Coal Handling

  • Titles Available:
    • Auxiliary Equipment
    • Ash Handling
    • Bulldozers
    • Barge Unloading
    • Car Dumpers
    • Coal Handling Overview 1
    • Coal Handling Overview 2
    • Coal Handling Overview 3
    • Coal Pile Management
    • Coal Preparation
    • Equipment
    • Coal Yard Maintenance
    • Control Equipment
    • Conveyors
    • Dust Control Equipment
    • Dust Control Equipment II
    • Dust Control Overview
    • Handling Wet and Frozen Coal
    • Rail Yard Operations
    • Stackers
    • Trippers

This series addresses the most common coal yard operations.

Instructional Features

This new, self-paced and interactive Web-delivered series includes up-to-date, award-winning content, crisp audio, stunning graphics, and engaging discovery activities – all to stimulate and involve the trainee. This series is an Internet browser-based application with centralized learning management capabilities and global end-user accessibility. Each unit contains challenge questions within the web-based training module and an examination at the end each module.

An online glossary is available for ease of reference. In addition, to reinforce the audio medium of delivery, a closed captioning feature allows you to read the lesson word for word, in its entirety.

The Learning Management System (LMS) keeps track of all trainee test scores, log times, and site-information access and provides custom reporting options. Whether you use the patented Learning Management System or integrate this award winning content into your Learning Management System, we can help.

Also includes:

  • High quality video of actual demonstrations from the field
  • Latest interactive instructional design methods to maximize learning
  • Graphical representations of coal yards and equipment components
  • Printable, online workbook
  • Materials available to support instructor-led training
  • Onboarding new staff or refreshing the knowledge base of your workforce
  • Increase retention and improve performance
  • Compliant with SCORM 1.2 and ADA 508(c) standards

Objective

This training series is designed to improve the knowledge and skills of coal yard workers by giving them an understanding of common coal yard systems and routine coal yard operating procedures.

 Benefits

The benefits of Web-delivered mechanical training include: reduction of learning time, consistency of delivery, increase in mastery scores, automated recordkeeping, increased motivation, greater retention, privacy, and remedial or refresher training. Additional benefits include increased trainee interest and flexible scheduling. Also, training units accommodate all learning styles through a variety of media presentation formats.

Structure

The 20 units in this series represent some of the most common coal handling systems and components in the industrial market. Topics covered range from routine coal yard receiving operations to dust control and ash disposal.

Auxiliary Equipment

Auxiliary equipment is used to perform support operations in a typical coal handling system. Support operations, such as weighing coal and collecting coal samples, help provide important information for coal handling and other plant operations. This course explains why coal is weighed and sampled, and describes some of the auxiliary equipment used to perform these jobs. It also covers some of the preventative maintenance tasks that coal handlers may perform to keep auxiliary equipment in good working condition.

Subjects:
  1. Introduction

    Introduction to Auxiliary Equipment

  2. Introduction to Stackers

    Topic I Learning Objectives

    Weighing Coal

    Characteristics of Coal

    Sampling Coal

  3. Weighing Equipment

    Topic II Learning Objectives

    Truck Scales

    Track Scales

    Conveyor Belt Scales

  4. Scale Operation and Preventative Maintenance

    Topic III Learning Objectives

    General Operation of Scales

    Track Scales

    Scale Calibration

  5. AUTOMATIC SAMPLING

    Topic IV Learning Objectives

    Collecting Representative Samples

    Automatic Sampling Equipment

    Scale Calibration

  6. Manual Sampling

    Topic V Learning Objectives

    Auger Samplers

    Collecting Samples by Hand

  7. Preventive Maintenance of Sampling Equipment

    Topic VI Learning Objectives

    Preventive Maintenance

    Troubleshooting Sampling Equipment

    Troubleshooting Sampling Equipment

Ash Handling

Ash is the solid residue that is produced when coal is burned. To keep a coal-fired plant operating, ash must be collected, removed from the plant, and properly disposed of. This course will provide a brief introduction to ash, including types of ash and systems used to handle it. It will also discuss methods of ash disposal.

Subjects:
  1. Introduction

    Learning Objectives

  2. Introduction to Ash Handling

    Topic I Learning Objectives

    Ash Production

    Ash Handling and Hazards

  3. Bottom Ash

    Topic II Learning Objectives

    Bottom Ash Storage and Removal

    Removing Ash from Dewatering Bins

    Ash Piles

  4. Fly Ash Systems

    Topic III Learning ObjectivesWet Fly Ash Collection

    Dry Fly Ash Collection

    Wet Fly Ash Collection

    Silos

  5. Drum Mixers

    Topic IV Learning Objectives

    Moving Ash to an Ash Conditioner

    Drum Mixer Operation

    Drum Mixer Maintenance

  6. Bowl Mixers

    Topic V Learning Objectives

    Operational Checks

    Bowl Mixer Maintenance

  7. Ash Disposal

    Topic VI Learning Objectives

    Permanent Storage Sites

    Ash Pongs

    Commercial Ash Preparation

    Ash Cleanup

Bulldozers

Bulldozers are used to spread coal out on storage piles and to reclaim coal from the piles when it is needed in the plant. Bulldozers are also used to manage coal piles to reduce the risk of fires and to minimize loss from erosion due to wind and rain. Coal handlers who use bulldozers must know how to operate them safely and correctly, and how to take care of them properly. This course focuses on the use of bulldozers in coal handling operations. Emphasis is placed on practical applications, inspection procedures, minor maintenance procedures, and basic operating procedures.

Subjects:
  1. Introduction

    Learning Objectives

  2. Bulldozers

    Topic I Learning Objectives

    Functions of Bulldozers in Coal Handling

    Major Types of Bulldozers

    Major Parts of a Typical Bulldozer

  3. Bulldozer Hydraulic Systems

    Topic II Learning Objectives

    Basic Hydraulic System Operation

    Hydraulic Application in Bulldozers

    Hydraulic System Inspection

  4. Inspection and Minor Maintenance, Part I

    Topic III Learning Objectives

    General In formation

    Bulldozer Lubrication

    Inspecting and Maintaining the Cooling System

    Checking the Electrolyte Level

    Checking the Fuel Supply

  5. Inspection and Minor Maintenance, Part II

    Topic IV Learning Objectives

    Inspecting and Maintaining the Air Cleaning System

    Adjusting Track Tension on a Trade type Bulldozer

    Checking the Tires on a Wheel-type Bulldozer

  6. Operation, Part I

    Topic V Learning Objectives

    Bulldozer Safety

    Bulldozer Instruments and Operating Controls

    Starting a Bulldozer

    Steering a Bulldozer

    Slowing and Stopping a Bulldozer

    Shutting Down a Bulldozer

  7. Operation, Part II

    Topic VI Learning Objectives

    Avoiding and Dealing with Hazards

    Bulldozer Reclaiming Techniques

Barge Unloading

Coal barges are generally loaded with coal dumped from trains. The loaded barges are taken to plants by tugboats, which also take the empty barges away to be reloaded. This course focuses on the operations involved in handling barges from the time they arrive at a plant until the empty barges are taken away. It examines in detail the components and operation of two types of barge unloaders: a bucket elevator unloader and a clamshell, or traveling tower unloader.

Subjects:
  1. Introduction

    Learning Objectives

  2. Bringing in Barges

    Topic I Learning Objectives

    Barges and Tugboats

    Make-ups with Cables and Lines

    Bringing a Barge into a Dock and Tying It Up

    Bringing in a Tow

    Hooking up to a Barge Haul System

    Safety

  3. Bucket Elevator Unloaders

    Topic II Learning Objectives

    General Description

    Unloader Components

    Cab Controls

  4. Operating a Bucket Elevator Unloader

    Topic III Learning Objectives

    Starting up a Bucket Elevator Unloader

    Lining up and Unloading a Barge

    Automatic and Manual Operation

    Shutdown

  5. Clamshell Unloaders

    Topic IV Learning Objectives

    General Description

    Unloader Controls

    Bucket Operation

  6. Clamshell Unloader Operation

    Topic V Learning Objectives

    Prestart Checks

    Operating the Unloader

    Shutdown

  7. Shifting and Taking Away Empty Barges

    Topic VI Learning Objectives

    Shifting Barges

    Taking Away a Barge

Car Dumpers

Coal handlers operate and maintain the equipment used to transport and unload coal cars. This equipment may include rotary car dumpers, positioners, and retarders. To help coal handlers develop the skills needed to work safely with this equipment, this course describes how rotary car dumpers, positioners, and retarders work. It also explains how this equipment is generally operated during receiving operations, and how it is maintained.

Subjects:
  1. Introduction

    Learning Objectives

  2. Introduction to Coal Car Unloading Systems

    Topic I Learning Objectives

    Receiving Operations

    Scales, Dust Control Equipment, and Retarders

    Coal Handling Responsibilities

  3. Rotary Car Dumpers

    Topic II Learning Objectives

    Rotary Car Dumper Components

    Dumper Platform

    Cradle

    Clamping System

    Spill Truss

    Drive System

    Limit Switches

    Mechanical Steps

  4. Controls, Inspections, and Preventive Maintenance

    Topic III Learning Objectives

    Dumper Controls

    Dumper Inspections

    Preventive Maintenance

  5. Receiving Operations

    Topic IV Learning Objectives

    Safety Considerations

    General Receiving Operations: Separated Cars

    General Receiving Operations: Rotarycoupled Cars

  6. Positioning Systems and Retarders

    Topic V Learning Objectives

    Positioning Systems

    Retarders

  7. Receiving Operations Using Positioners and Retarders

    Topic VI Learning Objectives

    Positioner and Retarder Inspections

    Receiving Operations

Coal Handling Overview

Coal handlers work with a variety of equipment designed to help them perform the job of keeping a plant supplied with coal. This equipment, known collectively as the coal handling system, provides an efficient way of carrying out basic coal handling operations. It is important for coal handlers to be familiar with the various types of coal handling equipment and with the jobs that they need to perform to keep a coal handling system operating safely and efficiently. This course explains how coal handling systems generally operate. It also describes equipment that carries out some of the major operations and support functions involved in coal handling.

Subjects:
  1. Introduction

    Learning Objectives

  2. Receiving Operations

    Topic I Learning Objectives

    Coal Handling Systems

    Receiving Coal

    Transporting Coal

  3. Outdoor Coal Storage

    Topic II Learning Objectives

    Stacking-out Coal

    Storing Coal

    Reclaiming Coal

  4. Coal Preparation and Indoor Storage

    Topic III Learning Objectives

    Coal P reparation

    Tramp Iron Removal

    Indoor Coal Storage

  5. Weighing, Sampling, and Dust Control

    Topic IV Learning Objectives

    Weighing Coal

    Sampling Coal

    Controlling Coal Dust

  6. Ash Handling

    Topic V Learning Objectives

    Ash

    Fly Ash Removal

    Bottom Ash Removal Systems

  7. The Coal Handler’s Job

    Topic VI Learning Objectives

    Safety on the Job

    A Coal Handler’s Duties

Coal Pile Management

Plants that need to burn large quantities of coal also need to maintain large coal reserves. The most common way of storing coal is in large outdoor storage piles. Coal pile management involves moving coal to and from storage piles, and maintaining the piles to deal with coal pile fires and environmental factors such as rain and wind. This course will cover these topics, as well the equipment used in coal pile management.

Subjects:
  1. Introduction

    Learning Objectives

  2. Introduction to Coal Pile Management

    Topic I Learning Objectives

    Coal Storage

    Coal Pile Management Functions

    Coal Pile Management Jobs

  3. Coal Pile Management Equipment

    Topic II Learning Objectives

    Bulldozers

    Front-end Loaders

    Scrapers

    Spray Vehicles

    Coal Pile Lighting

  4. Compacting, Contouring, and Grooming Coal Piles

    Topic III Learning Objectives

    Compacting Coal Piles

    Contouring Coal Piles

    Grooming Coal Piles

  5. Reclaiming and Coal Pile Management Safety

    Topic IV Learning Objectives

    Reclaiming

    Coal Pile Management Safety

  6. Managing Runoff

    Topic V Learning Objectives

    Adverse Effects of Water on a Coal Pile

    Dealing with Water in Coal Pile Management

    Handling Runoff

    Working the Coal Pile During or After a Rainstorm

  7. Coal Pile Fires and Wind Erosion

    Topic VI Learning Objectives

    Coal Pile Fires

    Wind Erosion

Coal Preparation Equipment

Coal preparation involves the use of special equipment that operators are often required to inspect, maintain, and troubleshoot. Operating coal preparation equipment properly can help prolong the life of the equipment and maximize the efficiency of the coal handling system. This course will provide an introduction to coal preparation equipment and its operation.

Subjects:
  1. Introduction

    Learning Objectives

  2. Introduction to Coal Preparation

    Topic I Learning Objectives

    What is Coal Preparation?

    Basic Methods Used to Reduce the Size of Coal

    Major Types of Coal Preparation Equipment

  3. Breakers: Principles of Operation

    Topic II Learning Objectives

    Major Parts of a Breaker

    Basic Breaker Operation

    Breaker Driving Mechanism

    Auxiliary Breaker Components

    Hammermills

    Refuse Plows

    Deflector Plates

  4. Breaker Operation

    Topic III Learning Objectives

    Breaker Lubrication

    Inspecting the Outside of a Breaker

    Inspecting the Inside of a Breaker

    Breaker Start-up

    Conditions to Monitor During Normal Operation

    Handling Breaker Operating Problems

    Breaker Shutdown

  5. Crushers: Principles of Operation

    Topic IV Learning Objectives

    Hammermill Crushers

    Major Parts

    Basic Operating Principles

    Ring Crushes

    Major Parts

    Basic Operating Principles

    Roll Crushes

    Two-roll Crushers

    Three-roll Crushers

  6. Crusher Operation

    Topic V Learning Objectives

    General Crusher Inspection

    Crusher Lubrication

    Removing Uncrushable Material

    Adjusting Crusher Clearance

    Crusher Start-up

    Conditions to Monitor During Normal Crusher Operation

    Handling Problems in Crusher Operation

    Crusher Shutdown

Coal Yard Maintenance

Coal is a heavy, abrasive, and corrosive material that can be difficult for equipment to handle. To handle coal, equipment must often run at high speeds and carry heavy loads. To do its job, coal handling equipment must be continually maintained to ensure it stays in good running condition. This course examines the maintenance jobs that are commonly performed on coal handling equipment and describes how coal handlers may be involved with equipment maintenance.

Subjects:
  1. Introduction

    Learning Objectives

  2. Maintenance Principles

    Topic I Learning Objectives

    Basic Coal Yard Maintenance

    Coal Handler Maintenance Responsibilities

  3. Idler and Pulley Replacement

    Topic II Learning Objectives

    Idler Replacement

    Pulley Maintenance

  4. Changing a Belt, Part I

    Topic III Learning Objectives

    Belts

    Preparations for Belt Installation

    Belt Installation

    Pulling the Belt

    Changing a Belt, Part II

    Topic IV Learning Objectives

    Belt Change out Using Rope of Cable

    Belt Splicing and Inspection

    Training a Belt

    Test Run

    Idler Adjustment

  5. Mechanical Splice

    Topic V Learning Objectives

    Mechanical Splice

    Preliminary Steps

    Splicing Equipment

    Splice Installation

  6. Vulcanized Splices and Repairs

    Topic VI Learning Objectives

    Vulcanized Splices

    Preparing a Permanent Vulcanized Splice

    Temporary Repairs

    Permanent Repairs

Control Equipment

The components of a coal handling system are operated with control equipment. The proper operation of the control equipment ensures that the components are started and stopped in the correct sequence so that coal moves smoothly from one component to the next. If one of the components in the sequence is not operated properly, the entire system could come to a stop, and equipment could be damaged. This course describes how control equipment is used to operate coal handling components so that they work together smoothly as a system. Troubleshooting procedures that can be used to determine the cause of a coal handling system malfunction also are covered.

 Subjects:
  1. Introduction

    Learning Objectives

  2. Introduction to Control Equipment

    Topic I Learning Objectives

    Control Methods

    Control Equipment Functions

    Types of Control Equipment

  3. Controlling Coal Flow

    Topic II Learning Objectives

    Coal Handling System Components

    Component Motor Controls

    Control Panels

    Electrical Circuits

  4. Monitoring Coal Handling Operations

    Topic III Learning Objectives

    Indicator Lights

    Annunciators

    Computer Graphics

    Ammeters and Other Indicators

  5. System Protection

    Topic IV Learning Objectives

    Sensing Devices

    Interlock Systems

  6. Start-up and Shutdown

    Topic V Learning Objectives

    Manual Control System

    Manual Control System Start-up

    Manual Control System Shutdown

    Semi-automatic Control System

    Automatic Control System

    Automatic System Start-up

    Automatic System Shutdown

  7. Troubleshooting

    Topic VI Learning Objectives

    Coal Handling Troubleshooting Steps

Conveyors

Coal handlers operate and maintain the equipment used to transport coal to a plant for burning or to a coal pile for storage. This equipment includes conveyors, feeders, and chutes. Coal handlers must also inspect and maintain equipment such as magnetic separators and cleaning devices, which help transport operations run smoothly. This course explains how the equipment involved in transport operations works, and how it should be inspected and maintained.

Subjects:
  1. Introduction

    Learning Objectives

  2. Conveyors

    Topic I Learning Objectives

    Coal Transport Systems

    Conveyors

  3. Belts and Idlers

    Topic II Learning Objectives

    Belts

    Idlers

  4. Pulleys and Drive Mechanisms

    Topic III Learning Objectives

    Pulleys

    Drive Mechanisms

    Safety Features

  5. Feeders and Chutes

    Topic IV Learning Objectives

    Feeders

    Chutes

  6. Magnetic Separators and Cleaning Devices

    Topic V Learning Objectives

    Magnetic Separators

    Cleaning Devices

  7. Preventative Maintenance and Troubleshooting

    Topic VI Learning Objectives

    Preventive Maintenance

    Inspecting Conveyors

    Lubricating Conveyor Components

    Inspecting Chutes

    Inspecting Feeders

    Troubleshooting

Dust Control Equipment I

When coal moves through a coal handling system, it produces a lot of dust, which can be harmful to those working in the plant. Coal dust can present a respiratory hazard to workers, cause fires, damage plant equipment, and cause air pollution. Coal dust must be controlled in order to reduce or prevent these harmful effects. This course focuses on the equipment that is commonly used to control coal dust in indoor locations, such as breaker buildings, tripper rooms, and car dumpers.

 Subjects:
  1. Introduction

    Learning Objectives

  2. Dust Suppression Systems

    Topic I Learning Objectives

    Spray Types

    Activating Sprays

    Checks and Minor Maintenance

  3. Dust Collection

    Topic II Learning Objectives

    Systems Description

    Operation

    Maintenance

  4. Baghouse Components

    Topic III Learning Objectives

    General Description

    Typical Baghouse Components

    Carbon Dioxide Fire Suppression System

  5. Baghouse Operation and Maintenance

    Topic IV Learning Objectives

    Baghouse

    Changing Bags

    Fire Detection and Suppression

  6. Indoor Vacuum Systems

    Topic V Learning Objectives

    Vacuum Systems

    Vacuum System Operation

    Maintenance

  7. Dust Treatment Equipment

    Topic VI Learning Objectives

    Pug Mill

    Pin Mixer

    Pug Mill and Pin Mixer Operation

    Briquetter

    Dust Treatment Equipment Maintenance

Dust Control Equipment II

Dust from coal handling operations must be controlled to protect personal health, equipment, and the environment. There are many different types of equipment used to control coal dust, and operating it may be part of a coal yard worker’s job. Dust control equipment is classified into two main groups: equipment used to control dust inside buildings and equipment used to control dust outside in the coal yard. This course focuses on the equipment used in the coal yard.

Subjects:
  1. Introduction

    Learning Objectives

  2. Introduction to Dust Control II

    Topic I Learning Objectives

    General Description

    Components and Systems

    Hydraulic System

    Pre-start Checks

    Start-up

  3. Spray Vehicles

    Topic II Learning Objectives

    General Description

    Filling from a Hydrant

    Filling at a Mixing Facility

    Spraying

    Minor Maintenance

  4. Vacuum Loaders

    Topic III Learning Objectives

    General Description

    Components and Systems

    Pre-start Checks

    Operation

  5. Vacuum Trucks

    Topic IV Learning Objectives

    General Description

    Components and Systems

    Pre-start Checks

    Operation

    Wetting Dust inside a Truck Hopper

    Dumping

    Changing Filter Bags

    Minor Maintenance

  6. Street Sweepers

    Topic V Learning Objectives

    General Description

    Pre-start Checks

    Start-up and Sweeping

    Dumping

    Minor Maintenance

Dust Control Overview

Dust control is an important part of coal handling operations. This course looks at where coal dust is produced, how it can spread, and how it can be kept from spreading. Specific attention is directed to equipment and techniques that are commonly used to control dust in coal handling systems.

Subjects:
  1. Introduction

    Learning Objectives

  2. Introduction to Dust Control

    Topic I Learning Objectives

    Sources of Coal Dust

    Reasons for Controlling Coal Dust

    Approaches to Controlling Coal Dust

    Dust Reclamation

  3. Dust Suppression

    Topic II Learning Objectives

    Suppression Methods

    Foam Sprays

  4. Dust Containment

    Topic III Learning Objectives

    Barge Unloading Operation

  5. Dust Collection

    Topic IV Learning Objectives

    Baghouses

    Cyclones

    Dust Collection Systems

  6. Dust Cleanup

    Topic V Learning Objectives

    Inside Cleanup

    Outside Cleanup

  7. Dust Reclamation

    Topic VI Learning Objectives

    Dust Reclamation Methods

    Dust Treatment Equipment

    Pin Mixer

    Briquetter

    Pug Mill

Handling Wet and Frozen Coal

Wet and frozen coal can create difficult problems for coal handlers, including clogging equipment and impeding or blocking coal flow. However, many of the problems resulting from wet or frozen coal can be greatly reduced, and sometimes entirely avoided by following certain precautions, by properly using specialized equipment, and, in some cases, by planning ahead. This course covers the types of problems caused by wet and frozen coal, as well as methods and equipment that are commonly used to avoid, minimize, or respond to these problems.

 Subjects:
  1. Introduction

    Learning Objectives

  2. Wet Coal, Part I

    Topic I Learning Objectives

    Wet Coal Problems

    How Wet Coal Sticks

  3. Wet Coal, Part II

    Topic II Learning Objectives

    Wet Coal, Part II

    Preparing for Wet Coal

    Detecting Wet Coal Problems

    Dealing with Water Accumulation

  4. Frozen Coal

    Topic III Learning Objectives

    Frozen Coal Problems

    How Coal Freezes and Sticks

    Handling Frozen Coal

  5. Mechanical Treatment

    Topic IV Learning Objectives

    Frozen Coal Crackers

    Travelling Hammermill Crushers

  6. Thermal Treatment

    Topic V Learning Objectives

    Thawing Sheds

    Torches

  7. Chemical Treatment

    Topic VI Learning Objectives

    Applying Anti-freeze to Conveyor Belts

    Treating Coal with Anti-freeze

    Multiple Approaches to Handling Frozen Coal

Rail Yard Operations

Rail yards make it possible for a plant to receive coal by train. This course will start with a brief introduction to rail yards, and then continue to cover tracks and switches. It will also present information on coal cars, air breaks, and trains and locomotives. Finally, this course will also describe rail yard safety and communication.

Subjects:
  1. Introduction

    Learning Objectives

  2. Introduction to Rail Yards

    Topic I Learning Objectives

    Rail Yard Equipment

    Coal Handler Jobs

  3. Tracks and Switches

    Topic II Learning Objectives

    Tracks

    Switches

  4. Coal Cars

    Topic III Learning Objectives

    General Features of Coal Cars

    A Coal Car Braking System

    Safety Procedures for Operating a Hand Brake

  5. Air Brakes

    Topic IV Learning Objectives

    General Features of Air Brakes

    Train Brakes and Automatic Brakes

  6. Trains and Locomotives

    Topic V Learning Objectives

    Couplers

    Locomotives

  7. Safety and Communication

    Topic VI Learning Objectives

    Mounting and Dismounting Coal Cars

    Isolating a Coal Car

Stackers

Plants that burn coal typically store their coal in outdoor piles. To move the coal to the storage pile, a machine called a stacker is often used. An important aspect of coal handling is operating a stacker, coordinating its operation with the rest of the coal handling system, and keeping it in good working condition by performing regular inspections and minor maintenance. This course will cover how to follow the procedures for each of these aspects of coal handling.

Subjects:
  1. Introduction

    Learning Objectives

  2. Introduction to Stackers

    Topic I Learning Objectives

    Stackers: Basic Function

    Major Types of Stackers

    Telescopic Chute Stackers

    Radial Boom Stackers

    Stackers/Reclaimers

    Stacker Control Systems

    Operating Responsibilities

  3. Drive Systems, Sensors, and Limit Switches

    Topic II Learning Objectives

    Stacker Drive Systems

    Cable Drives

    Hydraulic Luffing Systems

    Slew Drives

    Travel Trucks

    Sensors and Limit Switches

    Sensors

    Limit Switches

  4. Operation, Part I

    Topic III Learning Objectives

    Start-up

    Positioning a Stacker

    Setting up Operating Controls

    Turning on the Stacking out Equipment

    Stacking out Procedures

  5. Operation, Part II

    Topic IV Learning Objectives

    Monitoring Operating Conditions

    Operating Problems

    Stacker Conveyor Trips

    High Winds

    Boom Problems

    Shutdown

  6. Inspection and Minor Maintenance

    Topic V Learning Objectives

    Stacker Inspection

    Stacker Lubrication

  7. Stackers/Reclaimers

    Topic VI Learning Objectives

    Stacker/Reclaimer Varieties

    Start-up

    Reclaiming

    Monitoring Operating Conditions

    Operating Problems

    Shutdown

    Inspection and Minor Maintenance

Trippers

As long as there is coal in the bunkers, the plant can keep running without having to get coal from the point of delivery or from the coal pile. Whenever there is an interruption or a breakdown in coal handling, having a supply of coal on hand in the bunkers allows the plant to continue operating while the problem is corrected. To ensure that the bunkers are filled with coal, plants need equipment designed for that purpose. In many plants, the equipment used to fill bunkers are machines called trippers. This course will review tripper operation and maintenance, as well as tripper room duties.

 Subjects:
  1. Introduction

    Learning Objectives

  2. Introduction to Trippers

    Topic I Learning Objectives

    Bunkers and Silos

    Major Parts of a Tripper

    Tripper Controls

  3. Inspection and Maintenance

    Topic II Learning Objectives

    Inspecting a Tripper

    Adjusting Belt Scrapers

    Tripper Lubrication

  4. Tripper Operation, Part I

    Topic III Learning Objectives

    Tripper Start-up

    Filling a Bunker

    Moving a Tripper from One Bunker to Another

    Monitoring Tripper Conditions

    Tripper Shutdown

  5. Tripper Operation, Part II

    Topic IV Learning Objectives

    Stuck Coal in a Tripper’s Discharge Chute

    Tripper Belt Running Off-center

    Loss of Power to a Tripper

  6. Tripper/Bunker Room Duties, Part I

    Topic V Learning Objectives

    Inspecting a Bunker

    Bunker Problems

    Stuck Coal

    Fires

  7. Tripper/Bunker Room Duties, Part II

    Topic VI Learning Objectives

    Checking Bunker Levels

    Weighing Coal Fed to a Bunker

    Taking Coal Samples

    Cleaning the Tripper Room