COAL FEEDER

Coal Feeder
MEASURING THE MASS OR FLOW RATE OF MATERIAL TRAVELLING
OVER A CONVEYOR BELT OF ANY LENGTH.

VOLUMETRIC CONCEPT :  FLOW RATE

GRAVIMETRIC CONCEPT : MASS RATE

TYPES OF FEEDERS :
VOLUMETRIC FEEDER : 
THE RATE OF COAL FLOW THROUGH THE FEEDER IS DERIVED AS BY
R=QXBXN
R - RATE OF COAL FLOW IN KG/S
Q - VOL. OF COAL DELIVERED BY THE FEEDER PER ROTATION IN
M3/ROTATION
B - BULK DENSITY OF COAL IN M3/KG
N - SPEED OF FEEDER ROTATION PER SECOND
Q & B - MAKING THESE TWO CONTANT
N - ADJUSTING THE SPEED OR VARYING THE SPEED WE CAN
ABLE TO MAINTAIN THE REQUIRED COAL FLOW IN IT.

GRAVIMETRIC FEEDER:
THE RATE OF COAL FLOW IS OBTAINED BY
R=MXN
R - RATE OF COAL FLOW IN KG/S
M - MASS OF COAL ON UNIT LENGTH OF FEEDER BELT IN KG/M
N - SPEED OF FEEDER BELT IN M/S
WORKING DIAGRAM
Coal Feeder Basic
 A BELT BETWEEN TWO FIXED POINTS (SPAN) PRECISELY
LOCATED IN THE FEEDER BODY.
 A ROLLER, LOCATED MIDWAY TO THE SPAN AND SUPPORTED
AT EACH END BY PRECISION LOAD CELLS, SUPPORTS HALF THE
WEIGHT ON THE SPAN.
 THE LOAD CELLS GENERATE AN ELECTRICAL SIGNAL DIRECTLY
PROPORTIONAL TO THE WEIGHT SUPPORTED.
 BELT SPEED IS DETERMINED BY SAMPLING THE OUTPUT OF A
ENCODER ATTACHED TO THE MOTOR SHAFT.
 THE MICROPROCESSOR MULTIPLIES THE SPEED AND WEIGHT
SIGNAL FOR THE FEEDER RATE OF FUEL OUTPUT.
 THE MICROPROCESSOR MATCHES THE FEEDER OUTPUT TO
THE DEMANDED OUTPUT BY ADJUSTING THE FEEDER MOTOR
SPEED
 Feeder Structure

Main Drive

Speed Signal

Flow Rate Weighing Indicator PID O/P VFD DRIVE

Command
from DCS
Flow = Weight * Speed
Current Flow Rate
Value to DCS
COAL FEEDER CONSTRUCTION
 LOAD CELL BASIC
A Load Cell is a Transducer that is used to Create an Electrical Signal Whose
magnitude is Directly Proportional to The Force being measured. The
various Load Cell Types include Hydraulic, Pneumatic, and Strain Gauge.

There are several common shapes of load cells:

A. Shear beam: a straight block of material fixed on one end and loaded on
the other.
B. Double-ended shear beam: a straight block of material fixed at both ends
and loaded in the center.
C. Compression load cell: a block of material designed to be loaded at one
point or area in compression.
D. S-type load cell: a s-shaped block of material that can be used in both
compression and tension (load links and tension load cells are designed for
tension only).
E. Rope clamps: an assembly attached to a rope and measures its tension.
rope clamps are popular in hoist, crane and elevator applications due to the
ease of their installation; they have to be designed for a large range of
loads, including dynamic peak loads, so their output for the rated load
tends to be lower than of the other types.
F. Loadpin: used for sensing loads on e.g. axles.
Excitation and rated output:
the bridge is excited with stabilized voltage (usually 10v, but can be
20v, 5v, or less for battery powered instrumentation).
the cell output is rated in millivolts per volt (mv/v) of the difference
voltage at full rated mechanical load.
Example: so a 1.998mv/v load cell will provide 19.98 millivolt signal at
full load when excited with 10 volts.

 Four-wire Configuration:
The Excitation : labelled E+ and E−, or Ex+ and Ex−
The Signal : Labelled S+ And S−
 SPEED ENCODER PRINCIPLE

An optical encoder is an electromechanical device which has an

electrical output in digital form proportional to the angular position of
the input shaft.
Optical encoders enable an angular displacement to be converted
directly into a digital form. 
it has a shaft mechanically coupled to an input driver which rotates a
disc rigidly fixed to it. a succession of opaque and clear segments are
marked on the surface of the disc.
light from infrared emitting diodes reaches the infrared receivers
through the transparent slits of the rotating disc. an analogue signal is
created. 
then electronically, the signal is amplified and converted into
digital form. this signal is then transmitted to the data processor.
the sensing mechanism in an incremental optical rotary encoder
consists primarily of a light source, code wheel, and optical detector.
as the code wheel turns, a ring of alternating opaque and
transparent regions shutters the light between the source and detector,
creating a series of pulses.
SPEED ENCODER INTERNAL DIAGRAM
 CALIBRATION METHOED

1.Zero Calibration:
This is the primary method for performing a zero calibration. run the
belt empty and press the auto zero calibration button on the keypad.
you can cancel the calibration at any time by pressing the exit zero Cal
buttons. the recommended repeating this process as required range.

2.Span Calibration:
This is the primary method for performing a Span calibration. run the
belt with test weight and press the auto span calibration button on the
keypad. you can cancel the calibration at any time by pressing the exit
Cal buttons. the recommended repeating this process as required
range.
 Calibration Method
1.WEIGHT CALIBRATION
ZERO CALIBRATION:-
ZERO CALIBRATION TO BE CARRIED WHILE BELT RUNNING WITH EMPTY
BELT
THIS HAS TO BE REPEATED UNTIL ERROR PERCENTAGE IS LESS THAN +/-
0.25%
Span Calibration:-
Span Calibration to be carried by placing test weight of 25.2kg
THIS HAS TO BE REPEATED UNTIL ERROR PERCENTAGE IS LESS THAN
+/- 0.5%.
2. Speed Calibration.
Have to measure the time taken for ten full Belt Revolution during belt
running with maximum speed
Same has to be feed in the Controller and also the total belt length.
3. Demarcate Calibration.
Analog Board calibration from DCS Command (0% -4 mA DC & 100% -
20mA DC)
SPAN CALIBRATION
MENU

CALIBRATION

SPAN CALIBRATION

AUTO CAL

BGIN CAL

SPAN CALIBRATION STARTED (133 SEC)

SPAN CALIBRATION COMPLETED ( ERROR DISPLAYED IN %)

ENTR CAL
ZERO CALIBRATION
MENU

CALIBRATION

ZERO CALIBRATION

AUTO ZERO

BGIN ZERO

ZERO CALIBRATION STARTED (133 SEC)

ZERO CALIBRATION COMPLETED ( ERROR DISPLAYED IN %)

ENTR ZERO
SAIMO CONTROLLER 6105
Manual Error calculation
 Manual Error % Calculation=
(Measured value-Calculated value) / Calculated value
FLOW TOTALIZATION :-
THE TOTAL IS ACCUMULATED BY MULTIPLYING MASS PER UNIT
LENGTH BY INCREMENTAL LENGTH AND TOTALIZING THE RESULT
IN ENGINEERING UNITS

BELT SPEED CALCULATION:

SPEED = TOTAL BELT LENGTH FOR 10 REVOLUTION / TIME TAKEN

FOR 10 REVOLUTION (M/S)

= ( 10 X 6.37 ) / 131 (M/S)

SPEED = 0.486 M/S

 MEASURING FUNCTION
INSTANTANEOUS FLOW RATE CALCULATION :-
THE SIGNAL DELIVERED BY THE LOAD CELL(S), WHICH REPRESENTS THE
WEIGHT PER UNIT LENGTH OF THE BELT(KG/M), IS MULTIPLIED BY THE
SIGNAL DELIVERED BY THE SPEED SENSOR WHICH REPRESENTS THE BELT
SPEED (M/S). THE RESULT OF THIS OPERATION IS THE INSTANTANEOUS
FLOW RATE (KG/M X M/S=KG/S) WHICH IS THEN MULTIPLIED BY SUITABLE
CONSTANT TO OBTAIN THE VALUE I N THE REQUIRED ENGINEERING UNITS
(KG/H OR TON/H, ETC.).

CALIBRATION CONSTANT = (STATIC WEIGHTS KG/M)/1000 * 10 BELT

REVOLUTION * TOTAL BELT LENGTH M.
= ( [25.2/0.7] / 1 000)* 10* 6.37
= 2.293 T.
FLOW RATE (T/HR) = KG/M* M/S* 3600/1000 = (25.2/0.7)*(10*6.37/131)*3.6
= 36*0.486*3.6
= 61.948 T/H
WIRING DIAGRAM
 COAL FEEDER FIRST OUT SIGNAL

1.SEQ Step
2.Mill Emergency Trip
3.Mill Stopped
4.Outlet Gate Closed.
5.Coal Blockage
6.MFT
7.Temp High (65˚C ) Trip
8. Classifier motor stop
PROTECTION SIGNAL
BELT SWAY SWITCH ALARM :
A PROTECTIVE SWITCH FOR DETECTING THE BELT
DEVIATION OF BELT CONVEYORS.
CLEARING CHAIN BROKEN ALARM :
A SWITCH FOR DETECTING THE CHAIN RUNNING FEEDBACK
AND SIGNAL SEND TO ELECTRICAL TIMER UNIT.
NO COAL ON BELT ALARM :
A SIGNAL TAKEN FROM CONTROLLER OUTPUT ( LESS THAN 5
T/H).
COAL BLOCKAGE SENSOR ALARM :
A PROTECTIVE SWITCH FOR DETECTING THE COAL
BLOCKAGE OF FEEDER OUTLET CHUTE.
HIGH TEMPERATURE ALARM :
A PROTECTIVE TEMPERATURE SENSOR FOR DETECTIVE THE
SAIMO FEEDER SPEC:-
FEEDER CAPACITY: 100 T/H
CONTROLLER: SAIMO, 6105, 230VAC.
MAX. BELT SPEED: 0.49 M/S
BELT LENGTH: 6.37 M
TEST WEIGHT: 25.2 K92G
LOADCELL(2): SAIMO , 2MV/V, 100 KG.
COC: PROXIMITY SENSOR,230VAC, AUTO RUN: 5MIN ,AUTO
STOP: 10MIN. INDUCTIVE PRINCIPLE.2 WIRE
COAL BLOCK: PROXIMITY SENSOR, 24VDC, INDUCTIVE
PRINCIPLE.2 WIRE
INLET/OUTLET GATE: LIMITORQUE MOV.
TEMP SENSOR: HEADMOUNT RTD, 4-20MADC,0-100’C.PT-
100,3WIRE.
BELT SWAY SWITCH(2): NO/NC CONTACT, 230VAC,
BEFORE FEEDER START FOLLOWING STEP CHECK:-
(I). THE BELT CONDITIONS.
(II). LOAD CELL HEALTHINESS.
(III). SPEED SENSOR HEALTHINESS.
(IV). INLET, OUTLET & SEAL AIR GATE CLOSE
CONDITION.
(V). NO COAL ON BELT.

START THE FEEDER AT MAXIMUM SPEED (50HZ):-

(I). BELT ALIGNMENT.
(II). SPEED OUTPUT (FREQUENCY 170 TO 175 HZ).
Thank You