TRAINING & SKILL DEVELOPMENT FOR

TT (Transfer Tower) Attender

Route Map of Bulk Mechanised Handling System 1 & 2
J S W J AIG ARH P O RT LTD. BMHS CIRCUTE DIAGRAM
TAIL END Abbreviations
SUL Ship Unloader = 04 No's
TT Transfer Tower
RD Receiving & Dispatch
D Dispatch
SR Stacker Reclaimer = 03 No's
SUL 4 JNT Junction Transfer Tower
AFC Alternate Feeding Conveyor
C PLOT JTT Jett y Transfer Tower
JR Jett y Receiving
JRD Jett y Receiving & Dispatch
SUL 3 JSR Jett y Stacker Reclaimer = 02 No's
BL Barge Loader = 04 No's
JD Jett y Dispatch

TAIL
RORO YARD END
R 1A TT 1
SUL 2 SUL 1
JR-1A JD-5A BL 1
JTT 4
R 2A

JD-2A
JR-2A JR-2C
JTT 18 J TT1
JTT 2
JR-2B JD-5B BL 2
JTT 5

JR-3A R 2A
JR-3B A1 PLOT JD-2B

JSR1A JRD-1A
JD-5C BL 3
JTT 3 JTT 6
JSR1B JRD -1B

A2 PLOT
JD-3A
DUMP POND

JD-5D BL 4
JTT 7
R 2A

TT 2

B - 01 PLOT
RD -1
TT 7 TT 6
SR 1
R 3A

R4
D3 B - 02 PLOT
RD- 2

TT 8 TT 3
SR 2

B - 03 PLOT
R4
D3

B - 04 PLOT
RD-3
TT 9 TT 4
SR 3

D3 D1
AFC
B - 05 PLOT

TT 10 TT 11 TT 5
D4 D2

AFC 1 D5

TT 12 JNT
AFC 2

BCN 1B BCN 1A

Bunker
 SAFETY DEVICES
• There are Safety Switches for conveyor and material handling
conveyor system. These are the specially developed field mounted
enclosures with added safety features.
• Some of the Safety Switches in our plant are as follows:-

1) BELT SWAY SWITCH (BSS)

2) PULL CHORD SWITCH (PCS)
3) ZERO SPEED SWITCH (ZSS)
4) CHUTE JAM SWITCH
5) LIMIT SWITCH
6) EMERGENCY-STOP (E-STOP)
1. BELT SWAY SWITCH (BSS)

The switch allows smooth

running of the conveyor and
protects it from damages by
over swaying which can
occur due to uneven loading
of material, worn out idler
roller bearings etc. Belt
sway switch is also known
as Run Off Switch
2. PULL CHORD SWITCH (PCS)

Pull cord switch also

known as Rope
Operated Emergency
switch is used as a
safety switch to stop
the conveyor belt in
case of an emergency.
It is also known as pull
switch cord
3. ZERO SPEED SWITCH (ZSS)

Electronic Speed Monitor is used to

monitor speed of conveyors, crushers,
rolling mills, agitators, mixers,
stirrers, screw conveyors, and other
industrial machinery. This device
actuates relay contacts at preset
speed. Using these contacts desired
control action such as zero speed
protection/ under speed protection/
over speed protection can be
achieved.
4. CHUTE JAM SWITCH

To sense the material

jamming in a compact
chute in feeding
hoppers.
If it is not present there
are chances that there
will be coal
accumulation and can
damage the conveyor
belt.
5. LIMIT SWITCH

A limit switch is a
switch operated by the
motion of a machine part
or presence of an object.
They are used for control
of a machine, as safety
interlocks, or to count
objects passing a point. 
6. EMERGENCY-STOP (E-STOP)

An Emergency
stop or e-stop, is
a safety mechanism used
to shut off a device in an
emergency situation in
which it cannot be shut
down in the usual
manner. 
 BELT DETAILS :

TYPES OF BELT : STEEL CHORD & FABRIC TYPES

BELT SPEED : STACKING – 1500 RPM (Coal)

1035 RPM (Iron)
RECLAIMING – 1500 RPM (Coal)
1035 RPM (Iron)
BELT CAPACITY : STACKING – 9750 tons per hour
RECLAIMING – 5000TPH (Iron)
3000TPH (Coal)
 STACKER AND RECLAIMER (Phase 2) :

BELT CAPACITY : STACKING : 9750tph (As per Rated)

RECLAIMING : 5000tph (iron)
: 3000tph(coal
BELT LENGTH : 51 meter

BUCKET RPM : 7 RPM (9 BUCKETS)

GANTRY LONG TRAVEL SPEED : 20M/MIN(OPERATION)

: 30M/MIN(NONOPERATION)
BELT WIDTH: 2200MM
BELT SPEED: 3.1m/sec(IRON)
:4.7m/sec(coal)
 SCRAPPERS & ITS FUNCTION :

TYPES : 1. Internal Scrapper

2. External Scrapper
3. Diagonal Scrapper
4. V Scrapper
5. Counter Weight Scrapper

FUNCTION : A Scrapper is used to clear the material coming in Belt

WHAT IF SCRAPPER IS ABSENT??

If there is no Scrapper installed on a Belt there will be coal
accumulation in the Conveyor Route. It will require additional Man
Power to clean the material.
 SCRAPPERS & ITS FUNCTION :

TYPES : 1. Internal Scrapper

2. External Scrapper
3. Diagonal Scrapper
4. V Scrapper
5. Counter Weight Scrapper

FUNCTION : A Scrapper is used to clear the material coming in Belt

WHAT IF SCRAPPER IS ABSENT??

If there is no Scrapper installed on a Belt there will be coal
accumulation in the Conveyor Route. It will require additional Man
Power to clean the material.
 SEQUENCE OF STARTING CONVEYOR PATH :

1. HOOTER HONKS
If the Hooter doesn't honks inform it to Control Room. There are chances people
working on the Route and will get informed and move to a Safe place.

2. HT (HIGH TENSION) MOTOR STARTS

3. HYDRAULIC MOTOR STARTS

Its work is to circulate the oil from fluid coupling to Radiator Fan.

4. RADIATOR FAN STARTS

Its work is to cool Hydraulic Oil.

5. FLUID COUPLING
A fluid coupling is a simple mechanical device that connects a prime mover,
typically a squirrel cage motor, to a driven machine.

6. GEAR BOX (REDUCTION)

It reduces the speed and is used for speed control.
Berth 1 / Phase 1 conveyor route specification:
From Berth1 to B plots and to JSW Energy
Coal TPH
S. N. Conveyor number Speed
Rated Design
1 R1A 4000TPH 4400TPH 4.25 m/s
2 R2A 4000TPH 4400TPH 4.25 m/s
3 R3A 4000TPH 4400TPH 4.25 m/s
4 R4A 4000TPH 4400TPH 4.25 m/s
5 RD-1 4000TPH 4400TPH 4.25 m/s
6 RD-2 4000TPH 4400TPH 4.25 m/s
7 RD-3 4000TPH 4400TPH 4.25 m/s
8 D-1 2000TPH 2400TPH 3.75 m/s
9 D-2 2000TPH 2400TPH 3.75 m/s
10 D-3 2000TPH 2400TPH 3.75 m/s
11 D-4 2000TPH 2400TPH 3.75 m/s
12 D-5 2000TPH 2400TPH 2.5 m/s
13 AFC-1 1000TPH 1200TPH 3 m/s
14 AFC-2 1000TPH 1200TPH 3 m/s

Make Boom length luff angle Slew Angle C TPH (S/R)

ZPMC 42 meter ±11.9° ±110° 4000/2000
FLS 42 meter +10.5° / -12.8° ±110° 4000/2000
Berth 3A & 6A / Phase 2 conveyor route specification:
From Berth3A to A plots and to Berth6A
Iron ore TPH Coal TPH
S. N. Conveyor number
Rated Design Speed Rated Design Speed
1 JR1A 9750TPH 11000TPH 4.7 m/s 6000TPH 6800TPH 3.2 m/s
2 JR2A 9750TPH 11000TPH 4.7 m/s 6000TPH 6800TPH 3.2 m/s
3 JR2B 9750TPH 11000TPH 4.7 m/s 6000TPH 6800TPH 3.2 m/s
4 JR3A 9750TPH 11000TPH 4.7 m/s 6000TPH 6800TPH 3.2 m/s
5 JR3B 9750TPH 11000TPH 4.7 m/s 6000TPH 6800TPH 3.2 m/s
6 JRD1A 9750TPH 11000TPH 4.7 m/s 6000TPH 6800TPH 3.2 m/s
7 JRD1B 9750TPH 11000TPH 4.7 m/s 6000TPH 6800TPH 3.2 m/s
8 JD2A 2500TPH 3000TPH 3.8 m/s 1500TPH 1800TPH 2.6 m/s
9 JD2B 2500TPH 3000TPH 3.8 m/s 1500TPH 1800TPH 2.6 m/s
10 JD3A 2500TPH 3000TPH 2.2 m/s 1500TPH 1800TPH 1.5 m/s
11 JD5A 2500TPH 3000TPH 2.2 m/s 1500TPH 1800TPH 1.5 m/s
12 JD5B 2500TPH 3000TPH 2.2 m/s 1500TPH 1800TPH 1.5 m/s
13 JD5C 2500TPH 3000TPH 2.2 m/s 1500TPH 1800TPH 1.5 m/s
14 JD5C 2500TPH 3000TPH 2.2 m/s 1500TPH 1800TPH 1.5 m/s
From Berth1 to A plots
15 JR2C 4000TPH 4400TPH 4.2 m/s 4000TPH 4400TPH 3.2 m/s

Stacker cum Reclaimers in A plots

Qty Make Boom length luff angle Slew Angle F TPH (S/R) C TPH (S/R)
2 Sandvik 48 meter + 7.5°/ -12.0° ±105° 9750/5000 6000/3000
 COAL YARD STOCK CAPACITY AT JSW JAIGARH PORT :

Plot ( Dimensions )
Plot No Type Cargo ( mostly ) Bonded Area
L B Sq Mtrs Sq Ft

B1 OSY Coal/met coke/iron ore/other bulk Yes 385 50 19250 207205

B2 OSY Coal/met coke/iron ore/other bulk Yes 200 74 14800 159306
B2 OSY Coal/met coke/other bulk No 215 74 15910 171254
B3 OSY Coal/ Iron ore/other bulk No 415 35 14525 156346
B4 Covered shed Coal of JSWEL No 385 45 17325 186485
B5 Covered shed Coal of JSWEL No 385 45 17325 186485
A1 OSY Coal /Iron Ore of JSWSL No 705 51 35955 387016
A2 OSY Coal /Iron Ore of JSWSL No 705 51 35955 387016
A3* OSY Bulk/break bulk cargo No 250 140 35000 376737
Total Capacity 206045 2217848
SUL (SHIP UNLOADER) 1 & 2@ BERTH1
Rated lifting Capacity 52 t
Rated Capacity 2000 t/h
Outreach/ Backreach 33/14.5 m
Above rail 25 m
Hoist Below rail 19 m
Total 44 m
Hoisting 160 m/min
Lowering 180 m/min
Speed Main Trolley 220 m/min
Gantry 40 m/min
Boom Hoist 5 min
Power 6.6kv,3 phase, 50 Hz
Make ZPMC
No. of machines 2
Coal Grab - SMAG 40 CBM 4 nos
Iron ore Grab - Arul Linu 15 CBM 2 nos
SUL (SHIP UNLOADER) 3 & 4 @ BERTH 3A
Iron Ore Coal
Rated lifting Capacity 73 t 52 t
Rated Capacity 3250 t/h 2000 t/h
Outreach/ Backreach 52/25 m
Above rail 28 m
Hoist Below rail 30 m
Total 58 m
Hoisting 160 m/min
Lowering 210 m/min
Speed Main Trolley 250 m/min
Gantry 20 m/min
Boom Hoist 7 min
Power 6.6kv,3 phase, 50 Hz
Make DHHI
No. of machines 2
Coal Grab - SMAG 40 CBM 2 nos
Iron ore Grab - SMAG 24-17 CBM 2 nos
Spreader - RAM 20-40 ft, SWL:41 ton 1 nos
Rotator - DHHI 40 ton 1 nos
Coil Lifter - DHHI 32 ton 1 nos
SHIP / BARGE LOADER @ BERTH 6A

Rated Capacity - Iron ore 2500 t/h

Rated Capacity - Coal 1500 t/h
Conveyor extended length 42.2 m
Conveyor retracted length 26.53 m
Luffi ng angle 10-18 Deg.
Slew angle 270 Deg.
Slew speed 5.25 m/min
Belt width 1.4 m
Belt Specs EP630 6/2mm
Make TELESTACK
No. of machines 2
Thank You
&
All the best …..