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BWSR Safety Features PDF
BWSR Safety Features PDF
Abstract: This paper is a study with the actual situation of thermal power plant for increasing the safety measure by which the failure
rate of the components of stacker cum reclaimer in the thermal power plant, used for coal handling can be reduced. This study is made
to reduce the chances of failure in the components of a stacker cum reclaimer by using several safety measures and installing various
safety devices.
Keywords: Thermal power plant, coal handling system, stacker cum reclaimer, safety devices.
The bucket wheel drive consisting of motor, (fig 1) fluid The intermediate conveyor shall travel on the same rails as
coupling, thrustor brake and gear box, mounted on a drive those of machine. After receiving from tripper, discharge
pulley material on the boom conveyor by a chute. The 1. In the bench-type method the reclaimer starts at one end
intermediate conveyor drive comprising motor, fluid on the top bench or layer and reclaims that bench for the
coupling, brake and gear box, mounted on a drive frame, is full length of the pile. On reaching the end of the pile the
supported by a bracket. The hollow output shaft of the gear machine returns to the other end, the boom is lowered
box is clamped on the drive pulley shaft through a key-less and reclaiming commences on the next lower bench.
shrink disc element. 2. The modular method is accomplished by starting at the
top of the pile at one end and taking a series of cuts one
3.7 Tripper Conveyor bench deep end returning to the end of the pile, lowering
the boom and taking the same number of cuts on the
The tripper raises the belt of the yard conveyor and supports lower bench. This process is repeated up to the lowest
it over a concave curve and discharge through guide chute bench thereby completing one reclaim module.
onto intermediate conveyor. After passing over the discharge
pulley, the belt is guided back to the yard level over bend 5. BELT
pulleys.
Conveyor belt is the most expensive but durable part of a
4. Principles of Operation conveyor. During working, the belt is subjected to variable
loads, which makes the belt in a complex state of stress.
The rail mounted stacker cum reclaimer is suitable for There are several types of typical damage forms such as
serving two parallel stockpiles, one on either side of the working surface and edges are worn, striking, tearing and
track rails. The machine is designed to operate with a yard peeling caused by the impact of big ore particles, belt core
conveyor for stacking and discharging at the same end suffers from fatigue due to alternating bending via the idlers.
during reclaiming i.e. a reversible one. The following modes The various safety features for belt are discussed:
of operation are possible:
5.1 Iron Grid
4.1 Stacking
The feeder- hopper must have an iron grid at its mouth so
The material on the forward moving yard conveyor is raised that during transfer of coal to the belt through feeder-hopper
by the tripper and discharged through a discharge guide does not impact the belt which results in wear of the belt.
chute onto an intermediate inclined conveyor which lift the
material and ultimately discharges on to the boom conveyor 5.2 Impact Idlers
by a chute. The boom conveyor carries the material up to its
end and allows it to fall from a stockpile. The stacking The belt conveyor at the point of loading must be
operation as shown in fig 2 starts at one end of the stockpile empowered with impact idlers (fig 3) so that they reduces
with the boom kept low. The travel motion operates the impact wear of the belt due to force produced on the belt
simultaneously and at the other end of the stockpile, the at the time of loading.
motor reverse. After a number of such cycles the boom is
luffed up and the cycles repeated.
4.2 Reclaiming
The machine reclaims the material from the stockpile in Figure 1: Impact idlers
layers by the rotating bucket wheel swing across the pile.
The material picked up by the bucket is retained and guided 5.3 Interlocking Protection
by the ring chute as the buckets move up. When the bucket
is about 45 deg above horizontal, the material starts The conveyor must be installed with programmed
discharging it to the bucket wheel chute, which guides it to interlocking protection so that damage to the belt can be
the boom conveyor. On reaching the end of the conveyor, reduced. It provide sequence the of stopping of the belt
the material passes through the central chute and portal conveyor, i.e., the first conveyor is stopped first, then the
chute on to the yard conveyor belt, supported on the impact second one is stopped and so on. This is done to avoid
table. The reclamation of the entire stockpile can be carried damage of belt due to loaded start- up and from getting extra
out either by bench-type and modular methods. loaded at the time of uneven start- up.
The process of direct digging by the bucket wheel excavator It is provided to prevent slewing over yard conveyor unless
is realized in a combination of continual rotation of the boom is sufficiently raised and also prevent excessive
bucket wheel in the vertical, and arrow movement in the lowering of boom over yard conveyor.
horizontal plane. As a result of the drive performances,
characteristics of the soil, and inequality of digging 9. Long Travel Mechanism
resistances on the buckets, the bucket wheel excavator is
subject to a number of external loads. As a consequence, the The various safety features are discussed below:
vital parts of the excavator structure and driving mechanisms
are exposed to variable load which, when it exceeds critical 9.1 Travel Limit Switch
values, causes damage in the system. The safety features are:
It is operated by strikers placed along the track for stopping
6.1 Fluid coupling travel at either end of pile and permits reversal.
Bucket wheel drive is provided with a fluid (fig 4) coupling 9.2 Automatic Rail Clamp
for reduced load on motor, smooth acceleration, shock-free
operation and peak load limitation with protection against It is provided to drifting of the machine in storm condition.
overloading. Clamps are released by hydraulic cylinders which actuate
limit switches to permit travel motion.
6.2 Electro Hydraulic Thrustor Brake
10. Conclusion
It is provided for smooth stopping of the bucket and holding
it in the position during maintenance. This study is made for reducing the failure of different parts
of stacker cum reclaimer by using various safety features
6.3 Electronic speed switch and these safety equipments maintain the stacker cum
reclaimer in all operating conditions and hence helpful in
It is provided on the fluid coupling to monitor output speed reducing the failure.
vis--vis motor speed
The bucket wheel motor is tripped in the event of its speed
11. Acknowledgement
dropping below 95% of its rated speed due to over loading.
I express my gratitude to the management of Parichha
7. Boom Conveyor thermal power Jhansi and to the faculty of MITS for their
valuable support and help in my work.
The various safety features for boom conveyor are:
References
7.1 Zero Speed Switch
[1] Lihua Zhao (2001),The Adjustment Method of
It is provided at the non-drive pulley to monitor the pulley Conveyor Belt Deviation [J], Colliery Machine, No.5.
and thereby the belt speed and trip the conveyor motor in the [2] Lihua Zhao and Yin Lin (2011),Operation and
event of belt speed dropping below a preset value. Maintenance of Coal Handling System in Thermal Power
Plant [J], Colliery Machine, No. 2.
7.2 Belt Sway Switch [3] Zoran Marinkovic and Goran Petrovic(2004),
Processing the lifetime of bucket wheel excavator parts
It is mounted on the boom on either side of the conveyor, to in strip mine technologies.
trip thee conveyor in the event of belt running out of line and [4] Jevti V., Jovanovi M., Marinkovi Z., Janoevi D.
pressing against the rollers levers of the switches. "Supervision of Bucket Wheel Excavator Operation for
Condition Diagnostics and Maintenance Purposes.
7.3 Pull Cord Switch [5] Parichha Thermal Power Plant, Jhansi.