JPL Coal Handling Plant

THE ENTIRE COAL HANDLING SYSTEM DIVIDED IN THREE

SECTION.

1. CHP-1 situated inside plant boundary, capacity 1500 TPH

2. CHP -2 situated mine end, capacity 1000 TPH

3. CHP-3 Cross country conveyor which collect crushed coal

from CHP Mine end at TP-5 and discharge the same at TP-3 of
CHP inside plant, capacity 1500 TPH
COAL FLOW DIAGRAM
JPL COAL MINES

CHP MINE END

CROSS COUNTRY
CONVEYOR

CHP PLANT END

COAL BUNKER

PULVERISER

BOILER
JPL Coal Handling Plant

CHP-2(Mine End)
 Line diagram
ABON CHAIN D.U.H.
SIZER FEEDER.
BC-1A,1B
BC-1E
TP-1 CH-2 SCREEN
BC-1F STEEL
BC-1N,1P BUN.
BC-1J HOUSE
TP-1A RBF
BC-2A,2B
COAL WASHERY
TP-2

BC-2C,2D BC7A,B
TP-6 TP-7
BUNKER BC-6A,6B BC-8
CH-1
BC-3A,3B TP-5
BC-5A,5B
TP-3 TP-4
BC-4A,4B Cross country conveyor
System description:

The coal (1000mm aprx.) from coalmines has been dumped at DUH where the
material feed on to chain feeder (02 Nos) that carries the material to Primary
sizer (02 Nos). Primary sizer crushes the material from 1000mm and converts in
to 250mm and discharges the material on to conveyer-1A/1B that carries the
coal to TP-1 and discharges on to conveyor-1C/1D. Through conveyor-1C/1D
the material has been taken to crusher house-2 where the material has been
processed from 250mm to 50mm by the help of Ring granulator (02 Nos) and
discharges on to conveyor-1N/1P and conveyor-1J.

The material discharges on to conveyor-1J has been carried to steel bunker of

capacity (5000T) and then the material carries to coal washery where the
material has been washed and again fed on to conveyor-1F which carries the
coal to crusher house-2 and discharges on to conveyor-1N/1P.
The material discharges on to conveyor-1N/1P has been carried to TP-1A and discharges on
to conveyor-2A/2B, which carries the material to TP-2 and discharges on to conveyor-
2C/2D. Conveyor-2C/2D carries the material to RCC bunker floor and then the material fed
in to bunker hopper with the help of traveling tripper (02 nos). Then the material from
hopper has been discharged to conveyor-3A/3B through rod gate and weigh feeder.
Conveyor 3A/3B carries the material to TP-3 and discharges on to conveyor 4A/4B which
carries the coal to TP-4 and discharges on to conveyor-5A/5B. Conveyor-5A/5B carries the
material to Crusher house-1 and discharges on to roller screen( 02 nos), then Ring
granulator(02 nos) which processing the material from 50mm to –20mm. And discharges on
to conveyor-6A/6B, but the undersized material if any are directly discharges on to
conveyor-6A/6B from roller screen. Conveyor-6A/6B carries the material to TP-6 and
discharges on to conveyor-7A/7B which carries the material to TP-7 and discharges on to
conveyor-8 which carries the material to TP-5 and discharges on to cross-country conveyor.
 DUMPER UNLOADING HOPPER
DUMPER UNLOADING HOPPER RECEIVE COAL FROM OPEN COST
COALMINES, TRANSPORTED BY TRUCKS AND WILL BE UNLOADED INTO
HOPPER AMONG THREE SIDE AT A TIME. DEVIDED IN TWO SECTION EACH
CAPACITY IS AROUND 120 MT.SIX DUMPER CAN BE DUMPED INTO
HOPPER AT A TIME.MAXIMUM COAL SIZE 1000 MM.

CHAIN FEEDER- 2 NOS

A conveyor comprising one or two endless linked chains with crossbars
or flights at intervals to move the coal or mineral. The loaded side of
the conveyor runs in a metal trough, while the empty side returns along
guides underneath. The material is transported on the conveyor partly by
riding on the chain and flights and partly by being scraped along in the trough.
MAKE: SWETHA ENGG
TYPE: FLIGHT BAR TYPE CF-1/CF-2
CAPASITY: 1000 TPH
 ABON SIZER
Low Speed Sizing Technology is the employment of a combination of high torque / low roll
speeds and tooth profiles to arrive at specified end product sizes with a minimum of fines
production.
ADVANTAGE:
ROM feed size up to 1500 mm (60”)
Capabilities in excess of 10,000 mtph
Minimal fines creation
Insensitive to clay and sticky materials
Pre-scalping of undersize not required
Exceptionally low headroom requirements
Simple infrastructure requirements due to minimal dynamic loads placed on the supports and structure
Ability to start up under a full load
Long wear life of consumable components due to positive bite and minimal feed slip.
TYPE & SIEZE: LOW SPEED SIZER/6492 X 2884 X 1100 MM
MAKE: ABON
CAPACITY :1000 TPH
MANUFACTURER:ABON ENGG
 COAL CRUSHER

• Working principle:
• Ring granulator crusher having nos. of ring hammers mounted to rotor disc in a
suspension. Due to centrifugal action coal is being crushed between wear plate and
hammer after crushing coal is being discharged to bottom conveyor through
cage/screen plate. Coal sizes is maintained by adjusting the wear plate.

• Coal will crushed into two stage, in first stage coal is crushed 250 mm to 50 mm and in
second stage 50 mm to 20 mm.

• NOS OF RING GRANULATORTYPE CRUSHER – 04 Nos.

Model: 1017U
Capacity: 1000 TPH.
Manufacturer: L&T Limited.
BELT CONVEYORS – 1200 width (6282 R mtr.)
Belt Conv. – 1A (length): 193 meter.
• Belt Conv. – 1B(length): 183 met.
• Belt Conv. – 2A/2B(length): 389 met. x 2 Nos.
• Belt Conv. – 3A/3B (length): 214 met. X 2 Nos
• Belt Conv. – 4A(length): 124 met.
• Belt Conv. – 4B(length): 113 met.
• Belt Conv. – 5A (length): 226 met.
• Belt Conv. – 5B (length): 232 met.
• Belt Conv. – 6A (length): 59 met.
• Belt Conv. – 6B (length): 65 met.
• Belt Conv. – 7A (length): 83 met.
• Belt Conv. – 7B (length): 72 met.
• Belt Conv. – 2C/2D (length): 117 met x 2 Nos
• Belt Conv. – 1C (length): 81 met.
• Belt Conv. – 1D (length): 86 met.
• Belt Conv. – 1N/1P (length): 92 met.
Belt Conv. – 8 (length): ( 1400 width) 438 mtr
DUST SUPRESION SYSTEM – 02 Nos.

Make: Kaveri Products

Manufacturer: Kaveri
Supplier: FFE Minerals, Chennai
TRAVELLING TRIPPER – 02 Nos.
Make: Domacls products
Type: Motorized Traveling type
Capacity: 1000 TPH
Travel speed: 15 m/min

METAL DETECTOR – 02 Nos.

Type: Electronic coil
Manufacturer: Electromag Device PVT. Ltd
INLINE MAGNETIC SEPARATOR – 3 Nos
Type: Electro Magnet, Inline arrangement.
Make: Power Build limited
mounted on Bc-3A ,3B, BC8

SUSPENDED MAGNET – 02 No.

Model: SMNR- 135/ 50 OA, SM 1 and SM-2
Manufacturer: Power Build limited

VIBRATING SCREEN – 02 No,

Type- Spring mounted,
Capacity- 500TPH,
mounted at screen house
JPL Coal Handling Plant

CHP-INSIDE PLANT
 COAL FLOW DIAGRAM – CHP INPLANT

DUH

Suspended
CONV 1 Magnet in CONV 2
Pent
TP 1
House

Stacker-
Reclaimer
StockPile
TP 3A

CONV 5

StockPile
CONV 5A TP 3 CONV
3A/B
TP 4A CONV 6

ILMS
CONV
4A/B

TP 4

TP 5
TRAVELLING TRIPPERS ON BUNKER
FLOOR
 System Description:
A Coal collected from DUH is discharged through rod gate, rack
& pinion gate & vibro feeder to conveyor –1 which carry the
material to TP-1 and discharge the material to conveyor-2.
Conveyor-2 carries the material to TP-3 where the material has
been discharge to conveyor-3A/3B and conveyor-5 through
flap gate.

The material discharge to conveyor-3A/3B has been carried to

TP-5 where the material has been discharge to conveyor-
4A/4B and then it carries to boiler bunker and traveling tripper
(04 Nos, 02 nos with conv.-4A & 02nos with conv-4B) has
discharged the material to bunker hopper.
The material discharge to conveyor-5 has been carried to stacker
where the material kept stock at coal storage yard located at both
side of stacker. At the time of feeding of coal from the coal storage
yard, the reclaimer take the coal from storage yard through bucket
wheel and feed on to conveyor-5 which carries the material to TP-3A
where the material discharge on to conveyor-5A. Conveyor –5A carries
the material to TP-4A and discharge on to conveyor – 6 which carries
the coal to TP-4 where the material has been discharge on to
conveyor-3A/3B and the material has been carried to bunker hopper
as mentioned above.

B) The material collected from cross-country conveyor at TP-3 has

been discharge on to conveyor-3A/3B and conveyor-5 through
reversible belt feeder. The material discharge to conveyor-3A/3B and
conveyor-5 has been processed to bunker hopper as mentioned above.
To feed 1500 TPH coal from DUH to coal bunker and stacker
cum reclaimer to coal bunker.

This system includes the following equipments: -

BELT CONVEYORS – 1400 width (running length 6741 mtr)

Belt Conv. – 1 (length): 163.44 mtr.

Belt Conv. – 2 146.39 mtr.
Belt Conv. – 3A/3B 321.13 mtr. x 2 Nos.
Belt Conv. – 5 667.75 mtr.
Belt Conv. – 5A 60.60 mtr.
Belt Conv. – 6 658.00 mtr.
Belt Conv. – 4A/4B 416.75 mtr x 2 Nos.
Belt Conveyor – 1600 width 7.85 mtr
 Stacker & Reclaimer
System Description:
A reclaiming and stacking system for conveying bulk material has an
elongated yard conveyor for moving the bulk material in the longitudinal
direction of the yard conveyor; a rail-mounted undercarriage straddling
transversely the yard conveyor; first and second booms supported, at their
respective inner ends, on the undercarriage. There are further provided first
and second boom conveyors supported on and extending along the first and
second booms, respectively; a bucket wheel supported at the outer end of
the first boom for removing bulk material from a pile spaced from and along
the yard conveyor and discharging it onto the first boom conveyor at the
outer end thereof; a central chute supported within the outline of the
undercarriage and having a discharge end oriented towards the yard
conveyor; a first transfer arrangement for directly transferring bulk material
from the inner end of the first boom conveyor to the inner end of the second
boom conveyor; and a second transfer arrangement for transferring bulk
material from the inner end of the first boom conveyor into the chute for
deposition onto the yard conveyor.
•ROD GATE – 03 Sets
Size: 1328 mm x 1528 mm, RG 1, RG 2, RG 3.
Make: Mining & Material Handling Equipment (P) Ltd. Kolkata.

•RACK & PINION GATE – 3 Sets.

Type / Size: Electro mechanical drive with geared motor, 1328 mm x 1528 mm.
Make: Mining & Material Handling Equipment (P) Ltd. Kolkata.
Capacity: 500 TPH.

•VIBRATING FEEDER – 3 Nos.

Type : Electro Mechanical, floor mounted.
•Location : Under dumper unloading hoppers .
•Bulk density (volumetric) : 0.8 MT/cu.m
• (equipment design) : 1.0 MT/ cu.m
•Capacity : 0-500 MTPH
Manufacturer: International Combustion.
• SUSPENDED MAGNET – 01 No.
Model: SM 1
Capacity: 50 Kgs. – max.
Manufacturer: Electro Zavod (INDIA) Pvt. Ltd. Kolkata.
INLINE MAGNETIC SEPARATOR – 02 Nos.
Model: ILMS 1 & ILMS 2.
Capacity: 50 Kgs.
Manufacturer: Electro Zavod (INDIA) Pvt. Ltd. Kolkata.
• BELT WEIGHER – 03 Nos.
Type: Microprocessor based Electronics
Capacity: 1500 MTPH
Manufacturer: Power Build Ltd.
SUMP PUMP – 03 Nos.
Model: KDS 25 MS 100
Type: Vertical, submersible non-clog type sump pump.
Discharge Capacity (cum/hr): 55 m3/hour each.
SCRAPPER. EXTERNAL & ENTERNAL

Make: Kaveri Products

Type: Enternal scrapper, Elasto mount type

TRAVELLING TRIPPER – 04 Nos.

Function of traveling to discharge the materials from running belt

into hopper at intermediate location. Capacity is 1500
TPH and speed is 15 Mtr/min

GEAR BOXES– 08 Nos.

Make: ELECON ENGG.CO.LTD.

Type: Bevel Helical, Base Mounted
Input motor speed (syn.): 1500
INSTRUMENTATION

Protection instruments
Measuring instruments
Control room instruments
Protection System

1. Zero speed switch

2. Sway system

3. Pull cord
 COAL SAMPLING UNIT

Location : Transfer point –5.

Quantity : 1 set.
Type : Automatic two stage.
Material temp. : 50 degree c max.& 5 degree min.
Belt width : 1400 mm.
Belt speed : 3.0 m/s

METAL DETECTOR – 02 Nos.

Type : Electronic coil,Location : On conveyor belt no. 4A & 4B
Conveyor capacity : 1500 MTPH (Rated & Design)
Purpose of installation : To protect Coal mill.
Manufacturer: PBL
 CONTROL ROOM INSTRUMENTATION
• PLC based control system shall be configured of 1:1 not redundancy having
CPU of word length 32 bits minimum & serial data link interface module
for connecting input /output modules,redundant communication processors,
memory modules & power supply units.
• The power supply shall be derived from single phase , solid state 240V +_1%
A.C. UPS with Ni-Cd type battery to provide power to system for at least 30
minutes in case of power black out.
• SYSTEM HARDWARE SPECIFICATION
• Type : Enclosed self supporting.
• Enclosure class: IP-42
• Card mounting: 21” rack
• Harmony cycle time: 0.5 micro second
• I/o port: DMA , Program control
 JPL Coal Handling Plant-3

Coal handling plant has a singe pipe conveyor system which collect
crushed coal from CHP Mine end at TP-5 and discharge the same at
TP-3 of CHP inside plant, capacity 1500 TPH
 Concept of Pipe Conveyor

Open Type, Troughed Belt conveyor system has been conventional mode of
materials transportation. In the recent years, Pipe conveyor system has
revolutionized the concept by introducing an enclosed materials transfer principle.

The steel cord belt take a shape of a pipe during forward and/ or return run and
flattens itself at the loading and discharge. The idlers are typically arranged in
hexagonal array with 3 roll on one side of module and the balance 3 rolls on the
other side.
 Advantage of Pipe conveyor

• Protection of environment against pollution hazards

• Protection of materials against Rain,Dust,Temperature, wind etc
• Elimination of spillage & wastage.
• Reduction of noise emission from conveyor
• Reduction of numbers of conveyor for transporting long distance
• Elimination of theft of coal during transportation.
• Higher carrying capacity compare to conventional conveyor.
• Reduction of numbers of transfer points.
• Lower maintenance and lower manpower
 Advantage of steel cord belt

• Steel cord belts consist steel cords between top and bottom
rubber layer with phoenotec reinforcement which have following
advantage over conventional nylon ply belt conveyor.
• High tensile strength:-The High tensile strength of steel cord
belt for much higher working tension requirement as compared
to conventional belt.
• Smaller Pulley Dia: High longitudinal flexibility require smaller
pulley dia
• Excellent Troughability: Steel cord belt even with very high
strength it perfectly conforms to the contour deep toughed idler
this insure proper belt training and maximum capacity utilization
• Long Life: steel cord belt provide long life by utilizing the high
fatigue strength of steel cords
 Specification of Cross Country Pipe Conveyor

Supplier: M/S Macmet India ltd

Designing: M/S Bridgestone
Engg Support: Prof. Manfred Hager,Germany

Total Length of Pipe Conveyor : 6948 Mtr

Belt Specification: Width: 1800 mm, Weight: 55 Kg/Mtr, Pipe Dia:500 mm,
Speed: 3.75 m/sec
Steel cord belt ST1800 x 8mm top x 5 mm bottom FR
Motor Rating: 4 x 650 KW, 690 volts
Belt Supplier: M/s Phoenix Germany
Materials Handled: Crushed Coal of –20 mm size

Belt Capacity: 1500 MT per Hrs

 Line Diagram of Cross country Pipe conveyor

Primary drive

Motor-1
Mot

Tail drive
Motor-3

Sec drive Balance Wt

Rope wire

Take-up Trolley Arrgt

 System description
The pipe conveyor of length 7 Km will be carrying coal from the belt
conveyor no.8 of mine end CHP to the plant end CHP at 1500 tph on
top side and will return empty from the plant end CHP to the mine
end on bottom side. The pipe Dia and the conveyor is 500 mm and
3.75 mps respectively.
The pipe conveyor at the ends will be flat from the receiving zone,
the troughing of the belt will be gradually increased and ultimately
the pipe will formed through pipe shape keeping modules.At
discharge end ,pipe will open out and will gradually become flat at
the terminal pulley.
Total nos of motors: 4
3 nos at drive end (plant end) and 1 nos at tail pulley(mine end)
Each of motor are of 650kw,690v with 1500 rpm rated speed and
each motor will run through separate vvvf drive units.
 Operation and control

Over all operation and control of cross country conveyor pipe conveyor
will be normally performed through 2 nos PLC based operator consol
with 20 “ monitor and one nos laptop based engineering station. The
main PLC is provided in the CHP control room in plant end and a remote
PLC I/O unit is located in the mine end. The main PLC is connected with
remote PLC I/o through optical fiber cable.
The additional one no. control desk is also provided in the CHP control
room for operation of pipe conveyor so that the conveyor can be started
or stopped through the desk.
 Startup of cross country conveyor

The conveyor will start when the following condition are met with
The discharge end conveyor is (on) and signal is available in PLC
All four motors are healthy and not in local maintenance mode
All four VVVF drive are healthy
All four transformer are healthy
Feeding conveyor at mine end (BC-8) is stopped
Limit switches in take up area and zero speed switches are healthy.
If above condition are met the conveyor is ready for sequential start. Indication will
be available and start signal can be given either from the OWS or control desk
push button.
Before starting of the conveyor an audible warning through hooter at TP-3 and TP-
5 will come to warn the operators working in any of equipments of conveyor.
 SEQUENCIAL STARTUP

Then all the four motors will get start signal simultaneously
through the PLC. However the drive at the mine end will be
started after a time lag of approximately 5 seconds. The
acceleration and deceleration time for these motors will be set
about 400 seconds and 200 seconds respectively. The speed
control for the drives will be achieved through VVVF unit. The
VVVF units will work under master & slave mode. One VVVF unit
will be considered as master and the other three will be acting as
slave.
 SYNCHRONIZATION

All the necessary inputs from the respective drive motor and
VVVF units will be made available in the PLC and the PLC will
give the necessary outputs to the VVVF drive units to follow the
master so that the synchronization of drives are made and the
torque is shared equally among all the drives. The VVVF drive
panel in turn adjust automatically to the requirement and
operate the conveyor drives in a synchronized manner for the
smooth running of the conveyor.
 SHUT-OFF PROCEDURE

• NORMAL SHUT-OFF

The stopping of the conveyor will also be controlled through

VVVF units under normal conditions. On giving the ‘Stop”
command the feeding conveyor at the mine end will stop first
and the succeeding pipe conveyor and discharge conveyor at
the plant side will stop in that sequence after a time lag.
 EMERGENCY SHUT-OFF

• During emergency condition that is when “Emergency switch” is

actuated or power failure occur, then there will be no controlled
stopping. This sudden stopping of the system will trigger the
“Disk brake” provided on the capstan shaft in take-up, through
gear & pinion arrangement. This will arrest movement of trolley
under emergency condition. After 10 seconds, the brake will be
gradually released so as to balance the tension of the system
and the applied tension.
 RF Communication Scheme Between The PLC and
Maintenance Trolley

• In order to facilitate the RF communication between the main PLC and the
maintenance trolley a data link radio with a small PLC operating in a specified
licence free frequency band will be provided in each maintenance trolley.

• Another radio link unit will be located in the main CHP control room which in
turn will be connected with the main PLC for the cross country conveyor
located in the control room

• The radio link unit will have compatible connectivity with the main PLC
unit.The radio link unit will have transmission range of about 15 km . The
antenna for the radio communication system in the maintenance trolley will be
located suitably on the side / top of the unit located in the control room the
antenna will be located suitably in the CHP control room building.
• As per repair / maintenance requirements the maintenance trolley traveling
on fixed rail will be started by the operator and moved to the desired
destination.On reaching the destination the trolley will be stopped. If the
operator cum maintenance man feels that the conveyor need to bestopped ,
then he will operate a switch provided in the trolley for that purpose.

• The switch contact will initiate the PLC input / output in the trolley and
transmit the data through the radio link in the trolley to the radio unit in the
main control room which in turn will initiate the main PLC circuit for
automatic stopping of the conveyor. The conveyor will now stop as per the
logic provided in main PLC.

• Similarly after completing the repair / maintenance work the opertor of the
trolley again operates a switch and the data will be transmitted to the control
room PLC , giving clearance for starting of the conveyor by an operator.
 MAINTENANCE TROLLEY

• Two no. mobile self driven trolleys will be provided for inspection , servicing
and maintenance of the conveyor .Drive for each trolley will be through
diesel engine , coupling , gearbox and wheels connected by chain & sprocket
arrangement .Trolley will be traveling along the tracks laid over the
conveyor gantries .Side guide wheels will be provided for stability and
additional safety of the trolleys .Necessary safety arrangements will be
incorporated in the trolley design including parking clamps.Operator cabin
will be adequate to accommodate four personnel in case of any major
maintenance work.

• The trolley platforms will be designed for good access to all parts of the
conveyor for the maintenance and servicing The trolley will be provided with
necessary lighting arrangement for night operation.Communication between
the trolleys and control room will be through walky talky.Provision for
carrying out welding work will be provided in the trolleys.Two no. parking
station , one each at power plant end and mine end will be provided for the
trolleys
 The pipe conveyor specifications are as follows

Conveyor length, pulley centers 7 KM

Overall lift 15.2 m
Belt speed 3.75 m/s
Conveyor capacity 1500tph (initial);
2100tph (future)
Belt Breaking Force Less then 26.4 KN
Pipe diameter 500mm
Belt width x thickness 1800mm x 18.4mm
Belt specification and covers ST1800 ,130 steel cord ,
5.5 mm dia
Horizontal radius 700m
Vertical inclination (max.) 300 m
Horizontal deflection 90 degrees
Location of take- upHead-end
Type of take-up Horizontal trolley, gravity mass
Take-up travel distance 25,0m live; 19,0m available
Take-up mass 12 tons
Belt type Steel cord conveyor belt
Phoenix ( Germany )
Installed power Head=3x650kW; Tail=1x650kW
VVVF Drive
High tension and
drive pulley diameters 1000mm
High tension pulley
face width 2000mm
Gearbox ratio (norminal) 20: 1
Type of reducer Flender –Bevel Helical gear
Motor type ABB 3 p squirrel cage induction
moter
Motor shift speed 0 – 1490rpm
Type of high and
low speed couplings Resilient Coupling, Flexible
geared couplings
Low tension / take-up
pulley diameter 1000 mm
Low tension pulley face width 2000mm
Idler diameter 127mm
Idler gauge length 305mm
Number of idlers per panel 12 off
Pitch of idlers – straight sections 2000mm
Pitch of idlers – curved sections
For Vertical inclination - 1000mm
For Horizontal inclination –1500
 Vulcanizing Arrangement
Phase-1

In Phase-1, laying of top and bottom belts between the discharge end (TP-3) and girder GR63 will
be done. The belt will be loaded on Belt decoiling equipment in front of the discharge (Primary
drive) Pulley. The belt pulling equipments viz. The derrick post, Deflection pulley, Electrically
operated winch, Guy ropes for stabilization and arresting ropes will be arranged below GR63 as
indicated in the sketch. The winch, deflection pulley and 2 nos. of guy ropes in position, will be
held in position by mounting them on R.C.C. Concrete blocks.

Wire rope of suitable size and length will be laid along the top pipe belt through the rollers fitted
in the modules. One end of the rope will be fixed to the winch and the other end to the belt
through special ‘conical pulling device’. This conical pulling device helps to form the pipe
configuration of the belt. Heavy duty straight roller need to be provided at the entry point of the
belt to avoid damage to the belt and to the structure as well.

The belt will be slowly pulled into the segmental rollers by operating the winch. The belt in pipe
configuration will be strapped at every 20 m to avoid the change of overlap. Similarly, the belt
edges will be specially treated to reduce the friction between the belt surfaces
After one full length belt laying is completed, the next belt will be loaded on the decoiling equipment
and both the belts will be joined on the ground by hot vulcanizing. The second belt will be then pulled
on to the conveyor structure. In the same manner, the top and bottom belts between the discharge and
GR63 will be laid.
Phase-2
The decoiling equipment and the vulcanizing equipments will be shifted to GR63 and the belt
pulling equipments to GR137 and grouted firmly.
As described earlier, the belts both the top and bottom pipe conveyor between these two box girder
locations will be completed.
Phase-3
Laying of belts between box girders GR 137 and GR 243 will be carried out in the same way as mentioned
above.
Phase-4

Laying of belts between box girders GR243 and the receiving station (TP-5). Afterwards the twist if any, in
both the bits right from the discharge end to the receiving end will be manually removed so that the
overlap of the carrying belt is on the top and that of the return belt is at the bottom of the pipe.
The free end of the beltings in girders 63, 137 and 243 will be jointed together at the ground after
inserting the required number of modules around the concerned belts.
 Pre-Final Joint

Both the top and bottom belts will be pulled towards the receiving end and the box girders 63, 137
and 243 have to be assembled to the conveyor system. Pre-final joint will be done on the conveyor
near the receiving end.

Final Joint

The belts will be tensioned, clamped and final joint will be done on the discharge structure of the
conveyor.
 Splicing Procedure of Steelcord Conveyor Belts

Calibration of vulcanising press, temperature control and accuracy

A test heating before delivery has to be conducted; most conveniently at the premises of the
manufacturer of the press. At least 15 thermocouples will be applied to each heating platen at the
contact surface to the splice. In between the platens a test belt is heated under site conditions.
All temperatures shall be recorded. Maximum deviation from the mean temperature must be within
 5°C in order to achieve an acceptably even level of curing. Thermocouples shall be arranged acc.
to figure 1.
Figure 1: Arrangement of thermocouples
During the test heating the pressure of the press and all mechanical features will be checked with
regard to their reliability. 2/3 x W HP

1/3 x WHP
1/2 x LHP

1/4 x WHP 50
1/2 x WHP
 Splicing Procedure of Steelcord Conveyor Belts

1. Both belt ends are aligned roughly on the splice table.

2. On both belt ends the complete splice dimensions are marked. In case of an oblique splice
the overlap length of the splice extends itself by about 0.3 x belt width.

3. Within the splice length the edge rubber is cut off up to the outer steel cords. This has to be
done on both belt ends.
4. One belt end is flipped back onto the working table to allow parallel working
5. Along the marking the belt cover lying on top is cut with a "Don Carlos“-knife under an
angle of approx. 45° up to the steel cords.
6. The cover rubber is peeled of under tension up to the steel cords in approx. 500 mm wide
stripes. A suitable tool for this operation is also a "Don Carlos“-knife.
7. After folding the belt ends the belt cover plates lying below are peeled of in accordance
with points 5 and 6.
8. At both belt ends the rubber between the steel cords is cut out up to the crosswise
oblique cut ("outfingering" of the steel cords). The square steel cord profile has to be cut in
a way that the metallic surface is visible.
9. The cords are roughened with hollowed out wire buff wheels.
•
10. Behind the oblique cut the exact belt center line has to be marked on both belt ends. Three dot
marks (reference points) in steps of approx. 1,5 m, which are measured on each belt end, are
necessary and helpful to align the center line.

11. The belt ends must be aligned exactly. Decisive within this procedure are:
- Observing and keeping the dictated splice length.
- Observing and keeping the minimum covering of the heating elements,
both in width and length.
- The center line dots on both belt ends (reference points) have to be
under true alignment.
This can be checked with a tensioned and chalked string line, see figure 1.

Left belt end Splice Right belt end

Line

1500 1500 50

Figure 1.: Splice alignment

12. Both belt ends are clamped in a way that a slipping out of the true alignment is impossible.
13. The splice ramps lying above are roughened with rotating wire buff wheels. The arising rubber
dust is removed with a banister´s brush or compressed air.
14. The belt ends with the "outfingered" steel cords are folded back and the steel cords are
arranged in a parallel way.
15. The splice ramps formerly lying below and now lying above are also roughened, (see point 12).
• 16. The splice ramps lying above and the "outfingered" steel cords of both belt ends are
cleaned, specially from attached roughing dust and other impurities.
• 17. The steel cords of both belt ends are coated with a special rubber solution thinly.
Important! Before continuing with the processing at the cords it is essential that the solution has
completely evaporated (checking with hand test). Do not use any cleaning solvent!

• 18. The Phoenix cover tissue "Vulkatrix" is laid out evenly on the lower heating elements. The
tissue must cover the total heating element length with a surplus of 300 mm in longitudinal
direction.
• 19. The cover plate, temporarily cut in width and length, is laid on the "Vulkatrix"-tissue.
• 20. The intermediate plate is laid on the roughly spread raw rubber cover plate. Afterwards
the intermediate plate is rolled up. If necessary the synthetic Phoenix reinforcement breaker is
laid between the cover and the intermediate plate and also rolled up.
• 21. The ramps of the folded back belt ends lying above are thinly coated with the special
rubber solution.
• 22. The length and width of the prepared raw rubber package consisting of cover and
intermediate plate (respectively cover plate, reinforcement breaker and intermediate plate) are
cut in such a way that the ramp of the folded back belt end overlaps approx. 10 mm with the
ramp of the raw rubber package. Also the distance between the ramps of both belt ends has to
correspond to the splice length. Before turning over the belt ends the ramps of the raw rubber
package are thinly coated with the special rubber solution.
• 23. The belt ends are turned over and the raw rubber package becomes a unit with the
vulcanized ramps. This unit is realized by hitting this area with a hammer.
• 24. On both belt ends the steel cords are counted and signed to determine the both middle
cords of the belt ends.
• 25. On the surface of the raw rubber package all the support lines which are necessary for
the splice manufacturing are marked with a chalk dusted string line. The dimensions of the
support lines are taken from the splice scheme.
• 26. Marking of the exact belt center line on the raw rubber package using the dot marks
(reference points) on both belt ends.
• 27. To keep the marked chalk lines visible they are dragged along with a pair of scissors or a
knife before they are coated with the special rubber solution.
• 28. The surface of the raw rubber package is lightly freshened with the special rubber
solution whereby the chalk lines are removed.
• 29. In accordance to the given splice scheme the steel cords are laid onto the raw rubber
package, beginning with the middle cords (the intermediate plate is laying on the top) and
pressed against each other. A special pair of cord scissors are used to cut the cords. Between
the cords, a stripe of intermediate rubber (called "noodle" or "record") is put in.
• 30. Any still existing gaps between the cords (e.g. in the cord transition zone and the gaps
between the cord tails) are filled out properly with intermediate rubber according the cord height
on the package.
• 31. Next to the two edge cords an edge rubber stripe of cover plate quality is inserted. The
thickness of this rubber stripe is in accordance to the cord height as well as the cord diameter.
The edge rubber stripes should be so wide that the result is a 20 mm overlap at the edges of
the base splice package.
•
• 32. The entire splice area and both ramps are coated with the special rubber solution thinly. Important!
The special rubber solution has to be coated very thinly and it is necessary to wait until the solution has
completely evaporated (checking with hand test).
•
• 33. The upper intermediate plate is laid on and rolled up. If necessary the Phoenix reinforcement breaker
is laid on the intermediate plate and rolled up too.
•
• 34. The upper raw rubber cover plate, temporarily cut in width and length, is laid on the package. After this
procedure it is cut to the exact distance, skive to skive (with 10 mm overlapping). With hammer hits or a pressing
roll a unit within the skive areas is produced between the raw and the vulcanized rubber.
•
• 35. Both splice edges are signed with a chalk dusted string line. Surplus material i.e. rubber from the raw
rubber package is cut off.
•
• 36. The edge bars corresponding to the belt thickness (bar thickness = belt thickness minus 2 mm)
enclose the splice package.
•
• 37. Using bar stretchers (e.g. made of chains) or screw platens the edge bars are prestressed outside the
heating elements or within the bolts.
•
• 38. The splice alignment as well as the straightness is checked with a string line, which is laid over the
middle dot marks respectively the reference points (see also point 10). If necessary the splice is to be realigned.
•
• 39. The upper "Vulkatrix"-tissue is laid upon the raw rubber cover plate smoothly. The tissue must cover
the total heating element length, each more than about 300 mm. In cross direction the tissue passes straightaway
to the edges. The heating tins, upper heating elements and press tie-bars are built up. Be alert that the outer pairs
of press tie-bars are positioned outside of the splice zone and that they are spread regularly over the heating
element area. This is required for an even pressure allocation.
 Afterwards the edge bars are stretched again and the bolts are put into the tie-bars. The connection between
the tie-bars allows the pressurization according to the mechanical principle of the press.

40. The necessary specific vulcanization pressure of min. 10 bar/145 psi is built up and the heating elements are
heated up to the vulcanization temperature of 150 5 °C.
The vulcanization temperature has to be maintained for a certain period of time in accordance with the given
diagram.
41. When the cooking time is finished the heating elements are cooled down to 70 °C.

42. Dismounting and taking down of the vulcanization equipment.

43. Finally the lateral rubber waste at the splice edges and the ramp areas are removed with a disk grinding
machine. At last the splice has to be checked.
The splice will be rejected according to table 1. Please note that these events are most unlikely to happen.

Cause for concern Check Threshold Value Action

Air pockets visual New splice

 20 % of splice surface

Visible cords (edge) visual 1 cord Repair

Cord contact within  10 % of complete

X-Ray New splice
splice contact area of the two
belt ends

Splice thickness Caliper St 2000:  2,5 mm Repair

St 6300:  3 mm

Shore A -
Splice hardness Repair
meter  10° Shore A (Average)