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SUMATERA, INDONESIA
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Contract No.
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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
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
textbook, it will be improved and modified if the material is intact. Sincerely welcome the
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
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
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
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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
material stacking and reclaiming equipment which reclaim the material and delivery
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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
stacking coal chute through tail car and drop on the stacking and reclaiming belt
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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.
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
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
the top of walking beam, hoisting mechanism at the bottom of walking beam,
reclaiming belt conveyor, mobile belt conveyor, tripper car reclaiming coal chute,
tripper car stacking and reclaiming coal chute, tripper car stacking and
voltage electrical room, low voltage electrical room, driver's chamber, single
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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
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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
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
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
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
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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
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
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
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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
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
gearbox adopts oil tank splashing lubrication, natural cooling; adopt cycle oil
gearbox low speed shaft or driving roller driving roller(when the power is larger,
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The idler is used to support the belt and the coal loaded on. At the same time,
and limit the sag degree between belt and idler groups so as to make sure the
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
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
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
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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
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
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
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h) Replace the sweeper scraper which is seriously worn.
I) Test the electrical control device and safe protection device; replace the failure
no crack or abrasion.
b) Loosen the belt driving roller and it should be flexible with no stuck, or replace
replace it; after being replaced, adjust the tensioning strength of spring and
press it tightly.
1.3.3.7 Roller backstop maintenance
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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 frame after the adjustment; make sure the counterweight device can slide
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
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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
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
and nuts.
Oil volume inspection Add oil if there is shortage
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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
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
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
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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
end part of prepared belt for peeling off the head. The contact length should be
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
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
layer surface to make the adhesive cement leak into the canvas layer when
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
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actual condition; the second brushing could be conducted when the glue fail to
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
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
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
decrease and increase twice to remove the air inside the contact and avoid the
vulcanization pressure should be adjusted between 1.8 and 2MPa. Monitor the
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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
may damage the vulcanized contact and affect the quality of the contact.
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
hammer type fine crusher, its rated power is 250t/h, feeding size is not larger than
Material dmax10mm
Granularity
Indoor Noise 85dBA
Indoor Dust 10mg/m3
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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
Hose connectors.
safe zone.
side.
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Maintenance
Maintenance Process Quality Standard
Item
connected with bearing base and frame.
chute flange.
Dismantle Lock the drive motor; disconnect coupling. When dismantling the
bearing Disconnect all hydraulic lines connected bearing, avoid the heating
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
bearings).
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Maintenance
Maintenance Process Quality Standard
Item
small sealing rings from rotor shaft.
Clean up the new bearing, inspect bearing
clearance.
shaft
requirements.
Bearing lubrication
Hammer head Lock the drive motor.
shaft end.
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Maintenance
Maintenance Process Quality Standard
Item
hammer shaft from hanging scaffold and
head.
Replacing the crushing plate can be
Single or partial
deformation
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
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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
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
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lower than 85dB in one
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
gravity component, the materials will be thrown away. Because of the continuous
operation of vibration motor, the materials jump forward continuously so that the
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
Coal Feeder
Vibrating feeder
Type
Number 2 set
Rated Output 250t/h
Feeding Size 50mm
Indoor Noise 85dBA
Indoor Dust
10mg/m3
Density:
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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
works wiring
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No. Fault Phenomenon Fault Cause Handling Method
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
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
Motor is normal, Coal 1. Keys on guide rail are damaged; 1. Change the key
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Fault Phenomenon Fault Cause Handling Method
the middle position, 2. Keys of big gear wheel fall off. 3. Replace the screw
distance
1. The coal plough rises too high; 1. Turn the root of motor
Motor is normal, coal inner screws and nut, springs of reset the buffer spring
higher position 2. The screw head shaft elastic 2. Reset the big gear,
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
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Fault Phenomenon Fault Cause Handling Method
Motor does not rotate 3.Screw is bended or badly to inspect for the first
is self-cooled and fully sealed structure with the advantages of great penetration
depth, strong attraction, and dust removable, water-proof, corrosion resistance and
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
b) In normal condition, gear motor adopts sump lubrication with the oil level
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
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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,
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
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
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
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
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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
grease inside the bearing and sealing ring. Bearing oil filling level is 2/3 of the
idler and equip the hair pad and clamp ring. Check if they work smoothly by
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
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
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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
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
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device.
Primary belt feeder is used to guarantee uniform flow and prevent jamming. The
part of coal handing system belt conveyor through bucket hoister. Bucket hoister is
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
and
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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
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:
machine
1.1 Reducer Gear oil N68,N100,N150, Every 6 months
GB3141
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1.2 Bearings with Lithium base grease 2# Every month
support GB7324-87
2 Material feeder
ZBE36005-88
2.2 Driving chain Ordinary open gear oil Every month
ZBE36005-88
4 Sample collector
reducer GB3141
4.2 Roller bearing of Synthetic calcium base 1 year
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
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
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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
the belt.
c) To guarantee the balance of rotor. The total weight of hammer heads on each
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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
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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
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
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c) Dust-contained air flow will directly be exhausted to atmosphere if the Filter
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
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.
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2 General Equipment Maintenance
existing defects. Organize workers, material, spare parts, tools and technology
safety measures well. The condition should be known before maintenance and
order and wipe them clean; pay attention to prevent dust and collision. After
assembling the equipments, compare the clearance variation before and after
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.
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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
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.
Maintenance
Process and Methods Quality Standard Attentions
Items
Inspection 1. Inspect if there is flaw in inner and
used.
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Maintenance
Process and Methods Quality Standard Attentions
Items
is no sense of clearance when
is 0.05-0.1mm.
be disassembled with
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Maintenance
Process and Methods Quality Standard Attentions
Items
scraper, the method of tap
adopted.
Cleaning Dust, degenerative lubricating oil and
installation
1. When heating the bearing, the oil 1.Sleeve and
ring, outer ring, shaft bearing with flame directly. The fit assembling
adopted for bearing with to bearing shoulder, inner ring and the bearing
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Maintenance
Process and Methods Quality Standard Attentions
Items
processing technology condition is allowed. cushioned.
if certain assembling
tension cannot be
shaft diameter.
position must be
perpendicular to bearing
application.
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Maintenance
Process and Methods Quality Standard Attentions
Items
the bearing on the inner
wall of bearing.
Clearance 1. Outer sleeve clearance
pressure; choose
gasket according to
regulations based on
required clearance.
2.Clearance adjustment of
inner sleeve(big
diameter outward
bearing clearance is
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Maintenance
Process and Methods Quality Standard Attentions
Items
degree based on bolt
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
to laboratory for
analysis; determine if to
cannot be used.
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Maintenance
Maintenance Process Quantity Standard
Item
bolts of motor and
disconnect coupling
decelerator; move
motor to specified
position.
leakage point on
marked obviously.
components which
cannot be exchanged.
a) Remove the bolts and 1. Uneven degree of junction face cannot
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
exposed completely. hoisting process for the big cover using thrust
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Maintenance
Maintenance Process Quantity Standard
Item
d) Suspend out big cover bearing.
position; it should be
supported by sleeper.
placed upward if
possible.
well.
body.
sealant; it is not
surface is damaged.
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Maintenance
Maintenance Process Quantity Standard
Item
whose junction surface
contact condition.
i)Welding up and
machining should be
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
components which are The tortuosity and twist are forbidden, the non-
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
requirements.
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Maintenance
Maintenance Process Quantity Standard
Item
0.12mm.
Install the gear inside should set aside certain clearance whose
2.Assemble gear from 2. When the clearance of key top is too large,
4.Adjust shaft and bearing smaller than 60% and not smaller than 45%
shaft. 0.751.5mm.
6.Add lubricating oil for 6. Clearance between shaft and shaft end cover
generally.
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Maintenance
Maintenance Process Quantity Standard
Item
there is no oil leakage during rotation process.
0.05mm.
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
lube oil.
disassembly 1. Place the output shaft Take out output shaft, tap shaft end
of decelerator.
2.Disassemble input
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Maintenance
Maintenance Process Quality Standard
Items
parts.
3.Disassemble output
parts.
1. There should be no flaw and deformation
to the sequence of and 2. Various sealing part and junction face are
condition.
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3 Hoisting Equipments
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.
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
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
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Type and
NO. Name Unit Quantity Remark
Specification
HB1 T-6m
Lifting height:6m
Under 6m girder of crusher
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
is two tons
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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
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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;
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
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
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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
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
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.
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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
0.005D (D is wheel diameter) and the diameter difference with wheel should be
with gasket in order to guarantee there is 2~4 mm clearance between lower edge
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thickness due to the corrosion or abrasion of stress section, it should be
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4 Fuel Equipment Specification
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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
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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
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_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
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 ---
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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
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No. Items Unit Number Value
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
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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
Quantity 1 3
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Rated load-carrying of
12T 12T
suspension device
Travelling trolley model DX-3 DX-3
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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
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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
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
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No. Title Equipment Parameter Comment
Weight kg
Equipment L 1340 1780 2120 2630 3410
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
mm
Dust remover /
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No. Title Equipment Parameter Comment
proper heat
insulation
Dust removing
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
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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
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No. Title Equipment Parameter Comment
ash discharging
valve
Ash discharging
Star type
valve type
Ash discharging
valve 200*200
specification
Motor power of
valve Kw
Ash remover
rapping device
Ash hopper
rapping type
Specification of
rapping device
Ash hopper
power Kw
Dust remover
1.7
explosion hole
Anti-explosion
Screen
vent type
Size of anti-
mm
Anti-explosion Aluminum alloy
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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
1.10 matched pipe Only equipped for JJWM-180A Type dust remover
screw
Screw conveyor
LS-200
mode
Screw diameter: 200
Throughout 8m3/h
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