and it needs to be reselected until EFFECTIVE PROCESS
information popped up.
6) After the popping up of the EFFECTIVE PROCESS, there are two means to
operate the damper and the coal plough.
First means: Move the cursor and click PRESTART button and the sound
device will inform the operator on duty: the damper of the selected process is
properly positioned. As to the condition of PROGRAM BLEND, the device will
inform: the coal plough at the end of the raw coal bunker falls down while the
other ploughs are up. After several seconds, the properly positioned damp
changes to red and there appears signal for the properly positioned plough.
On the upper part of the master computer display, it hops up the STARTUP
PERMISSION information and voice announcement is sent out as well.
Second means: Observe the total process display on the master computer. If
the damper selected is properly positioned, it turns to red. If the damper is
improperly positioned, after attaining notification to operate the damper from
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the local operator, move the cursor to open the AUXILIARY EQUIPMENT
display. Operate the MANUAL CONTROL DAMPER button to make the
damper in its place. Then move the cursor to open COAL BLEND display, use
the cursor to drop down the coal plough at the end of the raw coal bunker and
lift up the other ploughs.
If there is no positioned signal for the damper or no signal for the dropping
down or lifting up of the plough, the sound device announces DAMPER
JAMMED or PLOUGH JAMMED. At this time, inform the patrol personnel to
check or repair the damper or plough.
7) When the process is correctly selected and all the dampers are properly
positioned, move the cursor and select the head equipment on the bypass
process selected in the direction contrary to the coal flow, the corresponding
CONTROL AND STATE INQUIRY window pops up. After three times of alarm
bell, click the STARTUP button of the equipment and start up the belts and
equipment selected in order till all of the belts and equipment are completely
started up. In the operation, the following principles should be obeyed:
Start up the belt conveyor after the preset of the damper position is
completed.
Start up the magnetic separator first and then the belt conveyor.
Start up the rear belt of the crusher and then the crusher.
8) During the startup process, observe the operating signal and current of the
monitoring display on the computer. Ensure that the former belt is started up
and then start up the latter section.
9) Based on the operating process confirmed, properly order the driver of the
double beam bridge type crane or bucket stacker and reclaimer to conduct the
startup operation accorfing to regulated output.
b) Manual shutdown via interlock
1) In the process of PROGRAM CONTROLLED COAL BLEND, after the
sequenced high level coal blend is completed, the PROGRAM BLEND
COMPLETE information pops up on the upper part of the master computer
display and operators on duty should timely inform the driver of double beam
crane or bucket wheel stacker and reclaimer to stop feeding coal.
2) After affirming that the double beam crane or bucket stacker is shut down,
move the cursor and shut down the equipment in operation along the coal
flowing direction. When the equipment is shut down, on the master computer,
it turns from red to green. In the process of shutdown, all the following
principles should be obeyed:
Properly estimate the no-load running time of the belt based on its length.
Only after ensuring that there is no coal on the belt through industrial
television monitoring display can the equipment be shut down along the coal
flowing direction.
Stop the belt conveyor first and then the magnetic separator.
3) Check that all the equipment of the process has been stopped.
4) After shutting down all the equipment, move the cursor and call out the MAIN
PROCESS display. Select the bypass process that has been shut down and
click off all the equipment selected. On the computer, the equipment changes
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from green to blue.

5) Move the cursor and click ZERO CLEAR button and BLEND CLEAR button to
reset the program to the initial state.
6) Move the cursor and click NEUTRAL button to cancel the selection of all
control modes of coal feeding and coal stocking.
7) Record and calculate the total number of every belt scale and the overloading
time before shifting.
2.6.3.3 Manual coal blend
Manual coal blend is to lift up and drop down the coal plough by hand to blend coal.
Under this situation, in every silo, the time to blend coal is completely controlled by the
control platform, which is of help to adjust the coal level in the silo and put it into
operation in the condition of malfunction.
There are two means to blend coal manually: one is manual coal blend in central
control room (CCR) and another is local manual coal blend.
a) Manual blend in CCR
1) Move the cursor and click to disable NEUTRAL button. Select PROGRAM
CONTROL or INTERLOCK as the way to feed coal and MANUAL COAL
BLEND to blend coal. Start up the coal feeding process according to the
control mode of the PROGRAM CONTROL or INTERLOCK.
2) Move the cursor and call out COAL BLEND display. Operate the MANUAL
LIFT button and MANUAL DROP button of the coal via moving the cursor so
as to drop the coal plough at the end of the raw coal bunker.
3) Based on the indication of coal level, move the cursor and operate MANUAL
CONTROL button of every coal plough to control its lifting up or dropping
down to blend coal.
4) Before completion, inform the driver of double beam bridge type crane or
bucket stacker and reclaimer to stop. Select PROGRAM CONTROL or
MANUAL INTERLOCK to shut down every piece of equipment individually in
the process.
5) Check that all the equipment of the process selected has stopped.
6) After shutting down all the equipment, move the cursor and call out the MAIN
PROCESS display. Select the bypass process that has been shut down and
click off all the equipment selected. On the computer, the equipment changes
from green to blue.
7) Move the cursor and click ZERO CLEAR button and BLEND CLEAR button to
reset the program to the initial state.
8) Move the cursor and click NEUTRAL button to cancel the selection of all the
control modes of coal feeding and coal stocking.
9) Record and calculate the total number of every belt scale and the overloading
time before shifting.
b) Local manual blend
1) Put the transfer switch REMOTE/CONTROL of local control panel to LOCAL.
2) Only through operating the LIFT button or DROP button of the coal plough
can local manual blend be completed.
3) After the blend is over, put the transfer switch REMOTE/CONTROL of local
control panel to REMOTE.
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Notes: The local manual blend can only be used when malfunction occurs to
manual blend in CCR.
2.7 Monitoring Items and Precautions During Operation
2.7.1 Monitoring of Programmed Control
2.7.1.1 Check the display of equipment current, coal level in bunker, system alarm and light
indicator and monitor plate direction in order to get timely information of working
conditions and properly conduct the production control and troubleshooting.
2.7.1.2 Keep coal flow value on the belt scale change within rated range. Equipment overload
operation is not allowed.
2.7.1.3 Monitor coal level signal to prevent coal overflow or coal interruption and make sure
the normal operation of coal distribution.
2.7.1.4 When equipment trips, immediately check whether the equipment in this process flow
and coal source equipment experience interlock trips due to reverse coal flow and
inform driver of ship unloader or bucket wheel stacker and reclaimer to stop driving. If
interlock is abnormal, immediately press EMERGENCY button. Report to the foreman
and choose process flow to restart up after troubleshooting.
2.7.1.5 Regularly check and monitor the display of industrial TV in case of any abnormal
condition. Check system alarm, report to the foreman and inform maintenance
personnel when there is failure signal.
2.7.1.6 Keep in contact with site personnel in order to timely regulate and properly conduct
the production control.
2.7.2 Notes of Monitoring Programmed Control
2.7.2.1 Strictly monitor startup current and time of each piece of equipment when starting up
programmed control. If startup current exceeds the requirements of startup time,
immediately press EMERGENCY button.
2.7.2.2 Check and make sure that the startup sequence of equipment accords with process
flow requirements.
2.7.2.3 Closely monitor whether the color change of equipment in the display is normal,
whether coal ploughs in coal bunkers accord with requirements of Programmed Coal
Distribution, and whether the display of industrial TV is normal.
2.7.2.4 When some equipment cannot start up or trips after startup, ascertain the causes
through voice alarm and system fault inquiry, inform site personnel to confirm or
handle the problem, then report to the foreman and choose process flow to restart up.
2.7.2.5 When one or all process flows stop operating, check and make sure that all
equipment stop operating and ammeter’s arm turns to zero.
2.7.2.6 Check the reading of electronic belt scale after stopping operating every shift.
2.7.2.7 After finishing coal handling every time, manually operate each electrical 3-way valve
2-3 times to clear accumulated coal.
2.8 Common Failures and Solutions for Centralized
Control System
Table: 2-1 Common Failures and Solutions for Centralized Control System
Failures Solutions

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1 Stop or continue using the belt according to different conditions.

2 Ascertain the causes. If the cause is excessive coal flow, inform the
Belt overload
operators to decrease coal flow. Otherwise, take other solutions according
to different causes.
Trip of major 1 Ascertain the causes, inform maintenance personnel and change the
equipment system correspondingly.
Trip of auxiliary 1 Ascertain the causes, inform maintenance personnel and change the
equipment system correspondingly.
Contact the on-duty operator to get specific information of belt emergency
Emergency stop of
stop and troubleshoot according to different causes.
belt
Reset pull switch after troubleshooting.
1 Clear the misalignment signal.
Primary belt
2 Inform the on-duty operator to adjust belt according to misalignment
misalignment
causes.
Inform the on-duty operator to ascertain causes and take proper solutions
Secondary belt according to different causes.
misalignment Remove misalignment protection device and start up belt to adjust without
affecting safety.
Immediately stop belt.
Belt slippage
Inform the on-duty operator to ascertain causes and solve the problem.
Ascertain the causes, inform maintenance personnel and change the
Belt longitudinal
system correspondingly.
splitting
Ascertain the causes and inform maintenance personnel.
Inform maintenance personnel if on-duty operator cannot solve the
Damper jam
problem.
Manually distribute coal or immediately stop coal supply according to coal
level in coal bunker.
Coal plough jam
Inform maintenance personnel if the on-duty operator cannot solve the
problem.
Immediately stop the belt.
Failure of coal crusher Inform maintenance personnel after the causes has been detected by
operation personnel..
Startup failure Ascertain causes and inform electric maintenance personnel.
Check whether fuse is burnt.
Power supply faults
Inform electric maintenance personnel to ascertain causes.
1 Inform the on-duty operator to observe coal clogging condition. If coal
Coal clogging blocks severely, stop the unit to clear and then restart up.
2 Change corresponding systems and then clear the blocking part.

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3 Coal Unloading and Coalyard Equipment

3.1 Gantry Crane
3.1.1 Equipment Overview
Gantry crane is used to load and unload bulk coal in general port.
It is a rigid four lever jib type gantry crane. It mainly consists of hoisting mechanism,
luffing mechanism, slewing mechanism, operating mechanism, four lever jib system,
jib balance system, pillar, turntable, machine house, driver cabin, cylindrical gantry,
ladder and handrail system, electrical control system, and other auxiliary equipment.
The crane could lift 16 tons at maximum within 38 meters through grab bucket, and
could make horizontal displacement with load and 360 degree rotation. Hoisting,
luffing, and slewing mechanism could work individually or combinedly. The crane
could travel horizontally along rails. Hoisting, luffing, slewing and operating
mechanism all use alternating current (AC) variable-speed-drive (VSD) to adjust
speed. All mechanism is equipped with limit switches and interlock protection devices.
The slewing center is in the symmetric center of gantry. 4 groups of 8-wheel cart is
supporting as the support column at landside and seaside. Under the each end of
gantry beam there is a set of anchoring device. Both ends of operating mechanism
have buffers.
The crane is driven by 380V, 50Hz direct current (DC). Power in the power box on sea
side ground of port is led through hysteresis type cable drum on sea side support
columns to cable and then serve the crane. The fixed parts and slewing parts are
connected by central current-collector.
3.1.2 Equipment Technical Specifications
Table: 3-1 Equipment Technical Specifications
Jack-up capacity Grab bucket jack-up capacity 16t/38m

Maximum range 38m

Working range
Minimum range 11m

Lifting mechanism 55m/min

Variable range mechanism 50m/min

Working speed
Rotary mechanism 1.5rpm

Operation mechanism 26m/min

Above rail 16m

Lift height
Below rail 10m

Rail distance 10.5m

Clearance parameter Rail base span 10.5m

Gantry free height 7.035m

Maximum tail radius 8m

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Maximum height of the whole

49.91m(minimum range)
equipment
Width of buffer 18.292 m

Stroke distance ±90m

Every leg has eight wheels,
Stroke wheel among which four are driving
wheels.
Stroke parameter of the whole Anchor device Two units (manual)
equipment
Every leg has one unit (block
Buffer
rubber type)
Impact height of buffer 420mm

Total power of motor 391kW

Travel of the whole equipment Length 180m

Power supply modes
Power supply 380v 50Hz

3.1.3 Check Before Operation of Gantry Crane

3.1.3.1 Check whether the total number of breaking wires in a lay length is equal to or exceed
10% of the total number of wire ropes (13 pieces of wire).
3.1.3.2 Check if steel wire rope is twisting, deformed obviously and corroded seriously.
3.1.3.3 Inspect if the fixing device at the end of steel wire rope on drive pulley (drum) is tight.
3.1.3.4 Check if pulley (drum) has cracks.
3.1.3.5 Rope race of pulley should be bright and smooth and free from defect to damage steel
wire rope.
3.1.3.6 Brake rubbing surface of brake disc should be kept bright and clean without greasy
dirt or other foreign matters.
3.1.3.7 Frequently check whether wheels have cracks and the edge of wheel wears seriously.
If rim thickness of wheel wears 50% of its original thickness, the wheel should be
replaced.
1.1.3.8 Frequently check lubricating condition of gearbox and keep oil level within the
indication range of the oil level indicator. If there is oil leakage, handle it immediately.
Replace oil when lubrication oil is dirty or has other foreign matters.
3.1.3.9 Remove stopper before operation mechanism of the crane moves. If the anchor is
locked before it is fixed here, open it in advance.
3.1.3.10 Inspect the travel rail and remove the barriers on rail.
3.1.3.11 Frequently check safety device of every component and ensure safety device is in
good condition, only then operate.
3.1.3.12 Forbid operating when light is dark and sight is not clear.
3.1.4 Operation of Gantry Crane
3.1.4.1 Preparation before operation
a) Check if there is barrier or greasy dirt on crane rail and lift anchoring block.
b) Check lubricating condition of every lubrication area in ship unloader and check if

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Operation Manual Vol.1–5A Coal Handling Operation Manual

oil mass of oil tank and gearbox meets the requirement.

c) Check the wearing condition of steel rope and pulley and the reliability of the
fixed part of steel rope and check if the bolts are fixed and steel structure has
cracks.
d) Inspect whether air switch, contactor, hot relay of every control panel work
normally. The touch panel in driver’s cabin displays trouble of machine for
inspection.
e) Check if the emergency button is reset.
f) Check if every operation paddle and switch is at ZERO position and the
communication facility is complete. Be aware of power supply condition of master
power supply. If it is normal, plug in and energize.
g) Observe if voltmeter and ammeter indicate normally. Rotate every mechanism
with no load for several minutes and then check if its transmission and brake are
normal, reliable and flexible. See if the limit route switch and transmission signal
of lifting mechanism, rotating mechanism and crane operation mechanism are
normal and accurate.
3.1.4.2 Operation
a) Drivers should perform the following check and preparation and then drive.
1) Connect the power cord to apply power supply.
2) Check all control screens in the computer room and close main electric route
and control electric route of every mechanism.
3) Rotate two rotary brake hand wheels to loosen rotary brake. The gap
between brake shoe and brake wheel should not exceed 2mm.
4) Check up on voltage value of power supply three-phase by voltmeter and
change-over switch to see if power supply voltage is at normal value and
balancing condition of three-phase voltage.
5) Pre-operate lifting, luffing, rotation and travel. After assuring everything is
normal, put it into operation.
b) Latch on
1) First, check if main air switch is closed, namely, if the main loop power
supply (4Q1) in power supply panel is closed.
2) Then press CONTROL ON button on the control desk in driver’s cabin,
Control On button signal (green) is on. At this time, master contactor of every
mechanism will activate.
3) First check if control on button contactor (75k3) in power supply control panel
is closed when the switch cannot close and the light is off. Forbid stopping
loop, overspeed loop, limit loop and corresponding electric route immediately
during inspection.
c) Fault reset
Buzzer will alarm when there is fault. First Ascertain causes and then reset fault.
The procedures are as follows:
1) First see the presenting fault indication on touch screen to eliminate causes.
2) Reset the operation when two joysticks are all at neutral position.
d) Limit bypass
Switch LIMIT BYPASS on right control panel to OPEN position, anti-collision limit,
cable drum end, luffing on/off limit and alarm used when gale alarm is at
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ineffective state. LIMIT BYPASS is temporary action to face emergency. It can be

used in maintenance not at working condition.
e) Travelling control
Travelling control and support mechanism of lifting use the same frequency
converter. On the control panel, there is a selector switch: LIFT, UP and DOWN.
Switch to DOWN on the right control panel, travelling mechanism moves
downward and driver drives crane through joystick of grab bucket. When
switching to LIFT, crane will not work and support mechanism runs.
Notes: The speed of crane down operation is slow.
f) Hook control
When the selector switch HOOK and GRAB are switched to HOOK and selector
switch SUPPORT, DOUBLE MOTOR, ON-OFF are at DOUBLE MOTOR, two
motors run at the same time. If the selector switch is at SUPPORT or ON-OFF,
either support motor or on-off motor works. The details are as follows:
1) When the lift manipulate lever (joystick) is set at 1: the lifting signal controls
the operation of frequency converter by Profibus communication. At the
same time, brake relay of the two motors pick up and the rotary speed of
motor reaches 16%.
2) When the lift manipulate lever (joystick) is set at 2: the rotary speed of motor
reaches 50%.
3) When the lift manipulate lever (joystick) is set at 3: the rotary speed of motor
reaches 75%.
4) When the lift manipulate lever (joystick) is set at 4: the motor is at full
operation speed state 100%.
5) When the lift manipulate lever (joystick) is set at 0, rising direction signal
breaks. Under the control of frequency converter, motor slows down until
stops. When the speed of motor reaches approximately zero
(44rmp/min—58rmp/min), support brake contactor (29K3) and on-off brake
contactor (37K2) lose electricity. Brake resistance feedbacks brake, the
brake brakes.
6) The decreasing operation is as same as the rising operation.
g) Grab control
When the selector switch HOOK/GRAB on control panel is switched to GRAB,
need to set open-close grab position. The procedures are as follow:
1) Switch the selector switch SUPPORT/DOUBLE MOTORS/ON-OFF to
DOUBLE MOTORS and selector switch HOOK/GRAB is switched to GRAB.
2) Push the lift manipulate level (joystick) to LFTE to close grab, when the grab
is closed, press CLOSED GRAB SET OK button. If corresponding indicating
light is on, the set is successful. Then push the lift manipulate level (joystick)
to RIGHT to open grab. When the grab is opened at proper position, press
OPEN GRAB SET OK button. If the relevant indicating light is on, the setting
is ready. Switch the selector switch of HOOK/GRAB to GRAB, then the grab
set is finished.
Notes: set closed grab before grab setting and then set open grab. During
setting, the position of grab should be proper, neither too high nor too low.
Operate setting in accordance with operator’s habit. If the selector switch
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SUPPORT/DOUBLEMOTORS/ON-OFF is switched to single motor or PLC

power-off, the lights of OPEN GRAB SET OK and CLOSED GRAB SET OK
are off, then cancel the function of setting grab and reset grab. When the
grab is not set, grab will not work when switch the selector switch of
HOOK/GRAB to GRAB.
3) Push the joystick to LEFT when grab mode is at grab working condition, the
on-off single motor lifts. The speed varies with the positions of joystick.
Support single motor torque deep digging and slow speed lowers. When the
grab setting is close to closed grab, the single motor has the functions of
automatic slowing down, shutdown, canceling deep digging- support
function.
4) When the joystick is pushed to lifting position, two motors lift at the same
time. If the support rope is looser than on-off rope or vice visa, the two loose
steel ropes will automatically regulate to ensure the balance of carrying force
of the four steel ropes.
5) Push the joystick to RIGHT when at open grab working condition, the on-off
single motor moves down and the support single motor does not work. When
the on-off grab is at open grab setting position, on-off single motor can slow
down and shut down automatically. When the joystick moves down, two
motors will be down at the same time.
h) Variable amplitude mechanism
This mechanism is used to increase and reduce amplitude of gantry crane, the
operation is as follow:
1) Increasing amplitude:
When the joystick is set at increasing amplitude 1 position, increasing
amplitude signal controls frequency converter by Profibus communication,
brake relay picks up, brake opens and motor operates at 25% of the
speed.When the joystick is set at increasing amplitude 2 position, motor
rotates at 50% of the speed. When the joystick is set at increasing amplitude
3 position, motor rotates at 75% of the speed. When the joystick is set at
increasing amplitude 4 position, motor rotates at full speed.
When the joystick is set at o position, the increasing amplitude signal breaks,
motor controlled by frequency converter slows down until shutdown. When
the rotating speed is set at zero, brake contactor L3KMY loses electricity,
brake resistance feedbacks brake and brake brakes.
2) Amplitude reduction: the working principle of amplitude reduction is the
same as that of the increasing amplitude.
i) Rotary mechanism
Use series resistance to regulate speed for rotary mechanism. The working
condition is the same as that of conventional control. The sequence resistance
value of cut resistance varies from big to small.
j) Crane travelling mechanism
Use one lift and travelling motor to change relay 89K4, for support and crane
travelling use one same frequency converter. The pick-up and break of the relay
functions as travelling and lifting switchover, which is achieved by switching over
the selector switch SUPPORT, UP and DOWN on the control panel.
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