PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )

Presentation On:
Role of C&I in Stacker Reclaimer
&
Hydraulic System.
Participants:

DURGESH BAJPAI
Initials of the person who has
made theABHISHEK
ppt BHATTACHARYYA
Date
Version
By
TEAM POTENZA
( 2014-15 )

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Introduction :
LIFE LINE of Jindal Power Ltd. .....Hope everybody knows!!.

IT`S CCPC
Function of CCPC is to transport coal from
Mines end to main plant CHP.

Then what is the function of

Stacker & Reclaimer?
It stacks and reclaimsInitials of the
the coal personthrough
received who has
CCPC.
made the ppt
It acts as second lineDate
of defence in case of CCPC
breakdown for feeding stacked coal to bunkers for
Version
uninterruptable generation of power.

SO STACKER RECLAIMER IS AS IMPORTANT AS CCPC

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 PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Introduction :
• Bucket wheel Stacker Reclaimer travel on rail track alongside the piles of coal.
• Offers potential to selectively stack and reclaim coal in different stockpile section. Carried
out in two quadrant (direction) on both sides of the track.
• The travelling arrangement have compact geared motor having disk brake system. In our
system Long travel is controlled by VVVF drive system.
• There is rail clamping arrangement to safely secure the machine during cyclonic weather.
• An anemometer is installed on top of the machine to indicate the wind speed in the
operators cabin.
• The slewing drive arrangement have two drives with suitable braking arrangement.
• The machine has capability of slewing through + 105°.
• It has automatic lubrication system with lubrication flow indicators at various points.
• The luffing system has two hydraulic cylinders.
• The hydraulic system has independent pressure indicators for hydraulic cylinders. An
equaliser is provided to balance the pressures in both the cylinders.
• In the event of difference in pressure between hydraulic cylinders, a trip device is
provided to trip the hydraulic system.
• The bucket wheel provided is cell less type & nos. of buckets provided is generally 8.
• Capacity of the bucket wheel is such that it can handle required capacity per hour
continuously.

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )

Main Parts of Stacker & Reclaimer :

 LONG TRAVEL ARRANGMENT.  LUBRICATION SYSTEM.

 SLEW BEARING.  RAIL CLAMP.
 SLEW RING GEAR.  OPERATOR CABIN.
 BOOM  E-HOUSE.
 BOOM HEAD.
 COUNTER WEIGHT.
 CONVEYORS.
 HYDRAULIC POWER PACK.
 BUCKET WHEEL.

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 PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Typical Structure :
INNER BOOM UPPER MAST
LINK CWT
BOOM LINK
Operator
Cabin SLEW DRIVE GEAR BOX
with
BOOM MAST STAY
Electrical
CONVEYOR
items
TRIPPER STRUCTURE
Bucket Wheel
assembled
with Buckets ELECTRIC GANTRY
& Chute

SLEW DECK
SLEW RING
BASE FRAME

Top of rail, EL(+)0416

COMPENSATING
BEAMS
10-BOGIE WHEEL
TRIPPER LEGS
ASSY
6-BOGIE WHEEL ASSY EQUILISING BEAM

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Specifications :

1. General Particulars

2. Travel Gear

3. Slewing Gear

4. Bucket Wheel

5. Conveyor System

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
1.1 Material to be handled : Coal
General Particulars : 1.2 Bulk density, vol / wt basis, t/m3 : 0.8 / 1.2
1.3 Capacity, rated / design, t/hr
a. While stacking : 3000 / 3000
b. While reclaiming : 3000 / 3000
1.4 No. of stockpile : Four
1.5 Total length of each stockpile, M : 626/570
(Bottom of stockpile)
1.6 Width of stockpile at base, M : 50
1.7 Max height of stockpile, MM : 10000
1.8 Machine travel, M : 580.6/ 524.6
1.9 Centre distance of track, M : 8.2
1.10 Rail section : IR 52
1.11 No of support points :4
1.12 Distance from machine centre to
Bucket wheel centre M : 41
1.13 Total service weight of machine : 385 T
1.14 Wind pressure considered :
a) While operating : 0.25 KN/M²
b) Non-op. (Anchored position) : 1.5 KN/M²
As per IS- 875
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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
2.1 No. of wheels M/c & Tripper : 50
Travel Gear : 2.2 No. of driven wheels : 20
2.3 Wheels diameter, mm : 500
2.4 Max wheel Load during operation : 20.2 T
2.5 Travelling speed, m/min : 1.5 -15
2.6 Rail clamp : Hydraulic & Manual
2.7 Drive Details
a) Motor KW : 7.5KW, 10 Nos.
b) Coupling Type : Flexible coupling
Make : NAW
Model : C5 (SPL)
c) Brake Type : Electro Hydraulic
Model : EBTM 200/H
Brake drum dia : 200 mm.
Braking set Torque : 3.82 KGM
Make : Electromag
d) Gear box Type : Bevel-helical shaft
mounted.
Make : Elecon
Model : NK-KCUH 180 (SPL)
Ratio : 90:1
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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Slewing Gear :
3.1 Max. Slewing speed at BW tip : 6 - 30 m/min at Bucket wheel tip
3.2 Slewing Range : +/- 105o
3.3 Slewing gear PCD, mm : 4400
3.4 No. of teeth / module : 220/20
3.5 Drive Details:
a) Hydraulic Motor : CB280240SADNOC
: Torque 240 NM/ bar
: Displacement 15.1 I/rev
: Max pressure 350 bar.
b) Hydraulic Power pack :
Pump : SP-71
Max flow at 1485 rpm : 105 lit/min
Max pressure : 350 bar
Motor : 37 KW
Speed : 1485 rpm
c) Slewing Bearing Make : Rotherde, Double row ball Roller
Combination bearing with External gear rim

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Bucket Wheel :
4.1 Cutting Circle dia, M : 8.2
4.2 No. of discharges, / Min. : 52 approx.
4.3 R.P.M. : 6.5
4.4. Cutting speed, M/sec. : 2.8
4.5 Type of bucket : Cell-less
4.6 No. Of buckets :8
4.7 Bucket Vol, Net : 1300 lit
4.8 Bucket wheel inclination : 10o
4.9 Drive Details
a) Hydraulic Motor : CB 840 800CAONOO
: Torque 800 NM/bar
: Displacement 50.3 I/rev
: Max pressure 350 bar.
b) Hydraulic power pack
Pump : SP250
Max flow at 1485 rpm : 375 lit/min
Max pressure : 350 bar
Motor : 160 KW
Speed : 1485 rpm
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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Conveyor System :
5.1 Bucket wheel boom conveyor
5.1.1 Flow rate, rated / design, T / Hr. b) Coupling Type : Fluid Coupling
a) While stacking : 3760/3760 Make : Fluidomat Ltd.
b) While reclaiming : 3760 Model : SMDx-9/584/500
5.1.2. Belt width, mm : 1800 Oil Qty : 20 Ltrs.
5.1.3 Belt speed, M/sec. : 3.4 M/sec. c) Brake Type : Electro Hydraulic Thruster.
5.1.4 Belt slope, deg. : + 6.0 / -9.0 Model : EBTM 300/C
5.1.5 Max. Tensioning distance : 300 mm Brake drum dia : 300 mm.
5.1.6 Top of rail from bottom of : 1000 mm Braking set Torque : 140Kgm
Stockpile Make : Electromag
5.1.7 Belt : EP-1000/4 FR Grade 5/3 mm d) Gear box Type : Hollow Shaft Bevel helical
5.1.8 Drive details Make : Elecon
a) Motor KW : 160 x 1 no. Model : KCH-280
RPM : 1500 Ratio : 18: 1

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Conveyor System :
5.2 Intermediate conveyor
5.2.1 Flow Rated / design, T / Hr. : 3760 d) Gear box Type : Hollow Shaft Bevel helical
5.2.2 Belt width, mm : 1800 (Hold back)
5.2.3 Belt speed, M/sec. : 3.4 M/sec. Make : Elecon
5.2.4 Belt slope, deg. : +12.1 (approx) Model : KCH-280
5.2.5 Max. Tensioning distance : 600 mm Ratio : 18: 1
5.2.6 Belt : EP 1000/4 Cover 5/3 FR Grade
5.2.7 Drive details
a) Motor KW : 160 x 1 No.
RPM : 1500
b) Coupling Type : Fluid Coupling
Make : Fluidomat Ltd.
Model : SMDX-9, 584/500
Max. Oil quantity : 20 Ltrs.
c) Brake Type : Electro Hydraulic Thruster.
Model : EBTM 300/C
Brake drum dia : 400 mm.
Braking set Torque : 140 Kgm
Make : Electromag
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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Conveyor System :
5.3 Cross conveyor
5.3.1 Flow Rated / design, T / Hr. : 4000
5.3.2 Belt width, mm : 2400
5.3.3 Belt speed, M/sec. : 1.67 M/sec.
5.3.4 Belt slope, deg. : Horizontal
5.3.5 Max. Tensioning distance : 150 mm
5.3.6 Belt : EP 630/4 FR, 5/3
5.3.7 Drive details
a) Motor KW : 37 x 1 No.
RPM : 1500
b) Coupling Type : Fluid Coupling
Make : Fluidomat Ltd.
Model : SMDX-6,471/415
Max. Oil quantity : 10 Ltrs.
c) Gear box Type : Hollow Shaft Bevel
helical
Make : Elecon
Model : KCH-225
Ratio : 28: 1
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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )

VFD Controlled Slew & Long Travel operation. :

Slew operation. :
• VFD INSTALLED : YASKAWA,CIMR-F7A4030,400 V-30KW
• USED FOR CONTROLLING THE SPEED OF SLEW DRIVE MOTORS.

Slew left / Right Permisives :

• SLEW LEFT / RIGHT FULL HEAVY DUTY LIMIT SWITCH NOT OPERATED.
• SLEW LEFT / RIGHT OVER TRAVEL HEAVY DUTY LIMIT SWITCH NOT OPERATED.
• SLEW / LUFF ENVELOPE ACTIVE : YARD CONVEYOR CLEAR FROM BOOM COLLISION
THROUGH LIMIT SWITCH PROTECTION.
• BOOM OVER RAISE / UNDER BENCH LIMIT SWITCH (DOWN :9°, TOP:6°) OF BOOM
WHILE LUFFING SHOULD NOT BE OPERATED.
• SLEW VFD HEALTHY

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )

VFD Controlled Slew & Long Travel operation. :

Long Travel operation. :
• VFD INSTALLED : YASKAWA,CIMR-F7A4090,400 V-90KW FOR CONTROLLING
18 NOS. OF MOTORS.
• USED FOR CONTROLLING THE SPEED OF LONG TRAVEL DRIVE MOTORS.

Long Travel Permisives :

• MPCB ON FEEDBACK OF ALL 18 NOS. MOTORS.
• MPCB NO TRIP FEEDBACK OF ALL 18 NOS. MOTORS.
• STACKER RECLAIMER GENERAL HEALTHY
• LONG TRAVEL ELECTRICAL HEALTHY
• LONG TRAVEL VFD HEALTHY
• LONG TRAVEL EMERGENCY STOPS HEALTHY
• LONG TRAVEL VFD INPUT CONTACTOR ON FEEDBACK HEALTHY
• LONG TRAVEL BRAKE OVERLOAD HEALTHY

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Yasakawa VFD:

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )

C&I Scope in Stacker & Reclaimer :

• PLC SYSTEM • HUGGLAND POWER PACK.

• HMI FOR OPERATOR • EATON POWER PACK.
• AC DRIVE FOR LONG TRAVEL • RAIL CLAMP POWER PACK.
• BELTWEIGHER • CRD
• WIRELESS SYSTEM FOR • LIMIT SWITCH FOR VARIOUS
COMMUNICATION WITH PROTECTION
CHP PLC • SAFETY SWITCH FOR
CONVEYOR

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Cable Reeling Drum of Stacker & Reclaimer :

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )

Cable Reeling Drum System:

The reel acts to maintain adequate cable tension during all modes of operation. This is
achieved using one torque motor that produces a constant torque from zero speed to ±
nominal speed. Brake mounted on the motor acts to prevent the cable unwinding when the
motor isn’t operating.
The fan motor is to continue operate when the motor is running

FEEDBACK
The following feedback signals are provided:

Motor over-temperature, Reel full, Reel empty, Cable undertension, Cable overtension,
Cable direction

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Cable Reeling Drum System:
Major C&I Items
A geared rotary limit switch mounted in the collector housing acts to indicate reel full and
reel empty conditions.
The reel full switch(BF1) is used to bypass the under tension switch on the cable guide as
the machine moves over the feed point.
The reel empty switch(BF2) is set to trip when the last turn of cable is reached on the reel
drum. It should only trip if (a) the machine limits fail or (b) the cable is snagged at some
point resulting in it being pulled from the reel instead of recovering. Tripping of this switch
should immediately stop machine travel to prevent damage to the cable/hose.

The under tension switch(BG3) is actuated whenever the reel fails to recover the cable.
Tripping of this switch should immediately stop machine travel to prevent damage to the
cable.
The over tension switches(BG4) are actuated whenever the tension in the cable becomes
excessive. Tripping of either of these switches should immediately stop machine travel to
prevent damage to the cable.
The anti-condensation heater mounted in the collector need to be energised at all times.
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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Cable Reeling Drum System: Protection:

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )

Electrical / C&I Sections of Stacker & Reclaimer :

E-HOUSE

MCC / DRIVE / PLC PANEL

FIELD

OPERATOR CABIN HMI

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
MCC PANEL / DRIVE PANEL / PLC PANEL

AUXILLIARY FEEDER

LIGHTING TRANFORMER

CONTROL TRANSFORMER

MAIN FEEDER ACB

MOTORS FEE DERS

HPP LUFF,SKIRT CHUTE CRD,RAIL CLAMP,BOOM MOTOR

BUCKET WHEEL,SLEW MOTOR,OIL COOLER

BOOM BRAKE

SPARE FEEDERS

AC VFD DRIVE

PLC PANEL

UPS

BATTERY

LAP TOP

AC

PA SYSTEM

DBR FOR DRIVE

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )

OPERATOR JOYSTICK
CONTROL
BUCKET (
LUFF SLEW
CLOCKWISE LONG
( UP,DOWN ) CLOCKWISE
& TRAVEL
& CABIN /ANTICLOCK
ANTICLOCK MOVEMENT
(UP,DOWN) WISE
WISE )

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )

Instrumentation :
➢ Protection Instruments: Pull Cord Switch, belt Sway switch, Zero
speed switch, emergency stop switch, Heavy Duty Limit switch,
Pressure Switch, Temperature switch, Temperature sensor, Level
switch.
➢ Measuring Instruments: Temperature Sensor, Belt weigher,
Anemometer, Encoder

➢ Control Room / Op Cabin Instruments: PLC, VVFD, HMI, JOYSTICS

Redundancy :
Stacker / Reclaimer operation can be done through both hardwired (fiber
optic cable) mode as well as wireless communication thus providing
redundancy.

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Instrumentation : Protection Instruments:
(1) Pull Cord Switch – Pull cord type (manually reset type) emergency stop switches are
located on both sides of belt conveyors along the walkways for the entire length of
conveyors for emergency stopping of conveyor.
(2) Belt Sway Switch – Belt Sway switch of self resetting type is furnished at periodic
intervals to limit belt sway to permissible extent.
(3) Zero Speed Switch – Zero Speed switch is non-contact (Proximity) type electronic
switch. If the belt speed falls below 85% of the normal speed, the zero speed switches will
initiate TRIP command and stop the conveyor to prevent any damage to the belt.
(4) Heavy duty Limit Switch – Heavy duty limit switches act as safety switches for stopping
machine or motion of an object at desired position.
(5) Pressure Switch – Pressure switches act as safety switches for machine protection
through interlocking in electrical circuit / PLC signals.
(6) Temperature Switch – Temperature switches act as safety switches for machine
protection through interlocking in electrical circuit / PLC signals by detecting set
temperature.
(7) Level Switch – Level switches act as safety switches for machine protection through
interlocking in electrical circuit / PLC signals by detecting set levels.
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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Instrumentation : Measuring Instruments:

(1) Temperature Sensors- Measure the amount of heat energy or even coldness that is
generated by an object or system, allowing us to “sense” or detect any physical change to
that temperature producing either an analogue or digital output.
(2) Belt Weigher- Belt Conveyors are accepted means of moving bulk materials in Process
Industries. With the advent of this fast mode of transportation, accounting the quantity
of material transferred assumes great importance. Since weight remains as the most
reliable index of material accounting and can be measured directly and precisely.
The material passing over a Belt Conveyor exerts a downward force proportional to its
weight. The product of this force and the speed of the belt is the rate of flow, the unit
being Kg/min. or Tonnes/hour.
(3) Anemometer-This Anemometer is fixed type, non portable, suitable for Safe Area (Non
Hazardous). It is suitable for Mobile Cranes, Stacker / Reclaimers and other Heavy
Equipments which move on rail.
(4) Encoder- It is an electrical mechanical device that converts linear or rotary displacement
into digital or pulse signals.

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Control Room / Op Cabin Instruments:
PLC System :
PLC,SCHNEIDER,CPU,140CPU67160
PLC,SCHNEIDER,DI,DDI84100,10-60V DC IN
PLC,SCHNEIDER,DO,DDO84300,10-60VDC OUT
PLC,SCHNEIDER,NETWORK BUS,140 NOE77101

VVVF Drive System :

VFD,YASKAWA,CIMR-F7A4090,400 V-90KW : S/R1 Long Travel
VFD,YASKAWA,CIMR-F7A4030,400 V-30KW : S/R1 Slew drive

HMI :
SCHNEIDER HMI MODEL-XBTGT5330,SIZE:10.4 INCH,
MAKE:SCHNEIDER MEGLIS,FOR TRF SRACKER
RECLAIMER(CHP(I)) LOCATED AT OPERATOR CABIN.

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
PLC System :
CPU FOR PLC,MODEL - 140CPU 67160,
MODICON QUANTUM, FOR PLC S/R
NETWORK INTERFACE BUS MODULE
(ETHERNET),MODEL - 140 NOE 77101,
MODICON QUANTUM, FOR PLC S/R

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
HMI :
SCHNEIDER HMI MODEL-XBTGT5330,SIZE:10.4 INCH,
MAKE:SCHNEIDER MEGLIS,FOR TRF SRACKER RECLAIMER
(CHP(I))
USED FOR BOTH CONTROL AND
ANNUNCIATION.
VVVF Drive System :

• From fixed input voltage &

frequency, provides variable output
voltage & frequency.
• Used for speed control.
• Provides soft start, controlled ramp
up and down.
• Dynamic braking.
• Make: Yasakawa F7, Siemens.

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Stacking & Reclaiming Operational Check :
• STACKING OPERATION • RECLAIMING OPERATION

• 1. E-HOUSE ELECTRICAL HEALTHTY. • 1. E-HOUSE ELECTRICAL HEALTHTY.

• 2. CABIN MCC INCOMER ON AND CONTROL ON • 2. CABIN MCC INCOMER ON AND CONTROL ON AND
ALL ELECTRICAL STATUS OK.
AND ALL ELECTRICAL STATUS OK.
• 3. SELECT SELECTOR IN RECLAIMING MODE.
• 3. SELECT SELECTOR IN STACKING MODE.
• 4. HMI CHUTE GATE PUMP ON AND CHANGE ALL THE
• 4. HMI CHUTE GATE PUMP ON AND CHANGE GATE IN RECLAIMINGK MODE AND ENSURE ALL GATE IN
ALL THE GATE IN STACKING MODE AND ENSURE RECLAIMING MODE IN HMI.
ALL GATE IN STACKING MODE IN HMI. • 5.HMI BOOM MOTOR START IN REVERSE MODE AFTER
• 5. HMI BOOM MOTOR START ON IN FWD ENSURING YARDCONVEYOUR RUNNING (( before that all
pull cord/belt sway/zss in OK condition).
MODE( before that all pull cord/belt sway/zss in
• 6.HMI SLEW/BUCKET/OIL COOLER MOTORS ON ( before
OK condition). that all interlock healthy).
• 6.HMI SLEW/OIL COOLER MOTORS ON ( before • 7. HMI LUFF MOTOR ON.( Boom is not in crossing zone).
that all interlock healthy). • 8. RAIL CLAMP OPEN ( Rail clamp released).
• 7. HMI LUFF MOTOR ON.( Boom is not in • 9. LT VFD OK.
crossing zone).
• 8. RAIL CLAMP OPEN ( Rail clamp released).
• 9. LT VFD OK.

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Stacking & Reclaiming Interlocks :
• STACKING INTERLOCKS • RECLAIMING INTERLOCKS

• 1. BOOM IN RIGHT AND LEFT STACKING ZONE • 1. BOOM IN RIGHT AND LEFT STACKING ZONE
i.e NOT IN CROSSING ZONE. i.e NOT IN CROSSING ZONE.
• 2.OIL COOLERS MOTORS ON BEFORE STARTING • 2.OIL COOLERS MOTORS ON BEFORE STARTING
SLEW MOTOR. SLEW/BUCKET MOTOR.
• 3.ALL CHUTE GATE IN STACKING MODE TO • 3.ALL CHUTE GATE IN RECLAIMING MODE TO
START BOOM MOTOR IN FWD DIRECTION. START BOOM MOTOR IN REVERSE DIRECTION.
• 4.YARD CONVEYOUR WILL START ONLY WHEN • 4.BOOM MOTOR WILL START ONLY WHEN
BOOM MOTOR IN RUNNING. YARDCONVEYOUR IN RUNNING CONDITION.
• 5.BOOM WILL NOT SLEW WHEN BOOM LUFF IS • 5.BOOM WILL NOT SLEW WHEN BOOM LUFF IS
NOT YARDCLEARANCE ZONE. NOT IN YARDCLEARANCE ZONE.
• 6.YARD CONVEYOUR WILL STOP WHEN BOOM • 6.BOOM MOTOR/BUCKET WILL STOP WHEN
MOTOR STOP. YARDCONVEYOUR STOP.
• 7. LT MOTORS RUN WHEN RAIL CLAMP IN OPEN • 7. LT MOTORS RUN WHEN RAIL CLAMP IN OPEN
CONDITION. CONDITION.

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 PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Hydraulic System :
It deals with Generation, Transmission and Control of power using pressurized fluid.
It covers the physical behaviour of fluids in motion.
It is generally used for precise control of large forces.

Important properties of fluids-

1.Shapelessness: liquids have no natural shape. They conform to
the shape of the container. So they can be easily transferred from
one location to other through pipes.
2. Incompressibility: liquids are essentially incompressible.
They regain their original volume once force is removed.
So there is no permanent distortion.
3. Transmission of force: the force is transmitted almost equally and
undiminished in all directions.

Pascal’s Law
Magnitude of force transferred is in direct proportion to its surface area.
i.e. Pressure = Force/Area

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Hydraulic System :

Advantages Disadvantages

􀀹 High output force 􀀹 Fluid might leak out

􀀹 Accurate hydraulic pressure 􀀹 Fluid will degrade due to heat
􀀹 No corrosion 􀀹 Fluid flow speed is limited
􀀹 Continuous variable 􀀹 Pipes are complicated
transmission 􀀹 Working fluid is often
flammable.

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Components in the Hydraulic system:
➢Pump to generate hydraulic power input (flow generator)
➢Motors or cylinders to obtain useful mechanism output (actuators)
➢Valves to control the direction, pressure and level of the applied power
➢Connections to join system components and provide power conductors.
➢Fluid media, namely liquid providing rigid and stiff control
➢Fluid storage and conditioning equipments (tank) to ensure quantity and
quality of fluid(Filter).
➢Accumulator

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Hydraulic System :

Schematic Symbols

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )

Poppet Valves:

Directional poppet valves consists of a housing bore in which one or more

suitably formed seating elements ( moveable ) in the form of balls, cones
are situated. When the operating pressure increases the valve becomes
more tightly seated in this design. With poppet the sealing is good.

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 PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Spool Valves:
Two-Way Valve ( 2/ 2 DCV):

Valve closed Valve opened by actuation

The spool valve consists of a spool which is a cylindrical member that has large diameter
and machined to slide in a very close- fitting bore of the valve body
The spool type of valves allows very fine control or throttling of flows.
The sealing is not very good.

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 PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Pressure Relief valve

Its primary function is to limit the system pressure. Relief valve is found in practically all the
Hydraulic system. It is normally a closed valve whose function is to limit the pressure to a
specified maximum value by diverting pump flow back to the tank.

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Hydraulic System :
Hydraulic systems are closed systems, always recirculating the same
oil.

control
cylinder filter
valve
hydraulic

cylinder
oil pump valves
motor oil
reservoir
oil
relief valve
reservoir

pump

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )

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Instrumentation :

Electronic Pressure • Diaphragm pressure switch Hydro-electric pressure switch

Switch/ Transmitter

PISTON PRESSURE SWITCH

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )

Instrumentation :

Level Switch Temperature sensor Accumulator

Pressure Gauge Temperature Gauge Clogging Indicator

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )

Hydraulic System :

WARNING :

1. Low Oil Level

2. Oil Temp at 55 deg C
3. Filter Clogging Indicator for Drain & Pressure line
4. High Pressure

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Hydraulic System :

SHUTDOWN :

1. Very Low Oil Level

2. Oil Temp above 65 deg C
3. Suction Line valve closed FB
4. Charge Pressure Low at below 8bar
5. Emergency Stop PB applied

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Hydraulic Power Pack System :

Hagglunds Drive for Bucket

Wheel & Slew operation

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Hydraulic System :
General data
Weight complete, oil tank empty: ~3300 kg Brake circuit filter
Main voltage: 4150 V ± 10% / 50 Hz ± 5% Contamination switch: p 5 bar
Tank oil volume: 600 l (Signal lock-out at oil temperature < 30°C)
Oil level switch By-pass: p 7 bar
Level from tank top: Low 200 mm Air/Oil cooler: HDCA 710-6
Min 265 mm Ambient temperature, design: max 50C
Temp. Sensor: Pt100 Electrical motor power: 5,5 kW
Settings in Spider: Max (Alarm) 67C
High (Interlock) 65C
High (Warning) 58C
Start cooling 40C
Min (Alarm) 10C
Oil type, design: ISO VG 100
Return and drain line filters
Contamination switch: p 2.2 bar
(Signal lock-out at oil temperature < 30°C)
By-pass: p 3.5 bar
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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Hydraulic System :
PUMP UNIT 1; PUMP UNIT 2;
left hand side (Bucket wheel drive) right hand side (Slew drive)
Pump: SP250 Pump: SP71
Max flow at 1485 rpm: ~375 l/min Max flow at 1485 rpm: ~105 l/min
Max pressure: 350 bar Max pressure: 350 bar
Pump compensator pressure: 330 bar Pump compensator pressure: 310 bar
High pressure relief valves: 370 bar High pressure relief valves: 350 bar
(Crossover relief valves) (Crossover relief valves)
Charge pressure: 15 bar Charge pressure: 15 bar
Control pressure, internal: ~30 bar Control pressure, internal: ~30 bar
Charge pressure switch: 8 bar Charge pressure switch: 8 bar
System pressure transmitter, MAB-port: 4-20 System pressure transmitter, M1-port: 4-20 mA
mA / 0-400 bar / 0-400 bar
Electrical Motor Electrical Motor
Power: 160 kW Power: 37 kW
Speed: ~1485 rpm

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Hydraulic System :

BRAKE CIRCUIT
Pump: SNP2/11
Max flow at 1470 rpm: ~16 l/min
Pressure relief valve: 70 bar
Electrical motor: 3 kW (ABB)
Pressure switch: 60 bar

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Hydraulic Systems Installed at Stacker :
1. Hydraulic Power pack for BW Chute, Probe & O’ Cabin unit:
Motor : 3.7KW-V1-ABB
Pump : PGF1-2x/2,8RA01VP1
Coupling : 24/28-Rotex
Oil tank capacity : 63 Ltrs.
Cylinder for Bore dia. Rod dia. Solid length Stroke length
Cabin Levelling unit 63 mm 45 mm 965 mm 220 mm
Lifting BW chute 80 mm 45 mm 1010 mm 200 mm
Lifting probe 50mm 36 mm 1275 mm 840 mm
2. Hydraulic Power pack for Boom hoisting:
Motor : 37KW-B35-ABB
Pump : A10VS071TR-31
Coupling : 48/60- Rotex
Oil tank capacity : 630 Ltrs.
Cylinder for Bore dia. Rod dia. Solid length Stroke length
Boom hoisting unit 320 mm 200 mm 3700 mm 1500 mm

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Hydraulic Systems Installed at Stacker :

3. Hydraulic Power pack for Rail clamp:

Motor : 3.7KW-V1-ABB
Pump : PGH2-2x/006RE07VU2VP1
Coupling : 24/28-Rotex
Oil tank capacity : 63 Ltrs.
Cylinder for Bore dia. Rod dia. Solid length Stroke length
Rail clamp 80 mm 45 mm 630 mm 160 mm

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Hydraulic Systems Installed at Stacker :

4. HYD. CYLINDERS FOR BOOM LUFFING

1. Cylinder size : Dia 320 x 200 x 1500 stroke
2. Retracted length : 3700 mm
3. Protracted length : 5200 mm
4. Push load : 1246KN
5. Pull Load : 1053KN
6. Speed : 510mm/min

7. Maximum Operating pressures :

On piston side : 225 bar
On Rod side : 165 bar
Set pressure on cylinder : 160 bar (both ends)
Test pressure on both sides : 300 bar

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Hydraulic Systems Installed at Stacker :
5. OTHER HYDRAULIC CYLINDERS
5.1 Hydraulic cylinder for adjusting of operator’s cabin
Sr. Nos Description Particulars
1. Hydraulic Cylinder for adjusting operator’s cabin –size
: 63 dia. / 45 x 220 mm stroke
2. Retracted length : 965 mm
3. Protracted length : 1185 mm
4. Working pressure : 233 bar

5.2 For Bucket wheel chute

1. Hydraulic Cylinder for adjusting Bucket wheel chute - size
: 80 dia. / 45 x 200 mm stroke
2. Retracted length : 1010 mm
3. Protracted length : 1210 mm
4. Working pressure : 233 bar
5. Test pressure on both sides : 375 bar

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Hydraulic Systems Installed at Stacker :

5.3 For Probe adjustment

1. Hydraulic Cylinder for probe adjustment -size
: 60 dia. / 36 x 840 mm stroke
2. Retracted length : 1275 mm
3. Protracted length : 2115 mm
4. Working pressure : 233 bar
5. Test pressure on both sides : 350 bar

5.4 For Rail Clamping

1. Hydraulic Cylinder for rail clamping - size
: 95 dia. / 80 x 160 mm stroke
2. Retracted length : 630 mm
3. Protracted length : 790 mm
4. Working pressure : 160 bar
5. Test pressure on both sides : 250 bar

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Hydraulic Systems : SPIDER with cable holder

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )
Hydraulic Systems :
Supply 24V 10A Flash-memory 1MB (+1MB) Micro processor ARM7 Memory card for settings and
RAM-memory 1MB 32 bit Risc 33MHz drive log
Pumpdriver (+1MB)

Space for
RMS card

Heater Monitored relays for Fieldbus card

el.motor stop

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Instrumentation :

Directional control • Pressure differential indicators Hydro-electric pressure switch

valve WO for filters in pressure lines
• Backpressure indicators WO for
return line filters
• Electronic switching element

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4/3 proportional directional valves

direct operated, with electrical position
Feedback with integrated control electronics
Symbol of Proportional DC valve

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )

4/2 and 4/3 proportional directional valves

direct operated, with electrical position
feedback

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PROFESSIONAL CIRCLE PRESENTATION (4x250MW ) )

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Proportional valves modulate hydraulic or motion parameters according

to electronic reference signals.

Features
➢Direct operated proportional directional valve for the control of the direction and
magnitude of a flow
➢Operation is by proportional solenoids with a central thread and removable coil
➢Electrical(LVDT) position feedback improves performance
➢Sub plate mounting
➢Spring centred control spool
➢Robust construction similar to on/off directional valves
➢High flow capacity
➢Throttle area normally formed by notches cut into spool
➢Notch size and geometry determine flow capacity for a given housing
➢ Higher Power Limit
➢ Better Response Sensitivity
➢ Better Hysteresis < 0.3%

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Instrumentation :
HYDRAULIC PUMPS -WHAT DETERMINES THE TYPE OF PUMP
Gear Vane Piston Variable Volume Piston

Least MostExpensive
• Flow Required
• RPM’s the Pump will operate
• Hydraulic System Pressure Requirement
• Type of Hydraulic Valve [Open or Closed]
• Budget / Hours of Operation
• When full flow is not required, variable volume piston pumps are more attractive

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THANK YOU FROM POTENZA

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