Port Coal Stockyard 1

Transcription

1 Port Coal Stockyard 1

2 General Description of the Facilities for Sale 1. 2 Stacker / Reclaimers Manufactured by Stephens Adamson. 1.2 Stacking 4,000 tons per hour. 1.3 Reclaiming capacity 1,500 tons per hour. 1.4 Boom Length Stacking / Reclaiming, 40 meters 1.5 Hydraulic and electric systems. 1.6 Power Supply, 6.2 KV. 2. Belt Conveyors conveyors: 232, 332, 231, 331, 333, 235, 515, Conveyors Length ranges between 16m and 881 m. 2.3 The motors manufactured by Ushpiz. The Gears manufactured by Thissen. Hydraulic clutches manufactured by Voith. Rubber belts width 1400mm and 1800mm, PLY 4-5, Class Coal Sorting System Includes 4 conveyors: 412, 413, 414, 415 Conveyors Length ranges between 16m and 84m. The motors manufactured by Ushpiz. High speed flexible coupling. Rubber belts width, 600mm and 1400mm, PLY 3-4 Class Vibrating Feeder...23 Manufacturer - IFE Dimension X2000mm. 3.3 Sorting Machine...24 Manufacturer - IFE Model - FV - 2VEG5 Banana Screen Dimension X2500mm 2

3 4. Towers Six towers designed for transferring bulk between conveyors. 4.2 Steel construction with steel sheet walls. 5. Control and Electrical Rooms Monitoring and control panels 5.2 Electrical panels 5.3 Distribution boards 6. Train and Trucks Loading station Train Mover Manufacturer Elbram (South Africa) 7.2 Diesel Engine, Conmins 277 HP at 1800 RPM 7.3 Tractive effort 150 KN 8. Detailing of spare part will be given in separate list 3

4 1. Stacker / Reclaimers STACKER / RECLAIMER 1. The terminal includes 2 Stacker/ Reclaimers, Type 3RS6.7.x The machines were designed by Stephens Adamson Company Canada. 3. The mechanical and electrical devices were supplied by various American and Canadian companies 4. The construction was manufactured and the machines were assembled by a local company, under the close supervision of the representative of the designing company. 4

5 5. Automatic operation for stacking and reclaiming coal, with different stacking methods. 6. Stacking rate, 4000 tons per hour, each 7. Reclaiming rate, 1500 tons per hour. 8. The main components of the machine: 8.1 The machine base consists of the travelling body of the machine. 8.2 Central frame, type C FRAME A two-way conveyor and a bucket wheel excavator system, for local reclaiming, is mounted on the 40m long boom. 8.4 Counterweight boom with concrete ballast that ensures the stability of the machine at any condition. 9. The main system of the machine: 9.1 The reclaiming coal from stack system, consists of bucket wheel and a two way conveyor with electric motors. 9.2 Hydraulic hoisting machinery 9.3 Luffing and sluing mechanism with electric motors 9.4 Travelling mechanism consists of 13 electric motors and gears. 9.5 Local electrical and control cabinet, control from the main control room. 10. Electric motors, power supply 6.2 KV. 5

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8 2. Belt Conveyors CONVEYOR Conveyor length 88 meters 2. Equipment: 2.1 Electric motor manufactured by Ushipz, 250 KW/ 1500 RPM. 2.2 The gear manufactured by Thissen, KCN 315/5/50; ratio 1:22,4 2.3 Hydraulic clutch manufactured by Voith FH high-speed flexible taper lock type PX coupling. 2.5 Stretching belt system 2.6 Two types of belt cleaners rollers drums meters of rubber belt, 1800 mm width, CLASS 630 PLY 4 8

9 CONVEYOR Conveyor length 110 meters 2. Equipment: 2.1. Electric motor manufactured by Ushipz, 250 KW/ 1500 RPM The gear manufactured by Thissen, KCN 315/5/50; 1:22, Hydraulic clutch manufactured by Voith FH high-speed flexible taper lock type PX coupling 2.5. Stretching belt system 2.6. Two types of belt cleaners rollers drums meters of rubber belt, 1800 mm width, CLASS 630 PLY 4 CONVEYOR Conveyor length 801 meters 2. Equipment: electric motor manufactured by Ushipz, 250 KW/1500 RPM gears manufactured by Thissen, KCN 315/5/50; ratio 1: Hydraulic clutch manufactured by Voith, 650 TVVY_XDIA 90/ couplings DIA 160/ DLA Stretching belt system tower 2.6 Two types of belt cleaners rollers drums meters of rubber belt, 1800 mm width, CLASS 1250 PLY 5 9

10 CONVEYOR Conveyor length 881 meters 2. Equipment: Electric motor manufactured by Ushipz, 315 KW/1500 RPM Gears manufactured by Thissen, KCN 315/5/50; ratio 1: Hydraulic clutch manufactured by Voith, 650 TVVY_XDIA 100/ Couplings DIA 160/ DLA Stretching belt system tower 2.6. two types of belt cleaners rollers drums meters of rubber belt, 1800 mm width, CLASS 1250 PLY 5 CONVEYOR Conveyor length 134 meters 2. Equipment 2.1 Electric motor manufactured by Ushipz, 200 KW/1500 RPM 2.2 The gear manufactured by Thissen, KCN 315/5/50; ratio 1:22, Hydraulic clutch manufactured by Voith FH high-speed flexible taper lock type PX coupling 2.5 Stretching belt system 2.6 Two types of belt cleaners rollers drums meters of rubber belt, 1400 mm width, CLASS 630 PLY 4 10

11 CONVEYOR Conveyor length 118 meters 2. Equipment: 2.1. Electric motor manufactured by Ushipz, 250 KW / 1500 RPM The gear manufactured by Thissen, KCN 315/5/50; ratio 1:22, Hydraulic clutch manufactured by Voith FH high-speed flexible taper lock type PX coupling 2.5. Stretching belt system 2.6. Two types of belt cleaners rollers drums meters of rubber belt, 1400 mm width, CLASS 630 PLY 4 CONVEYOR Conveyors length 118 meters 2. Equipment: 2.1. Electric motor manufactured by Ushipz, 250 KW / 1500 RPM The gear manufactured by Thissen, KCN 315/5/50; ratio 1:22, Hydraulic clutch manufactured by Voith FH high-speed flexible taper lock type PX coupling 2.5. Stretching belt system 2.6. Two types of belt cleaners rollers drums meters of rubber belt, 1400 mm width, CLASS 630 PLY 4 11

12 CONVEYOR Conveyor length 644 meters 2. Equipment: Electric motor manufactured by Ushipz, 250 r<w / 1500 RPM Electric motor manufactured by Ushipz, 110 r<w / 1500 RPM Gear manufactured by Thissen, KCN 315/5/50; ratio 1:22, Gear manufactured by Thissen, KCN 250/5/50; ratio 1:22, Hydraulic clutch manufactured by Voith, 650 TWYB-X DIA90/ Hydraulic clutch manufactured by Voith, 487 TVVYB-X DIA80/ Coupling DIA 120/ Coupling DIA 160/ Stretching belt system Two types of belt cleaners rollers drums meters of rubber belt, 1400 mm width, CLASS 1000 PLY 4 12

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14 3. Coal Storing System. Conveyor 412 sorted product / Conveyor 413 sorted product 1. Conveyors length 46 meters 2. Equipment: 2.1 Electric motor manufactured by Ushipz, 22 ~ / RPM FH high speed flexible taper lock type PX coupling 2.3 Stretching belt system 2.4 Cleaning belt system rollers drums meters of rubber belt, 600 mm width, CLASS 400 PLY The gear manufactured by Thissen, KDH 140 ratio 1:14 14

15 Conveyor 413 Excess Reclaiming 1. Conveyors length - 46 meters 2. Equipment: 2.1 Electric motor manufactured by Ushipz, 22 KW /1500 RPM FH high-speed flexible taper lock type PX coupling 2.3 Stretching belt system 2.4 Traveling mechanism 2.5 Cleaning belt system rollers d rums meters of rubber belt, 600 mm width, CLASS 400 PLY The gear manufactured by Thissen, KDH 180 ratio 1:56 Conveyor 414. Excess / Conveyor 415. Excess 1. Conveyors length 56 meters 2. Equipment: 2.1 Electric motor manufactured by Ushipz, 22 ~ /1500 RPM FH high-speed flexible taper lock type PX coupling 2.3 Stretching belt system 2.4 Cleaning belt system rollers drums meters of rubber belt, 600 mm width, CLASS 400 PLY The gear manufactured by Thissen, KBH 140 ratio 1:14. 15

16 Vibrating Feeder 1. Manufacturer IFE Company 2. Dimensions of the stainless feeder 2000X2000 mm. 3. The driving system consists of two electric motors, unbalanced GM 665 T. 4. Maximum feeding rate 200 tons per hour. 5. Feeding is controlled by a gate at the exit of the feeder. 6. The feeder is supported by steal cables, and at its base, by 4 springs. Sorting Machine 1. Manufacturer IFE Company. 2. Type: high speed linear movement vibrating sorting machine FV- 2VEG5 banana screen 3. Screen dimensions: 9000X2500mm. 4. The linear movement is caused by two unbalanced Electronic motors GM665T. 5. The screen is divided into three parts, with different sizes of openings: 5.1 The first part- 80mm X 8mm grooves. 5.2 The second part- 80mm X 14mm grooves. 5.3 The third part- 28mm X 28mm square openings. 6. The sorting machine was designed, originally, to sort coal into four particle sizes: Up to 6 mm, 6 to 12 mm, 12 to 24 mm, above 24 mm. At later stage, after the construction was completed, it was changed into 3 sizes: Up to 6 mm, 6 to 25 mm, above 25 mm. 16

17 4. Towers 17

18 Tower A three storey high, steel construction with steels sheet walls. 2. Tower 201 receives coal from conveyor The tower includes a special system that enables coal flow to conveyor 332, or alternatively, to conveyor The hopper in tower 201 receives coal from conveyor 414 that transports excess coal from the coal-sporting machine to industry. 5. The tower includes regular illumination system as well as emergency illumination system. 6. The maximum designed flow throw this tower is 4000 tons per hour, normally. 7. An ionizing radiation system is installed the tower, this system can detect obstructions in the tower, stop the coal feeding and prevent the flow into the tower. 8. A misting system (compressed air and water), which is mounted over the transferring hopper, prevents airborne dust and environmental pollution. Tower A three storey, steel construction with steel sheet walls. 2. Tower 301 receives coal from conveyor 332 that conveys the coal through a hopper to conveyor The hopper in tower 301 also receives coal from conveyor 415 that transports excess coal from the coal-sporting machine to industry. 4. The tower includes regular illumination system as well as emergency illumination system. 5. The maximum designed flow throw this tower is 4000 tons per hour, normally. 6. An ionizing radiation system is installed in the tower; this system can detect obstructions in the tower, stop the coal feeding and prevent the flow into the tower. 7. A misting system (compressed air and water), which is mounted over the transferring hopper, prevents airborne dust and environmental pollution. 18

19 Tower A three storey, steel construction with steel sheet walls. 2. Tower 302 receives coal from conveyor 331 that conveys the coal through a hopper to conveyor The tower includes regular illumination system as well as emergency illumination system. 4. An ionizing radiation system is installed the tower, this system can detect obstructions in the tower, stop the coal feeding and prevent the flow into the tower. 5. A misting system (compressed air and water), which is mounted over the transferring hopper, prevents airborne dust and environmental pollution. 6. The maximum designed flow through this tower is 1500 tons per hour. Tower A four storey, steel construction with steel sheet walls. 2. Tower 202 receives coal from conveyor 333, and 231, and conveys the coal through a hopper to conveyor The tower includes regular illumination system as well as emergency illumination system. 4. A misting system (compressed air and water), which is mounted over the transferring hopper, prevents airborne dust and environmental pollution. 5. The designed flow through this tower is 1500 tons per hour. 19

20 Tower A four storey, steel construction with steel sheet walls. 2. Tower 203 receives coal from conveyor The tower includes special system that enables coal flow to conveyor 515 and to the loading station, or alternately, back to the beginning, to tower 101. By conveyor The maximum designed flow through this tower is 1500 tons per hour. 5. The tower includes regular illumination system as well as emergency illumination system. 6. An ionizing radiation system, that detects obstructions in the hopper, is installed in the tower. 7. A misting system (compressed air and water), which is mounted over the transferring hopper, prevents airborne dust and environmental pollution. 20

21 5. Control and Electrical Rooms 21

22 Control Systems in the Control All the monitoring and control systems, that control the operational section of the terminal, are located at the second floor of the control building. These systems include: *The terminal conveyors operating system can be managed in three ways: - Combined operation of all the conveyors -Manual operation of the conveyors -Transferring the control to local operation, on site. *Two computers, displaying graphical detail and control display of the conveyor system. *Computerized fire alarm and extinguishing center in the electricity rooms, the electricity boards and the terminals administrative building. *A synoptic board that can display the operational state of the systems in the terminal. 22

23 PS 1 Electricity Rooms 1. PS 1- electricity rooms are located in the control building. 2. These electricity rooms are divided into three categories: 2.1 High voltage electricity room that receives electricity in voltage of 22KV, with switching systems. 2.2 The transformers system reduces the voltage from 22 KV to 6KV, 440V, 220V. 2.3 Low voltage switching system and the controllers of the entire conveying system of the terminal. 3. The high voltage electricity rooms are equipped, with fire and smoke detection system. 4. The low voltage electricity rooms are equipped, in addition, with automatic fire extinguishing system. 23

24 PS 2 Electricity Rooms 1. These electricity rooms are located in a two storey high, concrete and blocks building. 2. The high voltage switching system - 22KV, located at the bottom floor. 3. Three step-down transformers reduce voltage from 22KV to 6KV 440V and 220V, are located at the ground floor. 4. The low voltage switching system and the distribution system to all the facilities on the northern part of the terminal are located at the first door. 5. The high voltage electricity rooms are equipped, with fire and smoke detection system. 6. The low voltage electricity rooms are equipped, in addition, with automatic fire extinguishing system. 24

25 PS 4 Electricity Rooms 1. This electricity room is located in a one storey high building 2. The electricity room receives electricity in 6 KV from PS 1, reduces the voltage with a transformer to 380 V, and distributes the electricity, through a switching system, to the charging station system, and the water system that includes coal wetting, the fire extinguishing water reservoir and the terminals drainage system. 3. The electricity room is protected by an automatic fire and smoke detection and extinguishing system. 25

26 6. Trains and Trucks Loading Station Trains and Trucks Loading Station 1. The train and Trucks Loading Station was designed by South African company, Bateman material LTD ELB. 2. The station facilities were manufactured in South Africa, the constructions; the chutes and the erection were done by a local company. 3. The train and truck loading station is of FLAKS type, the loads of each rail wagon are weighed. There is also a loading alternative to tricks. 4. The main systems of the train and truck loading station: 4.1 A supporting construction of the stockpile silo and the loading facilities. 4.2 The coal stockpile silo. 26

27 4.3 A weight flask 4.4 A loading chute 4.5 Control system 4.6 Hydraulic systems 4.7 Coal sampler 5. The stockpile coal silo is located at the upper part of the 30 meters high construction. 6. The 380 cubic meters silo is constructed from steel sheets and reinforcing profiles. The feed rate to the silo, by a conveyor, is 1500 tons per hour. 7. The coal is poured from the stockpile silo to the weigh flak. The feeding rate of coal is monitored by control system. 8. Loading chute. As the train wagons move through the station, under the loading chute, the chute descends into the loading gate of the wagon, and deposits the coal across the wagon, in order to prevent coal spillage. The train moves at a controlled speed of 40 meters per hour without sopping through the loading procedure. 9. The loading of the weigh flask is performed between the train wagons. 10. The control system, based upon PHOTOCELLS, identifies the train wagon and monitors the gate opening of the silo and the weigh flask with a programmable controller; the gate of the stockpile silo, the weigh flask and the descent of the loading chute are operated by a double hydraulics system, with electrical control. 11. The coal sampler is comprised of six units supplied by TEMA Company. 12. Sampler SW Coal sample splitter. 14. Coal sample masher (particle size 20 mm). 15. Rotational splitter of the coal sample. 16. Coal sample masher (particle size 5 mm). 17. Coal sample splitter. 18. The feeding rate of the coal sampler is 153 kg coal every 2 minutes; it prepares 3 representative samples, 10 kg each, for every train delivery of 1900 tons. 27

28 7. Train Mover Train Mover 1. The train mover was designed and constructed by the South African company, Bateman Material Handling LTD ELB, as part of the train and truck loading system with a train and truck loading station. 2. The train mover has a Cummins diesel motor, type 60 T A83-G, 277HP AT 1800 RPM. 3. The diesel motor runs hydraulic pumps with two drive systems. 4. When the train wagons, pulled by the train mover, are empty of load, the train mover wheels are driven by hydraulic motors. 5. During the loading of the wagons, the train mover, moving through the train and truck loading station at a controlled speed, is driven by a system of hydraulic pumps and rams. 6. Remote control of the train mover, during the operation of the rams. 7. A closed circuit system monitoring the entrance and exit of trains to and from the loading station. 28

29 8. The train mover is equipped with computerized control systems. 9. The speed of the train mover, while powered by the hydraulic engines, is about 5 km/hr, and while powered by the rams in 400 m/hr. Train Mover Technical Specification Motor: Cummins Diesel Type 60 T A83-G- direct injection Diesel Motor Power: 277HP at 1800 RPM Drive System: Independent hydraulic circuits, one for each of 2 the rams or combined for the wheels (loading and shunting mode). Mass with ballast : 52 tons Load per axle : 26 tons Tractive effort Speed ranges: Wheel drive : 150 KN nominal : 0-7 Km/hr Km/hr 29

30 Ram drive : 0-8 m/min Hydraulic motors for wheel drive Axel mounted hydraulic motors Overall length between couplings: 7.44m Axel centers : 6.9 m Overall width : 3 m Hydraulic pump tyres : See hydraulic description Air compressors : 1 off- hydraulically driven Suspension : Yoke suspension Sequence control : AEG Hydraulic circuit : + 10 Mpa normal Design pressure : + 30 Mpa emergency 30