Вы находитесь на странице: 1из 80

BANJARSARI MINE-MOUTH COAL-

FIRED STEAM POWER PLANT 2 X


Project Name
135 MW LAHAT SOUTH

SUMATERA, INDONESIA

File Number

Contract No.

Coal Handling Maintenance Manual

China National Electric Engineering Technology Co. Ltd.

Version Editor Date Preliminary Date Auditor Date Translator Date Approver Date

auditor
1 version
st

2nd version

3rd version

4th version

Final submission version Version


approver

PREFACE

The training textbook is specially compiled in accordance to the training need of Indonesia

Banjarsari 2135MW unit maintenance personnel; meanwhile ensure the safe, economical

and stable operation of the unit.


Based on the ministerial manual, referred to power standard and related standard of similar

power plant, combined the installment use instruction of Banjarsari 2135MW unit fuel

related equipments, the training textbook is compiled. The content of textbook should only

be used for training.


Since the material of site equipment is incomplete, there may be mistakes or omission in the

textbook, it will be improved and modified if the material is intact. Sincerely welcome the

comment and correction from you.


Contents

1 Maintenance of Coal Handling System...........................................................................1


1.1 Overview......................................................................................................................... 1
1.2 Maintenance of Bucket-wheel Stacker And Reclaimer....................................................3
1.3 Belt Conveyor Maintenance..........................................................................................15
1.4 Maintenance of Screening and Crushing Device...........................................................25
1.5 Vibrating Feeder........................................................................................................... 32
1.6 Plough Tripper............................................................................................................... 34
1.7 Electric Magnetic Iron Remover....................................................................................36
1.8 As-fired Coal Belt Sampling Device..............................................................................40
1.9 Dust Removing Equipments Maintenance....................................................................45
2 General Equipment Maintenance..................................................................................49
2.1 General Maintenance Process......................................................................................49
2.2 Maintenance of Rolling Bearing....................................................................................50
2.3 Gearbox Maintenance...................................................................................................55
3 Hoisting Equipments.....................................................................................................63
3.1 Definition of Hoisting Equipments.................................................................................63
3.2 Equipment Specifications..............................................................................................63
3.3 Maintenance Method And Quality Standard..................................................................66
4 Fuel Equipment Specification........................................................................................70
4.1 Gantry Stacker Reclaimer.............................................................................................70
4.2 Belt Conveyor System...................................................................................................74
4.3 Fine Crusher............................................................................................................... 124
4.4 High Amplitude Vibrating Screen.................................................................................127
4.5 Vibrating Coal Feeder.................................................................................................128
4.6 Electric Magnetic Iron Remover..................................................................................129
4.7 As-Fired Coal Belt Sampling Device...........................................................................130
4.8 Impulse Dust Remover................................................................................................133
1 Maintenance of Coal Handling System

1.1 Overview
There is one coal yard in the project and it is equipped with one gantry bucket

wheel stacker and reclaimer; its span is 50 meters and the stacking output is

500t/h, reclaiming output is 250t/h; there is a distributing device on the equipment;

the coal pile height is 10.5 meters; the capacity of coal yard is 33.75 thousand tons;

there are two underground coal hopper in coal yard and one vibration feeder is

equipped in each underground coal hopper to supply coal for double-way belt

conveyor; the output of vibrating coal feeder is 250t/h. The boiler of the project is

CFB boiler; the size requirement of the coal is between 1.885mm and 10mm; it is

equipped with primary screening device and primary coal crushing equipment;

screening device adopts vibrating sieve whose rated output is 250t/h and the

screening efficiency should not be less than 85%; the coal that fails to get through

the primary screening device will enter into crusher through coal chute; the size of

coal that get through the primary screening device is within 10mm which will be

delivered on C-3AB belt conveyor. The crushing device adopts hammer fine

crusher whose rated output is 250t/h and the feeding size is not larger than 50mm

and the product size should be within 10mm.


Coal supplying system adopts the belt conveyor whose width is 800mm, speed is

1.6m/s, output is 250t/h; it is double-way arrangement.


The system has two stage iron removers to separate the magnetic metal impurities

from coal; the two stage iron removers are installed in the head of external plant

1AB and 2AB belt conveyor respectively; the iron removers are belt iron remover.
The metal detector is set in the tail part of internal plant C-3AB belt conveyor to

detect the magnetic metal impurities which fails to be removed by the iron remover.
As fired coal sampler is set in the middle part of in-plant 3AB belt conveyor to

monitor the coal quality of as received coal and as fired coal. The sampling device

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
1
is equipped with crusher divider and residual coal return device.
There is electrical belt scale, cycle chain weights calibration device in 3AB belt

conveyor.
Table 1-1 Coal property analysis data

Designed Coal Verified Coal


Item Symbols Unit
Type Type
Carbon basis as
Car % 48.05 43.23
received
Hydrogen basis as
Har % 3.51 2.79
received
Oxygen basis as
Oar % 12.94 9.45
received
Nitrogen basis as
Nar % 0.63 0.70
received
Sulphur basis as
Sar % 0.67 2.35
received
Ash basis as received Aar % 5.59 9.38

Full water content Mar % 28.61 32.10

Air drying basis water


Mad % 16.04 9.30
content
Volatile content basis as
Var % 33.45 30.22
received
High heating value as
Qgr.ar Kcal/kg 4632 4153
received basis
Low heating value as
Qnet.ar Kcal/kg 4271 3809
received basis
Hartz grindability index HGI 54 41
1.2 Maintenance of Bucket-wheel Stacker And Reclaimer
1.2.1 Overview
MDQ250/500.50 mode gantry bucket-wheel stacker and reclaimer is professional

material stacking and reclaiming equipment which reclaim the material and delivery

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
2
it to belt conveyor and stacking the coal on belt conveyor to material yard. It can be

applied in large thermal power plants, industrial and mining enterprise and port bulk

material storage yard. The main features include high efficiency, safety and

reliability.
1.2.2 Equipment technical parameter
Table 1-2 Bucket Wheel Stacker Reclaimer

Type Gantry Bucket Wheel Stacker Reclaimer


Number One set
Material stacking: 500t/h
Rated Output:
Material reclaiming: 250t/h
On-rail: 9.5m
Stacking Height:
Under-rail: 1m
Crane Gauge: 50m
Railing Car Gauge: 5m
Crane Traveling Speed: Working speed7.5m/min
Regulating speed25m/min
Maximum Working Air
250N/m2
Pressure
Maximum Non-working
800N/m2
Air Pressure
Recommended Steel
50kg/m
Rail
Railing Car Type: Pass-type
Power Supplying
Cable roller drum
Type
Power Supplying
6KVCable rolling drum
Voltage
Power Supplying
50Hz
Frequency
Control Mode PLC semi-automatic and manual mode
1.2.3 Working principle and mechanism overview
a) Stacking: Materials from ground system belt conveyor is delivered to the

stacking coal chute through tail car and drop on the stacking and reclaiming belt

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
3
conveyor; through the coal chute in the middle of flexible beam, the coal drop

on the lower movable belt conveyor. When the movable belt conveyor operates

in stacking direction, it stacks the materials in flexible leg side yard; when it

operates in reverse direction, it stacks the materials in rigid leg side yard.

Meanwhile, since when it operates in reverse direction it can separate with

middle hopper completely to make the material enter into material yard directly

to fill up the depression and make full use of the material yard. When it stacks at

certain height, it can satisfy different stockpiling requirements with the

cooperation of walking beam and traveling mechanism.


b) Reclaiming: the idler wheel mechanism on flexible beam digs the material;

make the material fall into stacking and reclaiming belt conveyor on beam

through bucket wheel feeding hopper; fall on tripper car belt conveyor through

tail car coal hopper; the material is delivered to coal bunker through the reverse

operation of system belt conveyor. It can satisfy different reclaiming

requirements in reclaiming depth and feeding through the up and down

movement of flexible beam and the cooperation of traveling mechanism.


c) MDQ250/500 50 mode gantry bucket-wheel stacker and reclaimer is

composed of traveling mechanism, turn-back type single tail car, metal

structure, anchor device and clamping rail device, counterweight mechanism at

the top of walking beam, hoisting mechanism at the bottom of walking beam,

rolling wheel mechanism, cable handler of rolling wheel mechanism, cable

handler of mobile belt conveyor, reclaiming belt conveyor, stacking and

reclaiming belt conveyor, mobile belt conveyor, tripper car reclaiming coal chute,

tripper car stacking and reclaiming coal chute, tripper car stacking and

reclaiming change-over mechanism, detection device, ladder railings, high

voltage electrical room, low voltage electrical room, driver's chamber, single

beam crane, electrical system, etc.

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
4
1.2.4 Bucket wheel stacker reclaimer common faults and treatment
Figure 1-1 Bucket wheel stacker reclaimer

Table 1-3 Bucket wheel stacker reclaimer common faults and treatment

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
5
Causes and Possible
Components Faults Treatment Measures
Consequence
1. Abrasion of pulley 1.Installation is 1. Replace when the
groove is not incorrect, the uneven abrasion is
uniform lubrication of steel beyond 3mm.
2. Pulley does not wire rope is not well 2. Note the lubrication
rotate which worsen the situation, whether the
3. Pulley spindle is abrasion of steel wire mandrel and bearing
abraded and pulley is good.
4.Wheel edge is 2. Abrasion of spindle 3. Replace the mandrel.
broken, pulley and wire rope 4. Replace a new wheel,
1.Pulley
incline and become intensify which will adjust fastening
loose increase the positioning plate and
resistance. make the shaft
3. Lubrication is bad, fastened.
spindle is damaged,
and the resistance is
enlarged.
4. Locating plate on
shaft is loose.
Twist together and The steel wire rope will Find out the twisting point;
abrasion be broken the steel wire roper with
obvious deformation and
serious corrosion cannot
be used. The steel wire
2.Steel wire ropes whose actual
rope diameter is 7% or more
smaller than nominal
diameter cannot be used;
Total number of broken
wires exceed 10% in one
lay length cannot be used.
Brake torque of rail 1. The various flexible 1. Repair various hinge
clamper is small and hinge joint part has joints and add
cannot stop the stuck phenomenon or lubrication oil.
operation. poor lubrication; the 2. Replace new bearing
3.Rail
installation is not bush.
clamping
correct.
device
2. Brake bearing bush is
abraded, braking
torque reduces
obviously.
Bearing noise is large 1. Lack of lubrication oil 1. Check the lubrication oil
during work or bad installation amount in bearings and
2.Dirty oil exist in ensure it is proper.
bearings 2. After cleaning the
4.Roller
3. Poor assembly cause bearing, inject new
bearing
the stuck of bearing lubrication oil.
Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
4.Bearing
6 parts is 3. Check bearing assembly
damaged quality
4. Replace the bearing
1.belt offset 1.1 The installation of 1.1. If it runs to the
1.2.5 Daily inspection & maintenance
a) Check the abrasion condition of steel wire rope
b) Check gasket abrasion condition of various working mechanism brakes, and

check the abrasion condition of braking wheel


c) Check the tightness of fastening bolt of various parts, and check if there is

looseness in various supports.


d) Check the insulation condition of resistor, control cabinet, motor and electrical

element.
e) Check working condition of various contactor
f) Check the activation of various limit switch and safety device.
g) Check the activation condition of various electrical meters
h) Check the lube oil in gear box, clean or replace it according to the condition.
i) Check if the trolley rail and crane rail meets the accuracy requirement; check

the abrasion condition of trolley and movable beam hoisting&lowering guide

wheel.
j) Inspect and add lubricant oil for various lubricant points
k) Check if there is deflection operation condition during the lifting and lowering of

movable beam, and adjust it once the problem occurs.


l) Check the operation condition of various belt conveyors and handle belt offset

and sliding immediately to ensure the normal operation.


1.2.6 Annual inspection and maintenance
a) Periodically check the abrasion condition of gearbox and coupling; clean the

gearbox and replace the oil.


b) Check the various limit switch and the electric wiring.
c) Check the rusting condition of structure components, and paint oil every 3-5

years.
d) Check the abrasion condition of open-type gear and rolling bearing.
e) Periodically check and lubricate the lubricating points accordingly.
f) Periodically check the limit condition of balancing wheel, and adjust the

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
7
defection if it is serious; stop using the pulley rope groove when its unevenness

exceeds 3mm; replace the shaft immediately when the pulley center shaft is

worn or jammed; replace the roller drum timely if there is cracking.


1.2.7 Gantry and bucket lubrication
Table 1-4 Gantry and bucket wheel lubrication

Lubrication Lubrication
Lubrication Points Lubrication Cycle Remark
Material Method
Gear box Mechanical oil First three months Oil basin
Motor-driven roller No.N46 Later six months lubrication
Gear coupling Brush
Rolling, sliding bearing Oil cup Weekly
Open-type gear Lithium base First three months inspection
Guide wheel group
grease No.1 Later six months
Pulley, chain wheel and

chain Brush
Steel rope Monthly
Every three
Pin hinge joint
months
Outsourcing standard Lubrication and maintenance according to the

components instruction manual


1.3 Belt Conveyor Maintenance
1.3.1 Coal conveying system overview
The main components of belt conveyor include conveying belt, driving device,

roller, idler, tension device, frame, hopper, scattering rubber, cleaner and unloaded,

etc
a) Conveying belt
Conveying belt is the main part of pulling and bearing the material. DT series

adopt common type rubber or other material conveying belt. The cotton canvas

belt, polyester canvas belt, nylon canvas belt and steel rope core conveying

belt could be chosen based on different tensioning force.


The connection of conveying belt usually adopt sulfur connection; the

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
8
connection mode and joint length should be provided by conveying belt

manufacture
b) Driving device
The driving device is formed by fixing the driving unit which consists of motor,

gearbox, high speed rotor coupling or hydraulic coupler, brake, low speed rotor

coupling and hold stop onto the driving frame which is fixed on the ground

base at the same time


c) Gear box
Adopt DBY(two stages), DCY(three stages) cone and cylinder hard teeth face

gear reducer with the features of large bearing capacity, high efficiency, light

weight, long lifetime and etc. The input shaft and output shaft are in vertical

arrangement which could reduce the occupied area of driving plant. The

working ambient temperature of reducer is between -40 and +45. The

gearbox adopts oil tank splashing lubrication, natural cooling; adopt cycle oil

lubrication or add cooling device when the thermal power is imbalance.


d) Brake
The brake for fuel equipment usually adopts hydraulic push rod. It has the

advantages of high working frequency, stable brake, adjustable brake torque,

easy replacement of friction pad, long service life, etc.


e) Backstop
IIN1 type roller backstop is adopted; it is used for belt which is conveying the

coal in inclined upward so as to prevent the retrograde motion of belt during

belt on-load shutdown


During the installment, it could be installed on the other end output shaft of

gearbox low speed shaft or driving roller driving roller(when the power is larger,

it should be installed on driving roller shaft as possible)


f) Roller
g) Idler

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
9
The idler is used to support the belt and the coal loaded on. At the same time,

it will ensure the stable operation of the belt


h) Tensioning device
Tensioning device is used to avoid the slippage between belt and driving roller

and limit the sag degree between belt and idler groups so as to make sure the

normal operation of belt


The tension device consists of screw type, vertical counter weighted type,

counter weighted car-type and fixed winch type. User can choose either of the

above types according to the tension force, tension stroke and the position of

tension device.
i) Frame
The frame is the main framework of belt conveyor. There are four roller frame

(head, tail frame), middle frame and support leg based on typical

arrangement . Head and tail frame adopt triangle structure which is welded by

groove steel and H type steel


j) Head hopper
It is the auxiliary device of belt conveyor which is used for material delivery and

storage.
k) Guide chute
The material dropping down from hopper will be collected to the center part of

the conveying belt through guide chute. The guide chute is usually composed

of one front section, several middle sections and rear section. The length of the

guide chute is confirmed by the designer based on the demand.


l) Cleaner
The cleaner is used to erase the coal stuck in the belt. The scrapper of this

series has two kinds: head scrapper and no-load section scrapper.
m) Coal plough
It is used in any place of belt conveyor middle part that needs to unload the

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
10
coal. The system has double side type of groove angle variable electrical coal

plough.
1.3.2 Maintenance content
1.3.2.1 Main maintenance content during minor repair
a) Conveying belt wear loss inspection: damage repair.
b) Fill or replace the lube oil for gearbox (according to instruction manual).
c) Wear loss inspection of brake shoe and braking wheel bear; replace it if the

wear loss is serious.


d) Roller rubber surface wear loss inspection and repair the worn part.
e) Check if there is cracking in the roller welding joints, and repair it if there is.
f) Replacement of roller bearing lubrication oil.
g) Replace the sweeper scraper and idler rubber ring which are seriously

abraded.
h) Check the tensioning stroke and safety protection device, and replace the

faulted one.
i) Replace the lining plate which is seriously worn.
1.3.2.2 Main maintenance content during overhaul
a) Carry out the item-by-item inspection, disassembling, cleaning and

replacement according to the instruction manual of gearbox.


b) Check wear loss of the roller rubber surface, inject rubber if it is abraded

seriously.
c) If there is large cracking in the roller and it is difficult to be patched, then

replace it.
d) Check and clean various bearing pedestal and bearing, repair or replace if

there is any damage.


e) Check various mechanical deformation conditions; check if there is crack in the

welding joints, and repair or patch it if there is.


f) Patch or replace the conveying belt according to the abrasion condition.
g) Replace the funnel lining plate which is seriously worn.

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
11
h) Replace the sweeper scraper which is seriously worn.
I) Test the electrical control device and safe protection device; replace the failure

element and the safety protection device.


1.3.3 Maintenance items and quality standard
1.3.3.1 Gear box maintenance
1.3.3.2 Roller maintenance
1.3.3.3 Driving roller maintenance
a) Disassemble coupling protective shield.
b) Disassemble the coupling bolts.
c) Inspect and clean the motor displacement and roller outer inspection and

cleaning;release oil for gear box oil.


d) Disassemble the gearbox for inspection; internal cleaning of various

component and shell proper; there is no cracking or corrosion in the shell;

there is no cracking, snaggletooth in the gear.


e) Add qualified lube.oil after the gear box is reassembled; there is no abnormal

noise or vibration during the commissioning.


1.3.3.4 Divert roller maintenance
a) Turning gear inspection and roller drum surface cleaning, making sure there is

no crack or abrasion.
b) Loosen the belt driving roller and it should be flexible with no stuck, or replace

it and add qualified lube oil.


1.3.3.5 Idler maintenance
1.3.3.6 Sweeper maintenance
a) Support is stable and reliable, and the bolts are tight.
b) The adjusting spring could expand freely and replace it periodically.
c) The cleaning rubber is intact without damage, and it contacts with belt well. or

replace it; after being replaced, adjust the tensioning strength of spring and

press it tightly.
1.3.3.7 Roller backstop maintenance

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
12
1.3.3.8 Maintenance of tensioning device
a) Disassemble the counterweight device and suspender.
b) Calibrate the weight countering guiding frame and calibrate the suspender.
c) Readjust the quantity of tensioning device counterweight hammer to regulate

the belt tensioning force according to the belt tensioning situation.


d) Adjust the counterweight frame according to the belt operation situation, and fix

the frame after the adjustment; make sure the counterweight device can slide

smoothly upwards and downwards.


1.3.3.9 Maintenance of coal receiving device
a) There is no looseness or falling off in lining plate.
b) Check and make sure there is no severe abrasion in the lining plate; replace it

when the wear loss reach 1/2 of original thickness.


c) Check and make sure there is no blister or crack in the welding joint, and the

sealing is good.
1.3.3.10 Hydraulic coupler maintenance
a) Procedure after the working oil is drained:
1) Open lube.oil Filter for checking and cleaning.
2) Disassemble the coupler and check it
3) Check the radial runout of input shaft and output shaft.
4) Disassemble the sliding regulator and driving lever from the box.
5) Disassemble the auxiliary lube.oil pump and motor.
6) Disassemble the auxiliary working oil pump and motor.
b) Disassemble and lift away the top cover, check the engagement of the gear
c) Procedures after dismounting and disassembling the input shaft and rotor

components:
1.3.4 Equipment daily maintenance
Table 1-5 Coal handling equipments daily maintenance

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
13
Allowable Use Limit and Handling
Items Inspection Items
Methods
Check if there is foreign matters or
Add sweeper or material receiving plate
material dropping in empty belt section
The offset should be within 5% of belt
Check if there is belt offset
width
Check if there is residual powder of
Find out offset cause and eliminate it
conveying belt on the idler carrier and
timely.
ground
Conveying
Check if there is adherent material Adjust the sweeper
belt Check if there is longitudinal scratching Check if there is foreign matter in material

or abrasion guiding skirtboard and chute.


Check if there is abnormal damage
Check if there is new crack or layering

splitting.
Check if there is naked core or broken

core
Measure the wear loss.
If there is abnormal sound
If there is abnormal overheat
If there is abnormal vibration Inspect if the connecting bolts are loose
Motor
If there is oil leakage in the outer shell Replace the oil sealing
Insulation resistance measurement
Radiating blade inspection and cleaning
Hydraulic If there is abnormal vibration
If there is abnormal sound
coupler
Check the oil volume and if there is
If there is abnormal heat generation
overload condition.
Check if there is oil leakage in oil sealing Replace the oil sealing timely whenever

surface the oil leakage is serious.


Check if there is looseness in the bolts

and nuts.
Oil volume inspection Add oil if there is shortage

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
14
Allowable Use Limit and Handling
Items Inspection Items
Methods
Check if there is oil leakage or damage in

fusible plug
1.3.5 Belt bounding process and quality standard
1.3.5.1 Size management
a) The maintenance department should appoint special personnel to manage the

size and responsible for the application of size; the incoming size should paste

nameplate and mark manufacture, type, specification, delivery time and

implement safekeeping measurements.


b) The size should be maintained at 20 constant temperature(laboratory

thermostatic room; Inspect the performance when the storage period exceeds

three months and guarantee that the quality of size meet the requirement with

no aging phenomenon.
c) Confirm the type of the size before soaking the size and ensure the size type is

correct.
1.3.5.2 Basic technical requirement of cementing
Table 1-6 Basic technical requirement of cementing

1 time larger than that of rubber belt


Cementing Head Length(mm)
width
Contact Angle(degree)

Contact Step (pcs) Belt layers-1

Step Length (mm) 150200

Cementing Method Hot vulcanization or cold cementing

1.3.5.3 Basic process of cold cementing


a) Confirm the length of the belt; if it is the part belt need to be replaced, measure

the length of the belt which will be changed on the old belt with steel tape or

tape directly and then add the twice length of the contact, that is the actual

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
15
length of new belt. If the whole belt needs to be changed, the length of the belt

equals to the twice center distance of the belt conveyor and half perimeter of

head and tail roller. According to the calculated length, set proper length aside

for the tensioning device. The elasticity of the belt should be considered at this

time ( 1.5% of the total length of the belt); cut off the unnecessary part before

the cementing of the belt.


b) When tension the two contact of the belt, it should be conducted with

professional clamping plate to fix the belt.


c) Drawing line. After the belt is tensioned and confirm the length, draw line in the

end part of prepared belt for peeling off the head. The contact length should be

twice longer than belt width.


d) Head peeling off. According to the drawn line, cut off the unnecessary part and

peel off coated rubber and canvas layer. Pay attention to the operation

direction of the contact during the peeling off, counter cementing is forbidden;

the step width is usually 200mm, the peeling and cutting face should be flat

and the canvas layer should not be damaged during the process. Before

peeling and cutting the belt, the center line of two contacts should be drawn

and then conduct cementing. Each ladder edge of should be perpendicular to

the center line. Pay attention to the cutting depth of each layer, the lower layer

fiber should not be damaged during the peeling and cutting; the edge should

be intact and the side rubber should not be torn.


e) Dehairing. The purpose of dehairing is to cut off the residual rubber on canvas

layer surface to make the adhesive cement leak into the canvas layer when

coat the cement.


f) Rubber coating. Clean the dehaired step with brush and dissolved gasoline;

brush the prepared glue which is mixed by JH-184 glue and professional

hardening agent whose ratio is 9:1 after the gasoline is dried. The brush should

be even and it should be brushed twice. The brushing interval depend on the

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
16
actual condition; the second brushing could be conducted when the glue fail to

stick the hand.


g) Adaption. The corresponding step should be aligned when seal the belt; then

knock and connect the belt from center to surrounding with rubber hammer to

discharge the air in the belt and make that the contact is firmly fixed. The

hammer force should be spread the whole contact and it can be operated with

load after 16-24 hours of natural vulcanization.


Figure 1-2 Cold cement schematic diagram

1.3.5.4 Hot vulcanization process


a) Repeat the various procedures of cold cementing (a-e)
b) Rubber coating. Clean the dehaired step with brush and dissolved gasoline;

brush the prepared rubber cement twice after the gasoline is dried completely;

the next brushing can only be conducted after the gasoline in the rubber

cement is dried completely


1.3.5.5 Vulcanization technical requirement
a) Spread white cloth or paper in shaped belt contact, cover vulcanized gasket

and install the beam and fasten it from beam center to sides and the tensioning

should be even.
b) Conduct vulcanization work in accordance with the specified time, temperature

and pressure
c) There should be special personnel to monitor and record the vulcanization

work. When the temperature rises to 100, the temperature could be

decrease and increase twice to remove the air inside the contact and avoid the

bubbling. When the temperature increases to 145, start record the

vulcanization time and maintain the temperature for 45 minutes. The

vulcanization pressure should be adjusted between 1.8 and 2MPa. Monitor the

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
17
temperature of vulcanizing machine parts; handle it if there is abnormal

condition.
d) The vulcanization period is 45 minutes; after that, decrease the temperature to

70 and remove the vulcanizing machine and the vulcanization of belt contact

finishes. Note that if the vulcanizing machine is removed when the temperature

is decreased too much, the vulcanizing machine may adhesive with the belt; it

will increase the difficulty of removing the vulcanizing machine, meanwhile it

may damage the vulcanized contact and affect the quality of the contact.

1.4 Maintenance of Screening and Crushing Device


1.4.1 Overview
Primary screening device and primary coal crushing device is installed in coal

crushing house. Screening equipment adopts vibrating screen, its rated output is

250t/h, screening efficiency is not less than 85, the coal which fail to get through

the primary vibrating screen will enter crusher through coal chute, the coal

granularity of getting through the primary screening device is not larger than

10mm, it is connected with C-3AB belt conveyor. Crushing equipment adopts

hammer type fine crusher, its rated power is 250t/h, feeding size is not larger than

50mm ,discharging granularity is not larger than 10mm.


1.4.2 Specifications of fine crusher
Table 1-7 Technical specification of fine crusher

Fine-particle dual-direction reversible crusher (heavy type; equipped


Crusher Type
with coupler and damping platform)
Rated Output 250t/h
Feeding Size 50mm
Discharging

Material dmax10mm

Granularity
Indoor Noise 85dBA
Indoor Dust 10mg/m3

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
18
Density:
Motor Rated
6000V;(Anti-sxplosion)
Voltage
Shell Protecting
IP55 F-level insulation
Grade
1.4.3 Maintenance process and quality standard of coal crasher
Table 1-8 Maintenance process and quality standard of coal crasher
Maintenance
Maintenance Process Quality Standard
Item
Dismantle the Lock the drive motor, disconnect couplings The rotor should be vertical

rotor Remove the feeding groove of crusher. when it is hung out;


Disconnect all hydraulic lines connected horizontal move the rotor in
with hydraulic cylinder, choke up oil right and left direction.
discharge port and Dental headpieces -

Hose connectors.

Dismantle hydraulic cylinder and place it in

safe zone.

Remove the supporting device of broken

pieces so that it could be moved away

with side body completely.

Loosen all flange bolts, lift up one side

door and crushing plate as a group with

crane and dismantle the connecting bolts

of the other two side doors; lift up the door

and get away from the frame.

Cut off and dismantle dust proof sealing

covers and framework packing on each

side.

Dismantle all pillow block type bolts

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
19
Maintenance
Maintenance Process Quality Standard
Item
connected with bearing base and frame.

Hanging out the rotor combination; make

spindle wheel go through material feeding

chute flange.
Dismantle Lock the drive motor; disconnect coupling. When dismantling the

bearing Disconnect all hydraulic lines connected bearing, avoid the heating

with hydraulic cylinder; choke up oil and prevent the damage of

discharge port and Dental headpieces - rotor shaft. Heating is the

Hose connectors. last and worst method.


Remove the bearing cover (If needs to In this situation, outer ring,

replace a new bearing, only remove the roller and bearing support

relevant cover and the bearing base bolts should be dismantled from

on the other end). Raise the rotor so that inner ring, then divide inner

rolling bearing could pass through. ring into four parts using
If the bearing in driving mechanism side grinding wheel and
needs to be replaced, remove the sealing dismantle them respectively.
ring whose diameter is smaller. .
Loose bearing locknuts on bearing about

9mm; do not dismantle them.

Connect the hydraulic pump hose with

screw hole on rotor shaft end, add oil till

the bearing loosen to the locknut place

with a sound bang (Normally we need to

use high pressure pump to remove the

bearings).

Dismantle the bearings, lock nuts and

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
20
Maintenance
Maintenance Process Quality Standard
Item
small sealing rings from rotor shaft.
Clean up the new bearing, inspect bearing

clearance.

Assemble the big sealing ring on rotor

shaft

Fasten the bearing on rotor shaft; screw

nut into rotor shaft. Clearance of new bearing is

Fasten the rolling bearing nut on inner between 0200mm and


Bearing
ring; tighten the nuts by hand and make 0.259mm, After the
installation
them move to the bearing inner ring on installation, the clearance is

rotor shaft taper; Continue to rotate and between 0.124mm and

lock the nuts until they meet the 0.145mm

requirements.

Assemble it according to the contrary

process of dismantling process.

Bearing lubrication
Hammer head Lock the drive motor.

Pack the crushing plate in one side and

remove them away from rotor.

Open the door.

Rotate the rotor manually until one row

hammer head match with the opening of

dismantled inspection door.

Lock the rotor in appropriate position.

Dismantle the split pin of hammer head

shaft end.

From the drive motor side, push out

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
21
Maintenance
Maintenance Process Quality Standard
Item
hammer shaft from hanging scaffold and

hammer head hole; dismantle the hammer

head.
Replacing the crushing plate can be

completed by opening side door and

dismantling the regulation screws or the


Crushing plate
hinge of crushing plate.

This section can be passed by hanging up

the side door.


Clearance between elastic

ring and coupling is 0.5-

1mm, maximum value is no

more than 1.5mm;

Single or partial

replacement of elastic ring is

not allowed, all of them

Coupler should be replaced.

The elastic ring of coupler

should have no bending and

deformation

Elastic ring of coupler

should not swell after being

fastened; it should be in a

free state.
1.4.4 High amplitude vibrating screen technical parameter
Table 1-9 High amplitude vibrating screen technical parameter

Vibrating screen High amplitude vibrating screen

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
22
Type
Rated Output 250t/h
Feeding
50mm
Material Size
Discharging
dmax10mm
Granularity
Indoor Noise 85dBA
Indoor Dust
10mg/m3
Density:
Motor Rated
380V;
Voltage
Shell Protection
IP55, F-level insulation Anti-explosion
Level
1.4.5 Maintenance quality standard of high amplitude vibrating screen
Table 1-10 Maintenance quality standard of high amplitude vibrating screen

Common Fault Causes Quality Standard

The machine fail to be 1. Power circuit is dead. Quality standard: the

started after the power is 2. Motor is stuck. screening machine starts

on 3. overload normally.
1 The abrasion of screen Replace it
The size of coal which get
plate and grate is serious Quality standard: the size of
through the screen is larger
2 The connection part of sieved material is normal
than normal size
screen frame is worn.
Abnormal noise become 1. Fastening bolts are loose 1.Fasten the fastening bolts

obvious gradually 2.Bearings are lack of 2. Add lube oil for bearing

grease or damaged or replace the bearings

3. Framework of sieve plate 3 Repair or replace the

is broken sieve plate

4 Quality standard: the

noise is normal and it is

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
23
lower than 85dB in one

meter away place


Damper spring is fatigued Change damper spring

Vibration of screening or damaged Quality standard: vibration

machine is abnormal of screening machine is

normal
1.5 Vibrating Feeder
1.5.1 Equipment overview
ZG series motor vibrating feeder is a new kind of feeding equipment which is made

up of feeding trough, vibration body, vibration motor and shock absorber. The

feeding process is achieved through the cycle line reciprocating vibration along the

tilt direction of feeding trough driven by specially-made vibration motor. When the

acceleration vertical component of feeding trough is greater than the acceleration

gravity component, the materials will be thrown away. Because of the continuous

operation of vibration motor, the materials jump forward continuously so that the

feeding process is achieved.


When the vibrating feeder continuously feeding normal materials, install 10 tilt

downward; for sticky material and material with high water content should be install

15 tilt downward. Set aside more than 20mm clearance for the installed coal

feeder and make the coal feeder in free state.


1.5.2 Equipment technical parameter
Table 1-11 Feeder technical parameter

Coal Feeder
Vibrating feeder
Type
Number 2 set
Rated Output 250t/h
Feeding Size 50mm
Indoor Noise 85dBA
Indoor Dust
10mg/m3
Density:

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
24
Motor Rated
380V; Anti-explosion
Voltage
Shell Protection
IP55 F-level insulation
Grade
1.5.3 Common faults and handling method of feeder
Table 1-12 Common faults and handling method of feeder

No. Fault Phenomenon Fault Cause Handling Method

1.Check the power


1. Power circuit is
source
blocked
Switch on and the 2. Repair the motor
2. Motor is jammed
1 power feeder fail to be 3. Light load startup
3. Too large load
started 4.Remove the
4.Joint part with other
connection with other
equipment is restricted.
equipments
1. Two vibration motors
1.Adjust the rotation
The amplitude is small run in same direction
direction of one of
and swings horizontally; 2. One of the vibration
2 them
the material is not in the motors does not
2. Replace the
centerline. work or works in one
damaged motor
direction
1. Adjust or replace the
1.The bearing produces
The temperature rise of bearing
heat
3 vibration motor is too 2.Handle the phase loss
2.Single-phase operation
high 3.Motor dismantling and
3.Rotor collides the stator
trouble shooting
4 Current increases 1. One of the two motors 1. Repair the motor and

works wiring

2. Too heavy load 2. Reduce the material

3. Bearing is jammed or thickness

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
25
No. Fault Phenomenon Fault Cause Handling Method

3. Replace the bearing


lack of lubrication oil
and add lubrication oil
Base bolts of vibration
5 Big noise Tighten or replace it
motor is loose or broken
Hanging bracket is Replace the hanging
6
broken frame screw rod
1.6 Plough Tripper
The plow type unloader uses vice- to combine the plow, plow board uses the

stainless steel, the forehead small angle modeling, plow board can paste the tight

skin rubber surface, Unloads cargo smoother is clean. The entire machines and

tools have the intensity to be high, the non- vibration phenomenon.


This plow type tripping device is the combined type, makes the power supply by an

electrically operated throw out lever, through electric appliance control box, control

movement. When Unloads cargo active status, the throw out lever stretches out the

function to the link motion gear, completes plow knife the where about, invariable

trough holds the roller group to put evenly, in the parallel request roller group lifts,

this time adhesive tape, working surface straight, plow knife the fitting is strict, the

material dismounts, completes unloads cargo the movement. When non- Unloads

cargo condition, the throw out lever retracts, completes plow knife on lifts to moves

height, variables trough holds the roller upheaval, the parallel request roller group

drops, this time adhesive tape working surface furnishing trough,achieved the

adhesive tape transports enable the material the cross section trough angle to the

theoretical level steadily to pass.


1.6.1 General faults and handling method of plough tripper
Table 1-13 Common faults and handling method of plough tripper

Fault Phenomenon Fault Cause Handling Method

Motor is normal, Coal 1. Keys on guide rail are damaged; 1. Change the key

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
26
Fault Phenomenon Fault Cause Handling Method

plough, which is in it is stuck after being deformed. 2. Reinstall it

the middle position, 2. Keys of big gear wheel fall off. 3. Replace the screw

does not go up and 3. Screw rod is bending. 4. Replace the nut

4. Screw nut is damaged.


down or just a little

distance
1. The coal plough rises too high; 1. Turn the root of motor

The fastening between pushrod blades with hands,

Motor is normal, coal inner screws and nut, springs of reset the buffer spring

plough stops at a shock absorber are too tight. screw.

higher position 2. The screw head shaft elastic 2. Reset the big gear,

collar is pulled off, the big gear is replace the elastic

out of alignment. collar


1. Coal plough falls too low; the Dismantle coal plough pin

screw head shaft use check ring or lift up the coal plough;
Motor is normal,
jacks off the big gear. The big turn motor impeller and
coal plough cannot
gear and small gear cannot mesh reset the push rod; fasten
be lift up after being
with each other. the nut and screw
laid down
2. The screw is separated with

nut. .
The coal plough fail 1. Power source fuse is burned 1.Replace the fuse

to be started down 2.Contact the electrical

2. The actuation of ac contactor is personnel to handle the

not good or the wire is burned faults of 2-4

down 3. Start the coal plough

3. Motor or electrical circuit is cut off after resetting the

4. The travel switch is damaged thermocouple

and cant reset

5. The thermocouple cant reset

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
27
Fault Phenomenon Fault Cause Handling Method

after being activated


Coal plough falls to 1. Limit switch is damaged or 1. Remove the fuse of

the assigned installation location is wrong coal plough and contact

position. Motor 2. Stop button is damaged and electrical maintenance

power cannot stop cannot reset staffs to handle it


1. Two-phase operation of motor 1.Contact electrical

2. AC contactor contact is bad maintenance personnel

Motor does not rotate 3.Screw is bended or badly to inspect for the first

but deliver buzzing damaged and second problem

sound 4. Keys on guide rail is badly 2. Replace the screw


damaged and causes the stuck 3.Repair key slot and

of pushrod. replace key


1.7 Electric Magnetic Iron Remover
RCDD series dry type automatic iron remover is one kind of iron removing device

that eliminates the magnetic impurities in powder or block material automatically. It

is self-cooled and fully sealed structure with the advantages of great penetration

depth, strong attraction, and dust removable, water-proof, corrosion resistance and

so on. It can operate reliably in extremely bad environment.


1.7.1 Technical parameters
Table 1-14 Electromagnetic iron separator technical parameter

Belt Electric Belt Electric


Items Magnetic Separator Magnetic Separator
(Head Installment) (Head Installment)
Quantity 1 3
Excitation mode Electromagnetic Electromagnetic
Appropriate belt
1000 800
widthmm
Appropriate belt
2.0 1.6
velocitym/s
Appropriate power
500 250
outputt/h
Groove angle 35 35
Material
50 50
particlemm
Indonesia
HangingBanjarsari
height 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
28
mm
Magnetic
inductionmT
1.7.2 Daily miantenance
1.7.2.1 As long as iron remover special failures do not occur, frequently clean dust

surrounding the iron mover and periodically lubricate the bearing during daily

maintenance.
1.7.2.2 Except for replacing power line and in special circumstances, do not open junction

box randomly in order to avoid insulation aging. Replacing power lines, please use

cables with the same specification; after opening junction box cover, ensure that it

is fully dry and the connection is firm; tighten bolts and bring it back to the original

state.
1.7.2.3 Periodically check iron remover belt and power line; replace it if there is outer

damage.
1.7.2.4 Gear box adoption instruction:
a) Gear box adopts pin-cycloid gear meshing and planetary driving. The gear

motor is used for continuous working condition, which is allowed to rotate in

direct and reverse directions with the ambient temperature of -1040.

b) In normal condition, gear motor adopts sump lubrication with the oil level

staying seen in the middle of oil window. It is recommended that extreme

pressure gear oil E90# is adopted or oil 40# and 50# is adopted as

substitution. During oil topping, screw off the ventilation cap on the upper part

of pedestal; during oil discharging, screw off the drain plug in the lower part of

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
29
pedestal for waste oil discharging.
c) After two weeks of operation with the oil topping for 1st time, its required to

replace the lubrication oil immediately (clean the waste oil inside); afterwards,

replace oil every 3-6 months of continuous operation.


If the operating condition is tough, shorten the oil replacement time as

required. During operation, make sure the oil preservation in the gear box

proper is in the rated level, both redundancy and shortage are not allowed;

open the ventilation cap on the pedestal or flange disk for oil makeup.
1.7.2.5 Winding is the key components of iron separator, therefore, its necessary to

monitor and check if the current and voltage indicated in the control panel is

normal; measure the winding insulation resistance, handling it immediately it is

faulted. As the iron separator adopts self magnetic mode, its required that clean

the ash off winding with compressed air periodically (at least once per month

accordingly), so as to help winding heat dissipation.


1.7.2.6 Industry Lithium base lubricating grease is recommended for each bearing, which

possesses stronger heat-resistant ability and is properer for more dust and higher

temperature occasion. Therefore, refill lubricating grease at least once per month.

For chain and pulley driving lubricating, fill the oil every day.
1.7.3 Equipment maintenance process
1.7.3.1 Replace roller bearing
a) Loosen the rubber belt before replacement first, then disassemble the setscrew

on the roller bearing pedestal.


b) During bearing disassembly, disassemble the inner-side end cover of the

bearing first, then disassemble the bearing pedestal and bearing with the

prolonged puller.
c) During new bearing installation, adopt the heating or cooling mode as required.
1.7.3.2 Idler maintenance process:
a) Take down the spring clamp, big&small sealed cover and hair pad; take idler

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
30
shaft and bearing out by knocking with the copper bar.
b) Reset shaft inside the idler and take down the bearing on the other end with

the same way for cleaning and inspection.


c) Before assembly, clean the idler shaft, bearing pedestal, seal and clamp ring

with gasoline or diesel.


d) Paint clean lubricating grease on the bearing two ends, and fill the lubricating

grease inside the bearing and sealing ring. Bearing oil filling level is 2/3 of the

shaft interval as required.


e) Match the shaft and bearing well with the special tools, reset them inside the

idler and equip the hair pad and clamp ring. Check if they work smoothly by

rotating manually after assembly is completed


1.7.4 Equipment maintenance quality standard
a) After maintenance, rotating parts shall be flexible and there is no jamming.
b) Hanging devices shall be tight and firm.
c) Iron remover installment height and inclination angle shall meet the

requirements.
d) Trial operation is stable; iron absorption and removal are normal.
1.7.5 Common faults and handling methods
Table 1-15 Common faults and handling methods of electromagnetic iron remover

No. Fault Description Fault Causes Handling Methods


Absorb and abandon ability Height or dip angle Adjust the height
1
reduces changes and dip angle
Crane trolley does not move There is foreign Check the trail.

matter between trail

2 and crane wheels or

trail has

deformation,.
1.7.6 Lubrication of belt type electric magnetic iron remover
Table 1-16 Lubrication of belt type electric magnetic iron remover

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
31
Lubricati Oil Feeding Lubricating
S. Lubricated Oil Volume of First Oiling
ng Volume Oil Can Be
N. Items Lubrication Interval
Methods Each Time Replaced.
Nearly
About 15 of Machine oil
1 Reducer Injection half a About 1.5
machine oil 30# 20#
year
Roller About 1.5
Nearly a
2 bearing, idler Injection molybdenum disulfide About 0.4 Without
year
bearing lithium-based grease
1.8 As-fired Coal Belt Sampling Device
1.8.1 Overview
As-fired coal sampling adopts middle part of belt sampling device. Working

principle of sampling system is that the sampling head rotates for a circle according

to specified time interval and gets a whole sectional sample from moving belt type

conveyor. Sample falls into primary sample feeder directly through inclined chute

then goes to crusher. Material will be crushed to the required granularity without

any loss and keep the moisture at scheduled value. Samples will be divided by the

riffle; finally they are collected in water-proof and dust-proof container. The rest

material in sampling system returns to lower part of conveyor through bucket

hoister.
As-fired coal sampling device includes primary sampler, primary belt coal feeder,

sample crusher, sample collector, rest coal returning system and control cabinet;

the pipes among coal feeding, crushing, riffle and sample preparation equipments

are made of stainless steel. The whole system has alarm protection function of coal

jamming at coal feeding port and coal outlet and coal interruption. There is linkage

relationship between sampling device and coal belt conveyor; they run

synchronously, get sample and prepare sample synchronously.


Primary sampler adopts scraper type sampling head and is connected with unit

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
32
device.
Primary belt feeder is used to guarantee uniform flow and prevent jamming. The

whole sealing structure is adopted in order to prevent dust.


Sample crusher is used to crush material particles to the required granularity.
The function of residual back system is to deliver the residual coal back to the lower

part of coal handing system belt conveyor through bucket hoister. Bucket hoister is

equipped with ladder and maintenance platform.


Sampling device can keep a good seal property without material loss.
Coal sampling devices are installed in the central section of 3AB belt conveyor of

the project coal conveying system.


1.8.2 Specifications of as-fired coal sampling device
Table 1-17 As-received coal sampling device parameter

Producing
S. N. Name Specification Unit Quantity Manufacturer Notes
Area
Australian
1 Sampler S70-800-150 set 2
Saimo
Primary Saimo
2 SF1-350 set 1
feeder Electrical
Australian
3 Crusher MM2 set 1
Saimo
Saimo
4 Riffler S73 set 1
Electrical
Oddment
Saimo
5 back F71 set 1
Electrical
device
Sample Saimo
6 S58-8/10 set 1
collector Electrical
7 Coal Set 1 Saimo

drop pipe Electrical

and

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
33
Producing
S. N. Name Specification Unit Quantity Manufacturer Notes
Area
support
Electroni
Saimo
8 c control Set 1
Electrical
device
9 UPS Set 1
Met
10 Cable 20
er
Communi
Met
11 cation 1000
er
cable
1.8.3 Daily maintenance of equipment
a) Periodically check lubricating oil of gear reducer.
b) Check feeder belt at least once every month.
c) Lubricate bearing at least once every month.
d) Check drive speed periodically to prevent it from deflecting adjusting value.
e) Check and tense belt every three-month and lubricate drive chain once every

month with oil.


f) Periodically check wear degree of equipments; judge whether some parts need

replacing, especially hammerhead of hammer crusher is the component that is

easy to be abraded.
1.8.4 Daily maintenance and oil-feeding cycle to the equipment:
Table1-18 Daily maintenance and oil-feeding cycle to the equipment:

S.N. Lubricating Type of Lubricant Lubricant- Remark

Position Feeding Cycle


1 Scrapper sampling

machine
1.1 Reducer Gear oil N68,N100,N150, Every 6 months

GB3141

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
34
1.2 Bearings with Lithium base grease 2# Every month

support GB7324-87
2 Material feeder

2.1 Roller bearing Synthetic calcium base 6 months

pedestal grease ZG-3H

ZBE36005-88
2.2 Driving chain Ordinary open gear oil Every month

(chain wheel) 68#~100#,SY1232-85


3 Crusher

3.1 Crusher Bearing of Synthetic calcium base Every month

principal axis grease ZG-3H

ZBE36005-88
4 Sample collector

4.1 Worm wheel Gear oil N68-N150 6 months Change oil

reducer GB3141
4.2 Roller bearing of Synthetic calcium base 1 year

principal axis grease ZG-3H

ZBE36005-88
1.8.5 Maintenance technology of the equipment
a) Disassembly the sampling head to repair. The following steps should be

followed when disassembling or changing the sampling head: Lift the sampling

head and fix it to the frame of conveying machine or set to the supporting

frame. The gap between cutter and belt should be checked. The axis line of the

cutter should be kept consistent with the central part of the conveying

machines belt. The plate is used to adjust the driving part to form a line.
b) After repairing, installing, and connecting the feeding machine, it should be

operated manually to check whether the belt is adjusted well. Bolt is used to

adjust the belt according to the usual practice of standardized conveying

machine. Safety facilities should be checked if the belt is not adjusted well.
c) Checking and repairing of hammer head. Hammer head is a fragile part. Both

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
35
ends of some hammer heads can be used. Thus one can use the other end if

one end is frayed. When all ends of the hammer head are frayed, then one

should coat it with special material to resume its original shape, or change a

new one.
d) When changing a hammer head, one should first disassembly the axis sealing

plate on both sides of the machine or the cover plate on both sides of the

crusher, and dismantle the back door. The surface nuts of easily-maintained

crusher can be dismantled to open the doors on both sides to gain working

space. If one needs more working space, the shutters of the doors should be

dismantled after lifting the doors. Rotate the rotor to make hammer rod along

lines with the side-frame opening on the axis. Then rotor is blocked to avoid

any movement. Dismantle the pins on both sides or draw out the hammer rod

from the locating retainer ring, through which one hammer head can be

disassembled and be put out from the mouth of crusher. Another row of

hammer heads can be changed after one row of hammer heads have been

changed.
e) Changing is required when the scale board is frayed. When the scale board is

severely frayed and cannot protect the major parts of crusher, instant changing

is required.
1.8.6 Quality standards of maintenance to the equipment
a) The designed gap between cutter and belt is 13mm. Yet the realistic gap can

be differed according to different conditions on the working field.


b) In the first few days, when operating with load, the belt of feeder will be

elongated. Adequate tensile force is required to avoid skidding when tightening

the belt.
c) To guarantee the balance of rotor. The total weight of hammer heads on each

hammer rod should be the same.

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
36
1.9 Dust Removing Equipments Maintenance
1.9.1 Basic principle of impulse dust remover
When the gas contained dust enters into dust remover through air inlet, firstly it

comes to the inclined board and baffle in air inlet, outlet middle part. Airflow will

change its direction and flow to ash hopper, at the same time airflow speed will be

decreased. Under the effect of inertia, the large dust particles in air will flow to ash

hopper and the preliminary dust collection is achieved. After entering into ash

hopper, the airflow will go upward and get through bag with metal frame inside it;

the dust will be collected in outer surface of bag. After being purified, the gas enters

into upper clean room of bag room (Filter cartridge); it is discharged after being

collected at outlet. During the bag purifying process of dust gas, the dust which is

attached on bag will increase along with the increase of time which will increase the

resistance of bag (Filter cartridge) and decrease the air amount; In order to

guarantee the normal operation of the dust remover, the resistance should be

controlled at a certain range and the ash on bag Filter cartridge must be cleaned.

When cleaning the ash, the impulsive controller will trigger various control valve in

sequence and open impulse valve. Compressed air in air box sprays into

corresponding bag through spraying pipe and various hole venturi pipe; bag (Filter

cartridge) will expand rapidly and the dust on bag (Filter cartridge) surface will fall

off and the bag (Filter cartridge) will be regenerated. Clean the dust and make it

drop into ash hopper; discharge it from the body through ash discharging system.

So the dust attached on bag (Filter cartridge) will be cleaned through periodical

impulsive ash cleaning; the purified gas will pass through normally and the dust

removing system will be guaranteed.


1.9.2 Basic parameters of dust removing equipments
Table 1-19 Basic parameters of impulse dust removing equipments

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
37
Equipment JJWM
JJWM-90A JJWM-110A JJWM-140A JJWM-180A
Type -70A
Quantity 4 9 4 1 2
Treatment air
7000 9000 11000 14000 18000
volume
Air distribution
100
ratio
Filtering area 70 90 110 140 180
Filtering air
1.67
speed
Equipment
1200
resistance
Equipment net
2600 2900 3250 4000 4800
weight
Equipment
3100 3400 3850 4600 5600
running weight
Equipment L 1340 1780 2120 2630 3410

appearance W 1950 1950 1950 1950 1950

size
H 4440 4440 4530 4630 4610
mm
1.9.3 Pulse dust remover faults and handling methods
1.9.3.1 Dust removing effect is not good and the ash exhaustion exceeds the standard.
a) Newly-installed clean Filter bag void is larger. During initial adoption, the dust

screening volume is larger, and the dust exhaustion volume which is not in

optical Filtering state is larger. With Filtering going on, dust forms as dust layer

on the Filter bag surface, minifying the void of outer surface of the Filter bag

and increasing the Filtering effect.


Therefore, Filtering effect measurement of pulse bag dust remover is more

accurate after one month of continuous operation.


b) Check if the Filter bag installation is correct.

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
38
c) Dust-contained air flow will directly be exhausted to atmosphere if the Filter

bag is broken, causing ash leakage of dust remover exhaust port.


1.9.3.2 Bag pasting occurs, and the pulse dust remover working resistance is larger.
a) The ash removing time is short, the removing cycle is too long, dust remover is

put into Filtering state without the ash on the Filter bag is not being clean out.
b) When the pulse bag dust remover is handling high-temperature and high-

humidity air, if the air temperature in operation is lower than the dew-point

temperature, the moisture will condenses into dew, which cannot be removed

even with compressed air, causing bag pasting.


c) Pulse bag bust remover usually works in the negative pressure; if there is

leakage in the device, abundant air and rain water from atmosphere will be

induced inside damping the Filter bag and increasing the Filtering resistance.
d) For pulse bag dust remover, blowing the ash with compressed air is usually

adopted; compressed air contains oil, water and sundries, which will smear

and dampen the Filter bag resulting in dewing when it is injected without being

Filtered.
1.9.3.3 Electromagnetic pulse valve air leakage
a) The electromagnetic pulse valve membrane is damaged.
b) There is sundries like iron rust and welding slag Membrane between

membrane gasket and exhaustion port, disabling jointing and causing the air

leakage.
c) For submerged pulse valve, if there is leakage in the injection tube of air

manifold.

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
39
2 General Equipment Maintenance

2.1 General Maintenance Process


General maintenance process is the principle process that must be followed during

maintenance work; it is the required knowledge for the maintenance personnel


2.1.1 Contents of general maintenance process
a) Before the maintenance, the necessary maintenance items and improvement

items should be listed according to equipment technology condition and

existing defects. Organize workers, material, spare parts, tools and technology

safety measures well. The condition should be known before maintenance and

conduct identification and comparison after the maintenance.


b) Equipment drawing quality requirements and maintenance process should be

mastered well by the maintenance personnel.


c) During equipment disassembly, the components that cannot be exchanged or

need to be assembled according to a certain direction should be marked well.

The mark should be marked on side rather than working surface.


d) Dismantling method should be suitable as well as tools and avoid damaging

the equipments. Dismantled components should be put in dry wood plate in

order and wipe them clean; pay attention to prevent dust and collision. After

spindly shaft is dismantled, support it with many supports, or place it vertically

to prevent the bending.


e) When disassembling the combination surface with gaskets, measure and

record the original thickness of gaskets or keep original objects. When

assembling the equipments, compare the clearance variation before and after

the repair and confirm the abrasion ratio of equipments or components.


f) For components which is easy to rust, butter should be coated and place it

well. For the bolts which is difficult to be removed, use loosening agent to

penetrate firstly. Use copper bar or soft material to tap the rusted components.

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
40
g) Working and combination surface of components should be cleaned with

cleaning liquid. Remove the rust if the component is rusted. In order to protect

the combination surface from damage, it is forbidden to use flat spade and

thick shovel. Grease the combination surface after the cleaning.


h) When clean the inner wall of equipment body
i) Maintain the dismantled protective cover, sealing cover, handrail, cover and

recovered them timely after the maintenance.


j) Precision measuring tools (vernier caliper, micrometer, dial indicator) should be

used correctly and kept well. It is not allowed to measure components with

rough surface and it should not be placed together with other tools.

2.2 Maintenance of Rolling Bearing


Table 2-1 Maintenance process and quality standard of rolling bearing

Maintenance
Process and Methods Quality Standard Attentions
Items
Inspection 1. Inspect if there is flaw in inner and

and outer ring of rolling bearing and if

identification there is obvious defect,such as

of rolling hard spout, peeling, rust on rolling

bearing channel. Inspect whether holder is

perfect and rotation is flexible or

not. If there is one of above

defects,the bearing cannot be

used.

2. (Radial ball bearing) except the

appearance inspect of bearing, the

clearance of bearing should be

measured; it is forbidden to use if it

does not meet the standard. There

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
41
Maintenance
Process and Methods Quality Standard Attentions
Items
is no sense of clearance when

wobble outer ring in radial direction

with hand. The normal clearance

between inner, outer ring of normal

radial ball bearing and rolling body

is 0.05-0.1mm.

3. The inner and outer ring of conical

roller bearing can be separated. In

normal case, the roller of conical

bearing should fall on middle

rollway of outer ring; The length

center of roller should coincide

with the width center of outer ring.

When the bearing is abrased, the

moving distance is not more than

1.5mm usually; distance between

roller front end and outer ring edge

should not be smaller than 2-3mm.


Disassembly Stress on inner sleeve

of bearing when disassembling the

bearing; bearing outer

sleeve can also be

stressed on if the force

cannot be placed on inner

sleeve. If the bearings can

be disassembled with

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
42
Maintenance
Process and Methods Quality Standard Attentions
Items
scraper, the method of tap

and pry should not be

adopted.
Cleaning Dust, degenerative lubricating oil and

before sundries inside the bearing should be

bearing cleaned completely.

installation
1. When heating the bearing, the oil 1.Sleeve and

1.Clean the installation temperature can not exceed hammer used

contact surface of inner 120. It is forbidden to heat for

ring, outer ring, shaft bearing with flame directly. The fit assembling

journal (or pedestal) of clearance between outer sleeve bearing

bearing, put some and bearing pedestal should not should be

lubricating oil on them. smaller than 0.02mm for move cleaned.


2.Heating installation about bearing. 2.It is not

method should be 2. Bearing should be disassembled allowed to tap

adopted for bearing with to bearing shoulder, inner ring and the bearing

tensioning force bearing shoulder should has no with hammer

cooperation and clearance. Gasket on bearing end directly.

measure bearing cover should be flat with no burr. Copper bar or

cooperation value 3.Bearing end surface with shock bar

before installation. The specification should face outside made of other

shaft should be for convenient inspection. material with

processed if the shrink 4. Lubricating oil should be enough a low

range is large. The when assembling bearing; inspect hardness

painting and other the rotation situation if the should be

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
43
Maintenance
Process and Methods Quality Standard Attentions
Items
processing technology condition is allowed. cushioned.

should be done for shaft

if certain assembling

tension cannot be

ensured due to small

shaft diameter.

3.During assembly, use

correct methods and

tools, the professional

sleeve which fits in the

diameter of inner and

outer ring used. Stress

position must be

uniform, suitable and

perpendicular to bearing

end face; Avoid

damaging the bearing

due to single side stress

application.

4. Apply force on the inner

sleeve of bearing when

install the bearing on

shaft journal. Apply

force on the inner and

outer sleeve at the

same time when install

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
44
Maintenance
Process and Methods Quality Standard Attentions
Items
the bearing on the inner

wall of bearing.
Clearance 1. Outer sleeve clearance

adjustment of (big diameter inward

conical roller installation along end

bearing direction), measure

bearing clearance with

end cover lead wire

method. Remove all

gaskets on end cover

when measure the

pressure; choose

gasket according to

regulations based on

measured value and

required clearance.

2.Clearance adjustment of

inner sleeve(big

diameter outward

installation along end

direction), adjust with

inner sleeve locking

nuts; it means that

screw nuts up till the

bearing clearance is

zero; and calculate wire

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
45
Maintenance
Process and Methods Quality Standard Attentions
Items
degree based on bolt

distance. Turn back the

nut to required angle,

add locking gasket and

then screw nut up and

fasten it.
2.3 Gearbox Maintenance
2.3.1 Maintenance of gearbox
Table 2-2 Maintenance process and quality standard of gear reducer

Maintenance
Maintenance Process Quantity Standard
Item
Preparations 1. Clean corresponding

before components of

maintenance decelerator, sweep dust

and oil dirt.

2.Drain the lubrication oil

in tank completely and

sample oil and send it

to laboratory for

analysis; determine if to

use it according to the

test report. Test the

new oil before adding it,

the unqualified oil

cannot be used.

3.Remove the anchor

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
46
Maintenance
Maintenance Process Quantity Standard
Item
bolts of motor and

disconnect coupling

between motor and

decelerator; move

motor to specified

position.

4.Inspect oil leakage point

and record it well; oil

leakage point on

junction face should be

marked obviously.

Position mark should

be done well for

components which

cannot be exchanged.
a) Remove the bolts and 1. Uneven degree of junction face cannot

hang big cover: exceed 0.5mm.

b)When disassemble 2. There is at least one closed contact line on

junction face bolts of junction face.

decelerator, place them 3. Disassemble bolts of end cover and keep

well and do not collide gasket well.

the screw thread. 4. It is forbidden to pry the wedge using crowbar.

c) Jack up big cover with 5. It should be steady when hanging the big

jacking wire until the cover with no collision. Prevent the outer ring

positioning pin is from falling down and damaging during the

exposed completely. hoisting process for the big cover using thrust

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
47
Maintenance
Maintenance Process Quantity Standard
Item
d) Suspend out big cover bearing.

and place it in specified

position; it should be

supported by sleeper.

The Junction face of

big cover should be

placed upward if

possible.

e)Take out various

gaskets and bind them

in group and mark it

well.

f)Clean and check

junction face of box

body.

g) Use relative cleaning

agent to clean dry

sealant; it is not

allowed to scrape with

screwdriver and other

hard and irregular tools

in case that the junction

surface is damaged.

h) Conduct red lead oil

inspection for the

reduction gear box

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
48
Maintenance
Maintenance Process Quantity Standard
Item
whose junction surface

has serious oil leakage.

Scrape according to the

contact condition.

i)Welding up and

machining should be

conducted when the

deformation of junction

surface is large or it is

seriously damaged.
Clean and check gear and The shaft should be smooth with no flaw or

shaft; Place the damage.

components which are The tortuosity and twist are forbidden, the non-

tested to be qualified in straigtness degree cannot exceed 0.02/100mm.

the specified position, and The allowance of ovality and conicity depends

Clean and then cover it with cloth for on the accuracy grade and size of shaft

check various installation. diameter; it is usually less than 0.03mm.

components There should be no flaw, burr, peeling or hemp

striae phenomenon; the geometry size of

various part should accord with drawing

requirements.

Change gear when gear abrasion exceeds one

third of primary thickness.


Cleaning and 1. Bearing rotates flexibly; inner and outer ring

inspection of are intact without serious abrasion and flaw.

bearing 2.Clearance of high speed shaft is 0.06-0.08mm.

3.Clearance of intermediate speed shaft is 0.08-

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
49
Maintenance
Maintenance Process Quantity Standard
Item
0.12mm.

4. Clearance of low speed shaft is 0.15-0.20mm.


Reinstallation 1.Clean and dry the 1. Cooperation tension between gear and shaft

components which is not smaller than 0.01-0.03. Key cooperation

should be installed; should accord with national standard; key top

Install the gear inside should set aside certain clearance whose

the gear. range is between 0.10mm and 0.40mm.

2.Assemble gear from 2. When the clearance of key top is too large,

driven end to high change a qualified key and it is not allowed to

speed end in order. add the gasket.

3.Adjust gear meshing 3. Meshing position deviation cannot exceed

position and meshing 2mm.

clearance. 4. Contact area of gear along teeth length is not

4.Adjust shaft and bearing smaller than 60% and not smaller than 45%

clearance. along teeth height.

5.Adjust parallel degree of 5. Teeth side clearance is within the range of

shaft. 0.751.5mm.

6.Add lubricating oil for 6. Clearance between shaft and shaft end cover

various bearings. is 0.1-0.25mm.

7.Paint sealant, then 7. Clearance between bearing outer sleeve and

cover and fasten it. shell is not less than 0.1mm.

8. Clearance between bearing outer sleeve and

seatbore is in the range of 0.020.04mm

generally.

9. Clearance of various bearing should accord

with the requirements. Sealing filler should be

pressed tightly and coincide to the shaft and

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
50
Maintenance
Maintenance Process Quantity Standard
Item
there is no oil leakage during rotation process.

10. Non-parallel of two shafts cannot exceed

0.05mm.

11. Shell is intact the oil level indicator is well

and vent hole, return oil hole are smooth. .

12. Decelerator should rotate flexibly and mesh

stably with no noise; the temperature increase

cannot exceed 40 during the operation.


2.3.2 Maintenance of cycloidal reducer
Table 2-3 Maintenance process and quality standard of cycloidal needle wheel reducer

Maintenance
Maintenance Process Quality Standard
Items
1. Lift off the cycloidal

needle wheel

decelerator from
preparations
equipments and clean
before
the body surface.
maintenance
2. Unscrew oil draining

plug and discharge

lube oil.
disassembly 1. Place the output shaft Take out output shaft, tap shaft end

of decelerator upward, cushioned by hard rubber gasket; then take

remove connection it out from pedestal.

nuts and bolts, and

separate the input parts

of decelerator.

2.Disassemble input

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
51
Maintenance
Maintenance Process Quality Standard
Items
parts.

3.Disassemble output

parts.
1. There should be no flaw and deformation

phenomenon in various parts.

2. Cooperation end face of box pedestal

Clean and needle gear shell should vertical to the

check various axial line of two axle hole.

parts 3. Two end faces of needle gear shell

should parallel with each other.

4. The surface of output shaft should be

smooth without flaw.


1.The sequence of 1. Scrap iron, rust and sundries cannot be

assembling is opposite left in decelerator box.

to the sequence of and 2. Various sealing part and junction face are

disassembly in good condition with no oil leakage.


Reinstall
2. Rotate input shaft by 3. Run stably without abnormal sound.

hand or auxiliary tools

and check rotation

condition.

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
52
3 Hoisting Equipments

3.1 Definition of Hoisting Equipments


Hoisting equipments is a kind of electromechanical equipment to transport or move

heavy objects. It includes the lifter whose rated hoisting weight is greater than or

equal to half ton; crane whose rated lifting weight is greater than or equal to one ton

and lift height is higher than or equal to two meters; the electrical hoist, hydraulic

moving van, fork truck and other equipments with fixed bearing type.

3.2 Equipment Specifications


3.2.1 Electric single girder hoist in coal bulldozer room
Number: 1
Maximum hoisting weight is five tons
Span of hoist is 7.5m
Motor hoist: lift weight is five tons, hoist height is not smaller than eight meters.
3.2.2 Manual/motor hoist

Table 3-1Specifications of manual/motor hoist

Type and
NO. Name Unit Quantity Remark
Specification
1 Motor hoist(anti- Hoist weight:5t Under 11.5m girder of crusher
set 1
explosion type) Lift height:5m room
Hoist weight:3t

Motor hoist(anti- Lift height: 4m, Under 16m girder of crusher


2 set 1
explosion type) turning radius is room

2.5m
HB 2t-20m hoist

weight:2t
Motor hoist(anti- Under top girder of crusher
3 Lift height:20m, set 1
explosion type) room
turn radius is

3m.
4 Motor hoist(anti- 6m set 2 Under top girder of crusher

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
53
Type and
NO. Name Unit Quantity Remark
Specification
HB1 T-6m

Hoisting room, under top girder of 2#


explosion type)
weight:1t transfer station

Lifting height:6m
Under 6m girder of crusher

HB1T-5M room, 21.5m girder of 2#


Motor hoist(anti-
5 Hoist weight:1t set 3 transfer station and under
explosion type)
Lift height:5m 47.5m girder of transfer station

among coal bunker bay.


HB3T-12M

hoist weight:3t
Motor hoist(anti- Under top girder of 0# transfer
6 Lift height:12m, set 1
explosion type) station
turning radius is

2.5m..
HB2T-12M

Hoisting

weight:2t
Motor hoist(anti- Under top girder of 1# transfer
7 Lifting set 1
explosion type) station
height:12m,

turning radius is

2.5m..
HB2T-6M Under 0m girder of 1# transfer

Motor hoist(anti- hoisting weight station, under top girder of


8 set 2
explosion type) is one ton transfer station among coal

Lifting height:6m bunker bay


9 Motor hoist(anti- HB2T-28M set 1 Under top girder of 2# transfer

explosion type) hoisting weight station

is two tons

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
54
Type and
NO. Name Unit Quantity Remark
Specification
Lift height:28m,

turning radius is

3m..
HB2T-45M
Motor hoist(anti- Under top girder of coal bunker
10 hoist weight:2t set 1
explosion type) bay
Lift height:45m
HB2T-4M

hoisting

weight:2t
Motor hoist(anti-
11 Lifting set 1 Under top girder of bunker bay
explosion type)
height:4m,

turning radius is

2.5m..
HB2T-52M

hoist weight:2t
Motor hoist(anti-
12 Lift height: 52m, set 1 Under top girder of transfer
explosion type)
turn radius is station of coal bunker bay

4m.
3.3 Maintenance Method And Quality Standard
3.3.1 Steel wire rope
a) Steel wire rope should accords with the rules of GB1002 with a qualified

certification; the standard of scrapping and update should accords with the

rules of GB6067 safety regulations of hoist machinery safety


b) When change steel wire rope, in the premise of ensuring the total breaking

pulling force equals to original design, the allowable deviation of diameter is

1mm when diameter is smaller than 20mm;it is 1.5mm when diameter is

larger than 20mm.


c) When the hook is in the lowest position of working position, except for the turns

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
55
of winding and fixing the rope, there should be at least 2 turns of winding

amount.
d) The dirt on the rope must be cleaned before lubricating the steel wire rope;

lubricating oil temperature should be heated above 80 during lubricating

process so the lubrication oil can immerge into the steel wire rope.
e) It cannot tie when winding or changing the steel wire rope.
3.3.2 Hooks
3.3.2.1 The hook can rotate flexibly in the range of 360in horizontal plane or more than

180in vertical direction.


3.3.2.2 Hook face should be smooth without exfoliation, acute angle, burr, breakage,

cockle, tool marks and other defects.


3.3.2.3 Hook thread should be smooth without burr, damage, breakage and dent.
3.3.2.4 Hook and its affiliated parts should be scrapped if one of following situations

occurs:
a) Flaw
b) Abrasion of emergency section reaches 10% of original size.
c) Opening degree increases by 15% compared with original size.
d) Twist and deformation exceeding 10 degree.
e) There is plastic deformation on emergency section or hook journal.
f) Bolt and hook girder have flaw and deformation.
3.3.2.5 It is not allowed to weld up the defect in hook.
3.3.3 Pulley
3.3.3.1 There should be no defects that damage the steel wire rope.
3.3.3.2 Radial circular bounce of rope race is 0.3mm, rope race split positioning is 1mm.
3.3.3.3 When there is sand hole on pulley rope race and its area is not greater than 2

mm2, and the depth is not larger than 25% of the wall thickness, weld up the sand

hole.
3.3.3.4 When there is sand hole on pulley axle hole supporting surface whose area is not

greater than 10% of the whole supporting surface, and the depth is not larger than

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
56
25% of the wheel hub, weld up the sand hole
3.3.3.5 Pulley should be scrapped if any of the following situations occurs:
a) Flaw
b) Uneven abrasion loss of rope race reaches 3mm.
c) Wall thickness abrasion of rope race reaches 20% of original thickness.
d) Bottom diameter decrement of rope race reaches 50% of steel wire rope

diameter due to the abrasion.


e) Other defects that damage steel wire rope.
3.3.4 Coiling block
3.3.4.1 The coiling block can be used continuously without welding up when there is one

air hole or sand hole whose diameter is within 8mm, depth is within 4mm and the

quantity should be no more than one for every 100mm length and no more than

five parts on total processing face of coiling block.


3.3.4.2 The wall thickness difference in various parts cannot be larger than 4mm after the

coiling block rope race is processed. Drill four holes whose diameter is 4mm

diameter and perpendicular with each other on same section and inspect them if

necessary.
3.3.4.3 The coaxiality of the two center line is 0.15mm for coiling block whose length is

within 1m; coaxility is 0.2mm for coiling block whose length is more than 1m.
3.3.4.4 Grooves ridge of coiling block rope race should not have the defect whose length

exceeds 2% of screw thread one perimeter and depth is larger than 2mm.
3.3.4.5 Coiling block should be scrapped if any of the following situations occurs:
a) Flaw
b) Wall abrasion reaches 20% of original thickness
c) The rope race is abraded and cannot control steel wire rope.
3.3.5 Wheel
3.3.5.1 Wheel should be scrapped if any of following situations occurs:
a) Flaw
b) Abrasion thickness of wheel edge reaches 50% of original thickness.

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
57
c) The deformation of wheel edge thickness reaches 20% of original thickness
d) Abrasion of tread thickness reaches 15% of original thickness.
e) Roundness deviation exceeds 1mm.
3.3.5.2 Driving wheel should be scrapped if any of the following situations occurs:
a) Flaw or teeth breakage
b) Pitting damage of gear surface reaches 30% of meshing surface and the

thickness reaches 10% of original thickness.


c) Gear thickness abrasion reaches 30% of original thickness (the value is 15%

for anti-explosion motor hoist).


3.3.5.3 The wheel should be disassembled and processed when wheel abrasion exceeds

0.005D (D is wheel diameter) and the diameter difference with wheel should be

less than 0.005D


3.3.5.4 Bearing
a) The cooperation between bearing and axle should adopt H7m6.
b) When assembling bearing, it can be assembled in hot state after being heated

for 15min with 100~120 oil, or heated by bearing heater.


3.3.5.5 When installing electrical crane, the distance among wallboard should be adjusted

with gasket in order to guarantee there is 2~4 mm clearance between lower edge

side surface of I beam and wheel rim.


3.3.6 Stopper
a) Stopper action must be flexible and reliable, the clearance between roof and

push rod of limit switch should not be smaller than 0.5mm.


b) When the hook is lifted to extreme position and impacts stopper roof, it should

act on the middle part of roof.


3.3.7 Track
a) Elasticity buffer should be equipped at both end of the track.
b) When bearing capacity of the rack reduces 87% of original design bearing

capacity due to the corrosion or abrasion, or thickness reaches 10% of original

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
58
thickness due to the corrosion or abrasion of stress section, it should be

scrapped if it cannot be repaired well.


c) It should be scrapped when running mechanism cannot operate normally

because of plastic deformation and it cant be calibrated with cold processing


d) High and low displacement of butt joint should be within 1mm, convex parts

should be polished to be flat.

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
59
4 Fuel Equipment Specification

4.1 Gantry Stacker Reclaimer


Table 4-1 Gantry stacker and reclaimer specification
4.1 Manufacturer Northern Heavy Industry
4.2 Equipment basic parameters
Model MDQ250/50050
1) Stacking capability 500t/h
2) Reclaiming capability 100~250t/h
3) Span (crane travel gauge) 50 m
4) Pile height: above track
Under track 1 m
5) Trailing car gauge 5 m
6) Traveling distance 110m
7) Maximal working air pressure 250Pa
8) Maximal non-working air pressure 800Pa
9) Rigid and flexible leg structure A type
10) Trailing car model Shunting trailing car
11) Power supply method: cable winding drum
12) Power supplying voltage: 6000V
13) Power supplying frequency: 50Hz
14) 50HzPower voltage: 380V
15) Installed total power 220 kW
16) Maximal load power 45 kW
17) Power receiving position Coal yard flexible leg side;
18) Rail model 50kg/m
19) Control mode Centralized manual and semi-automatic control on

equipment; control cable drum


20) Ground belt-type conveyor theoretical enter height (distance from rail

tread): seen in interface drawing


Belt width 1000mm
Speed 2m/s
Idler diameter 133mm
Trough angle 35
Output 500t/h
Operation mode Single-direction operation
21) Crane travel mechanism

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
60
Travel mechanism type Trolley type/small pulley wheel set
Speed 7.525m/min
Driving mode Three-in-one gear motor
Driving quantity 8pcs
Motor power 8X5.5kW (frequency variation)
Wheel sets numbers 16 groups
Driving wheels quantity 8pcs
Wheel diameter 630mm
Maximal wheel pressure 250KN
Rail clamp numbers 2
Rail clamp type Hydraulic
Steel rail: 50Kg/m
22) Movable beam hoisting mechanism
Driving device model Motor-driven steel wire rope hoisting
Motor power 50kwinterim
Driving device sets 2set
23) Stacking/reclaiming belt conveyor
Operation mode Bi-direction
Capacity 500t/h
Belt width 1000mm
Speed 2m/s
Idler diameter 133mm
Trough angle 35
Tensioning type Heavy hammer tensioning
Driving device type Motor-driven roller
24) Reclaiming belt conveyor
Operation mode Single-direction operation
Capacity 500t/h
Belt width 1000mm
Speed 2m/s
Idler diameter 133mm
Trough angle 35
Tensioning type Heavy hammer tensioning
Driving device type Motor-driven roller
25) Movable belt conveyor
Operation mode Bilateral operation
Capacity 500t/h
Belt width 1000mm
Speed 2m/s

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
61
Idler diameter 133mm
Trough angle 35
Tensioning type Screw tensioning
Driving device type Motor-driven roller
Traveling speed 13m/min
Driving mode cycloidal-pin wheel gear boxwith motor and brake+Open-

type gear
26) Trailing car
Operation mode Double-direction operation
Trailing car type Pass-type trailing car
Maximal inclination angle 16
Belt width 1000mm
Speed 2m/s
Idler diameter 133mm
Trough angle 35
Driving device Motor+coupling+brake+gear box
27) Roller mechanism
Roller type no layout
Diameter 6.8m
Bucket numbers 10pcs
Speed 4.13r/min
Driving mode Motor+coupling+brake+gear box
Travel speed 416m/min
Driving mode Three-in-one gear mode
28) Cable reel
Power cable reel type JDO-2000(D)-GA
Cable model YJGCFPB 3X25+3X16
Cable length 70m
Control cable drum model JDO-650(D)-KT24
Cable model Interim
Cable length 70m
29) Water spraying device
Type Water spray dust removing
Power 5.5KW
4.2 Belt Conveyor System
Table 4-2 Belt conveyor system technology and performance data

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
62
_1B_Belt
_1A__Belt
_2AB_Belt
_3AB_Belt
_4AB_Belt
_5AB_Belt
Conveyor
Conveyor Conveyor Items
Items Items Unit
Unit
Unit Technical
Technical
Technical
Parameters
Parameters
Parameters
1.Machine
1Machine
1.Machine specification
specification
specification
1.1
1.1Belt
1.1Belt
Beltconveyor
conveyor
conveyornumber number
number 1B Belt conveyor
5ABBeltconveyor
1A
2ABBeltconveyor
4ABBeltconveyor
3ABBelt
conveyor
conveyor
1.2
1.2conveyor
1.2conveyor
conveyortransporting
transporting
transportingamount amount
amount t/ht/ht/ht/h 250 250
500
250
1.3
1.3Belt
1.3Belt
Beltwidth
width
width mm mmmm mm 800 800
1200
800
1.4
1.4Belt
1.4Belt
Beltvelocity
velocity
velocity m/sm/s
m/sm/s 1.6 1.6
2.0
1.6
1.5
1.5Belt
1.5Belt
Belthorizontal
horizontal
horizontallength length
length m mm m 35.4 98.95/101.35
88.85/92.05
86.815m
123.85m
213.1
1.6
1.6Angle
1.6Angle
Angleof ofofinclination
inclination
inclination 14.3 12.6
14.25
0150
1.7
1.7Hoisting
1.7Hoisting
Hoistingheight
height
height m mm m 8.1 21.5
22.8
30.5
00
1.8
1.8Radius
1.8Radius
Radiusof ofofconvex
convex
convexarc arc
arc m mm m / //
1.9
1.9Radius
1.9Radius
Radiusof ofofconcave
concave
concavearc arc
arc m mm m / //
1.10
1.10Belt
1.10Belt
Beltsurface
surface
surfacetheory theory
theoryheightheight
height mm mmmm mm 1000 1000
1000
1.11
1.11Total
1.11Total
Totalquality
quality
quality KgKg KgKg 14.01 45.57
36.13
42.55
43.59
55.80
2.Motor
2.Motor
2.1
2.1Type
2.1Type
Type YB225M-4
YB225M-4
YB250M-4
YB280S-4
2.2
2.2Voltage
2.2Voltage
Voltage v vv v 380 380
380
2.3
2.3Power
2.3Power
Power kwkw kwkw 4555
75
45
2.4
2.4Current
2.4Current
Current A AA A 85.4
104.9
85.4
141
2.5
2.5Efficiency
2.5Efficiency
Power and
Efficiency and
and
and
power power
power
powerfactorfactor
factor
factor 89.8% 89.8%
92%
92.8%
92%
2.6
2.6Rotary
2.6Rotary
Rotaryvelocity
velocity
velocity r/min
r/min
r/min
r/min
2.7
2.7Quantity
2.7Quantity
Quantity SetDos
DosSet 1 22 1
2.8
2.8Heater
2.8Heater
Heaterpower
power
powerand and
andvoltage
voltage
voltage kw/V
kw/V
kw/V
kw/V 50KW/220 50KW/22060KW/220
60KW/220
2.9
2.9Encloser
2.9Encloser
Shell protection
protection
protection class class
class IP54 IP54
IP54
3.Reducer
3.Reducer
3.1Type
3.1Type B3SH04 B3SH05
B3SH04
H3SH07
B3SH05
B3SH07
3.2Machanical
3.2Mechanical
3.2Mechanicalpower power kwkw kwkw 33 58
33
109
58
86
3.3Shaft
3.3Shaftpower
power kwkw kwkw 11.92 25.47
11.66
42.46
25.95
33.02
3.4
3.4Velocity
3.4Velocity
Velocityratio
ratio
ratio 31.5 31.5
31.5
3.5
3.5Quantity
3.5Quantity
Quantity DosDos
DosSet 1 22 1
4.Tension
4.Tensiondevice device
4.1
4.1Tensioning
4.1Tensioning
Tensioningmethod method
method Vertical tensioning
Vertical
Verticaltensioning
tension
tension
4.2
4.2Tensioning
4.2Tensioning
Tensioningstroke stroke
stroke mm mmmm mm 700 2000
1800
3500
1800
2460
4.3
4.3Quantity
4.3Quantity
Quantity setSet
SetSet 1 22 1
4.4
4.4Tensioning
4.4Tensioning
Tensioningforce force
force KN KNKN KN 25 4050
2540
4.5
4.5Counter
4.5Counter
Counterweightweight
weightquality quality
quality kgkgkgkg 1500 4500
2700
2550
4500
5.Roller
5.Roller
5.1
5.1Driving
5.1Driving
Drivingroller
roller
roller
5.1.1
5.1.1Diameter
5.1.1Diameter
Diameter mm mmmm mm 630 630
630
800
5.1.2
5.1.2Spindle
Shaft
Spindle
head nose
nose diameter
diameter
diameter mm mmmm mm 90 110
90
130
110
5.1.3
5.1.3Bearing
Bearingtype/sizetype/size mm mmmm mm 3520 3524
3520
3528
3524
5.1.4
5.1.4Roller
Roller
Roller allowable
allowable
allowable tensioning
tensioning
tensioning
force kNkN kNkN 50 80
50
110
80
5.1.5 Roller allowable torque Nm 20
force
force
5.1.6 Roller rubber layer thickness mm
5.1.5
5.1.5set
5.1.5Roller
5.1.5set
Roller
coupler
coupler
allowable
allowable
torque
torque torque
torque Nm NmNm 6 614
1212
5.1.7 Roller rubber surface layer
5.1.6
5.1.6RollerRoller
rubber layer rubber thickness
layer mm mmmm 14 1414
70
hardness(Shaoer
5.1.7
5.1.7Roller
Roller rubberrubber A type) surface
surface layer 70 70
thickness
5.1.8 Roller rubber layer type Herringbone
hardness(Shaoer
5.1.7Roller rubber A type) surface layer 70
5.1.9 Driving roller quantity 1
5.1.8 Roller rubber layer type Herringbone Herringbone
hardness
hardness(Shaoer
5.2 Tail (ShaoerAAtype)
roller type)
5.1.9 Drivingroller
5.1.9Driving rollerquantityquantity 1 2
5.1.8 Roller rubber layer type
5.2.1Diameter mm Herringbone
630
5.2 Tail roller
5.1.9 Drivingroller
5.1.9Driving
5.2.2Bearing rollerquantity
quantity 2
5.2.1Diametertype/size mm 3524
mmmm 500 500
630
5.2 Tail roller
5.2.3Roller allowable tensioning force kN 64
5.2.2 Bearing type/size mm mm 3520 3520
5.2.1Diameter
5.2.4Roller rubber layer thickness mmmm 50012
5.2.3 Roller allowable tensioning kN kN 40 40
50
5.2.2 Bearingrubber
5.2.5Roller type/size surface layer mm 3520
force
5.2.3 Roller allowable tensioning kN 4060
hardness(Shaoer A type)
5.2.4 Roller rubber layer thickness mm mm 12 12
force
5.2.6Roller
5.2.5 Rollerrubber glue layer type Flat60 cast
5.2.5Roller rubber layersurface hardness(A
layer 60
5.2.4 roller
5.2.7Tail Roller quantity rubber layer mm 121
type0
hardness(Shaoer
5.3 Redirect rollerA type)
thickness
5.2.6
5.2.5Roller rubber layer type layer Flat cast Flat
5.3.1Diameter
5.2.5Roller
Roller rubber
rubber surface
surface mm 60 cast
630.500.400
5.2.7
5.3.2 Tail rollertype/size
Bearing Quantity
quantity mm 1 2
3524.3520
hardness(Shaoer
5.3
5.3Redirect
5.3.3Redirect roller A type)
roller
Roller allowable tensioning force kN 64.35.29
5.2.6Diameter
5.3.1 Rollerrubber
5.3.1Diameter
5.3.4 Roller rubberlayer layerthickness
type mmmm mm Flat cast
500/400/315 630/500/400
500/400/315
12
5.2.7Bearing
5.3.2
5.3.5 Tail roller
Roller rubber quantity
type/size layer hardness mmmm 3520/3516 260
3520/3516
5.2.7 Tail roller
5.3 Redirect quantity
roller 2
5.3.3
5.3.6 Roller
Roller
Roller rubber allowable
allowable
layer type tensioning kN kN 40/20 50/40/32
40/20
Flat cast
5.3Redirect
5.3.1 Diameter roller mm 500/400/315
5.3.7Redirect
force
5.3.1Diameter roller quantity mm 4
500/400/315
5.3.2
5.4 Bearing
Tension roller type/size mm 3520/3516
5.3.4
5.3.2Roller
Bearing rubber layer
type/size thickness mm mmmm 12 12
3520/3516
5.3.3 Roller
5.4.1Diameter allowable tensioning kN mm Plant 40/20
500
5.3.5
5.3.5Roller
Roller
Indonesia
5.3.3 glue
Roller glue layer
layerhardness
Banjarsari
allowable hardness
2135MW
tensioning Coal-firedkNPower 60 Coal Handling40/20 60
Maintenance Manual
5.4.2Bearing
forceRoller rubber
5.3.6 type/size layer type mm
63 Flat cast 3524
Flat cast
force
5.4.3
5.3.4Roller allowable
Roller tensioning
rubber force mm kN
layer 1235
5.3.7
5.3.7Redirect
Redirect roller
rollerquantity
Quantity 4 4X2
5.3.4
5.4.4Roller Roller
rubber rubber
layer thicknesslayer mmmm 1212
5.4
5.4Tension
Tension roller
roller
thickness rubber layer hardness
5.4.5Roller
thickness
5.4.1
5.4.1Diameter
Diameter mmmm 400 60
400
500
5.3.5Roller
5.4.6 Rollerrubber
glue layer hardness
layerhardness
type 60
Flat cast
5.3.5Roller
5.4.2 Bearing glue
type/sizelayer mmmm 3516 60
3516
3520
4.3 Fine Crusher
Table 4-3 Fine crusher specification

No. Items Unit Number Value

Pulverizing company of
1 Equipment manufacturer
Pennsylvania, US
2 Equipment type BC15-44
3 Working institution Three-shit
4 Rated capacity t/h 250
5 Feed size mm 50
6 Discharge size mm 95-100%10
YBJC450-6 anti-explosion type,
7 Motor type
anti-explosion rating ExdII
Power kW 375
Voltage V 6000
Rotate velocity r/min 1000
Insulation class F
Protection class IP55
The connection type with
Coiling spring-loaded coupling
crusher
8 Rotor diameter mm 1118
Length/Effective length mm / mm 2991/1854
Rotary velocity rpm 1000
Linear velocity m/s 58.56
Weight(except hammer head) kg 3124
9 Hammer head Quantity 78
Weight kg/Dos 7.48
Material A322 Forged steel
Hardness HRC 48-52
About 3000h refer to coal
Lifetime h
property
10 Arm quantity Combined with hammer
Weight kg/Dos ---
Material ---
Hardness HRC ---

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
64
No. Items Unit Number Value

Lifetime h ---
11 Bearing type Roller bearing SKF
Type 22234
Material Bearing steel
Lifetime h 100000
35KN (in condition that one Dos
Fine crusher dynamic force kN
hammer is missing)
Coil spring coupling size,type
12 1130T10/Us Fox Company
and manufacturer
Crushing plate(Adjustable gap
13 Adjustable
between hammerhead)
Type Sawtooth type
Material AR400 Wear-resistant Alloy steel
Lifetime h 12000
Fine crusher entrance air
14 m3/h 1500
quantity
15 Fine crusher exit air quantity m3/h 2500
End cover hydraulic open
16 YES YES
system
17 Inspection door Dos 2
18 Equipment total quality kg 14062
19 Singleton Maximum weight kg 3124
Singleton maximum mmmm
20 Diameter 11182991
sizelengthwidthheight mm
Equipment boundary
mmmm
21 dimensionlengthwidthheigh 3000 24641676
mm
t
One meter point noise value of
22 dBA About 90dBA
fine crusher jacket
23 Product overhaul cycle Year 4
Equipment requirement for all
24 375KW+1.5KW
power and itemize power

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
65
No. Items Unit Number Value

YBJC450-6 (anti-explosion type, anti-


Motor type,size and
25 explosion rating ExdII) /Shanghai
manufacturer
Motor Factory
4.4 High Amplitude Vibrating Screen
Table4-4 High amplitude vibrating screen specification
No. Title Parameter Unit
1 Application Raw coal rating
2 Feed size 50 mm
3 Discharge size 10 mm
4 Screen layers Layer
5 Screen size mm
6 Screen dip angle
7 Screen area m2
8 Screen hole size mm
9 Screen material/Lifetime
Screen plate

10 thickness mm Apply -

lifetimeh
11 Double-amplitude mm
12 Vibrate frequency 1/min
13 Processing capacity t/h
14 Screening efficiency
15 Equipment noise dBA
16 Total weight Kg
Install
17 mm
sizelengthwidthheight
Type -
18 Motor Sets/Power kW
Rotary velocity r/min

Working time
19 Live load Start and shut N

time

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
66
4.5 Vibrating Coal Feeder
Table 4-5 Coal feeder specification
No. Items Unit
1 Vibrating feeder size and type Dos ZGF-1322
2 Quantity Dos 2
3 Rated capacity t/h 250
4 Feed size mm 50
Product total weight/Maximum
5 t 2.4t/1.5t
singleton weight
6 Noise value dBA 85
7 Product overhaul cycle Year 4
Motor type ,power and exciting
8 - YZO-30-6
force
9 Amplitude mm 6-9
10 Frequency Hz 16
Feed plate material/Apply
11 16Mn/18000h
lifetime
Spring type /diameter/
12 16016030
decrement
13 Dip angle 10-20
4.6 Electric Magnetic Iron Remover
Table 4-6 Electric magnetic iron remover specification

Magnetic belt type iron Magnetic belt type iron


Product name
separator separator

Model RCDD-10T2 RCDD-8T2

Quantity 1 3

Applicable width 1000 800

Applicable speed 2.0m/s 1.6m/s

Suspension height 300 250

Induction of magnet intensity


120mT 120mT
in rated height

Suspension device model Steel wire, bolt Steel wire, bolt

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
67
Rated load-carrying of
12T 12T
suspension device
Travelling trolley model DX-3 DX-3

Iron drop trolley model RCDD-10T2 RCDD-8T2

Iron drop trolley volume 2.34m3 1.2m3

Iron drop trolley appearance


1.21.21(m) 1.211(m)
dimension
Drive motor power of iron
3KW 2.2KW
separator

Overall dimension 29201750950 27501630950

Total power 13.2KW 10.9KW

Entire weight 3700 2560

Cooling method Natural cooling Natural cooling

4.7 As-Fired Coal Belt Sampling Device


Table 4-7 As-fired coal belt sampling device specification
Items
1Sampling head
Sampling head type Scraper type
Sampling head mode S70-800-150
Motor mode R97DV112M4/BMG
Voltage grade 380V/50Hz
Motor power 4KW
Explosion Proof motor and Insulation class ExdII .IP55/F
Sampling head speed 61rpm
Sampling cycle Adjustable
Sampling hopper openness width 150mm
Sampling head quantity 2
Sampling Head Material Stainless steel
Sampling head manufacture Austrilian Saimo
2Belt coal feeder
Coal feeder type Belt type
Coal feeder width 350mm

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
68
Items
Coal feeder speed 0.04m/s
Coal feeder speed 2t/h
Voltage class 380V/50Hz
Motor power 0.25kw
Explosion Proof class and Insulation class ExdII.IP55/F
Coal feeder Quantity 1
Coal feeder manufacture Saimo Electrical
3Residual material return device
Bucket type elevator type F71-100
Bucket elevator output 2.5t/h
Motor type SA77DV100M4
Voltage grade 380V/50Hz
Motor power 2.2kw
Explosion proof class and Insulation class ExdII.IP55/F
Bucket elevator Quantity 1
Bucket elevator manufacture Saimo Electrical
4)Crushing equipment
Crusher type MM2
Crusher output 2t/h
Crushing size 6mm
Lifetime of crusher hammer head 10000hour
Voltage grade 380V/50Hz
Motor power 3kw
Explosion proof class and Insulation class ExdII.IP55/F
Crusher Quantity 1
Crusher hammer material ZGMn13-1
Crusher manufacture Australian Saimo
5Dividing device
Riffle type Suspension type
Dividing ratio 1:151:100
Adjusting type of dividing ratio Adjusting and dividing space
Voltage grade 380V/50Hz
Motor power 0.18kw
Explosion proof class and insulation class ExdII.IP55/F
Divider Quantity 1
Divider manufacture Saimo Electrical
6Sampler
Collector mode S58-8/10

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
69
Items
Collector mode Rotary switching type
Switching type of collector Automatic
Motor mode SAF57R17DR63L4
Voltage grade 380V/50Hz
Motor power 0.25kw
Explosion proof class and Insulation class ExdII.IP55/F
Collector manufacture Saimo electrical
7Electrical control system
PLC type Siemens S7-200
Quantity 1
Manufacture Simens
8Others
Coal chute diameter 300mm
Material of hopper and coal chute Stainless steel
Inner lined stainless steel of carbon
Belt type coal feeder casing material
steel
Bucket elevator casing material Carbon steel
Crushing dividing unit outer box material Carbon steel
The whole equipment weight About 9t
Power of the whole equipment About 20kw
4.8 Impulse Dust Remover
Table 4-8 Impulse dust remover specification

No. Title Equipment Parameter Comment

Impulse bag
1
dust remover
Basic
1.1
Parameter
JJWM- JJWM- JJWM- JJWM- JJWM-
Equipment type
70A 90A 110A 140A 180A
Quantity 4 9 4 1 2
Handling air
7000 9000 11000 14000 18000
amount m3/h
Air distributing
100
ratio

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
70
No. Title Equipment Parameter Comment

Filter are m2 70 90 110 140 180


Filter speed m/s 1.67
Equipment
1200
resistance Pa
Equipment net
2600 2900 3250 4000 4800
weight kg
Equipment

operating 3100 3400 3850 4600 5600

Weight kg
Equipment L 1340 1780 2120 2630 3410

appearance W 1950 1950 1950 1950 1950

dimension H 4440 4440 4530 4630 4610


mm
Dust removing
99.5%
efficiency
Impulse valve

brand and origin ASCO/American

place
Impulse valve
DN25
specification
Impulse blowing
0.6
pressure MPa
Proper input
7.5 11 15 15 22
power Kw
Dust remover
Steel plate
box material
Dust remover

box thickness 3.5

mm
Dust remover /

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
71
No. Title Equipment Parameter Comment

proper heat

insulation
Dust removing

inlet connecting 360 400 450 500 550

tube dimension
Dust remover

ash discharging
200*200
connecting pipe

size mm
Set Matched
1.2
centrifugal fan
B4-
B4-79-
Type 72- B4-79-4.5A B4-72-5A B4-72-8C
5A
4.5A
Matching fan
Shanghai Jinyongli
manufacturer
Air amount
7000 9000 11000 14000 18000
m3/h
Full pressure Pa 2400 2500 2960 2900 2400
Fan speed rpm 2900 2900 2900 2900 1600
YB13 YB160
YB160M1- YB160M2-
Motor mode 2S2- M2- YB180M-2
2B35 2B35
2B35 2B35
Power kW 7.5 11 15 15 22
Motor speed
2900
rpm
Motor
IP55
Protection class
Connection
Directly or driven by belt
mode

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
72
No. Title Equipment Parameter Comment

Matching air

1.3 compressor

system
V- W-0.9/7\7.5 W-
Air compressor V- W-
0.67/ 1.0/7\7
type 0.67/7\5.5 1.5/7\11
7\5.5 .5
Air compressor Shanghai Desilan

brand and

manufacture
Air supplying
0.67 0.67 0.9 1.0 1.5
amount m3/min
Air supplying
0.7
pressure MPa
Air storage tank 0.125 0.125 0.17 0.17 0.2

specification

and capacity
Air compressor
5.5 5.5 7.5 7.5 11
motor power Kw
1.4 Filter bag
Filter
130*2450
specification
Filter bag
70 90 110 140 180
Quantity
Filter bag type Cylinder type
Filter bag
Pinfelt
material
Filter bag 120

working

temperature
1.5 Dust remover

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
73
No. Title Equipment Parameter Comment

ash discharging

valve
Ash discharging
Star type
valve type
Ash discharging

valve 200*200

specification
Motor power of

ash discharging 0.55

valve Kw
Ash remover

1.6 ash hopper

rapping device
Ash hopper

rapping type
Specification of

ash hopper CZ25

rapping device
Ash hopper

rapping device 0.03

power Kw
Dust remover
1.7
explosion hole
Anti-explosion
Screen
vent type
Size of anti-

explosion hole, 600*600

mm
Anti-explosion Aluminum alloy

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
74
No. Title Equipment Parameter Comment

hole material
Firefighting
1.8
spraying system
Water amount
2 2.5 2.5 3 4
t/h
MPa Water
0.2
pressure Mpa
Power electricity
1.9
control cabinet
Electrical

control cabinet
500*800*250
appearance

size
Power control
IP54
class
Power source 380/220V(Three phase four wire)
PLC brand,

specification GE/MICRO/24

and I/O tally


Dust remover

1.10 matched pipe Only equipped for JJWM-180A Type dust remover

screw
Screw conveyor
LS-200
mode
Screw diameter: 200
Throughout 8m3/h

Indonesia Banjarsari 2135MW Coal-fired Power Plant Coal Handling Maintenance Manual
75