Coal Handling - Equipment

Duration: 1.00 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

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.

Learning Objectives

By the end of this course, you will be able to:

• Describe how ash is produced in a coal-fired plant.
• Distinguish between fly ash and bottom ash.
• Identify hazards associated with ash handling. Bottom Ash
• Describe how bottom ash is removed from a boiler.
• Explain how a dewatering bin functions.
• Explain how ash ponds are used to store ash temporarily. Fly Ash Systems
• Describe how fly ash can be removed from flue gas and collected in a wet fly ash collection system.
• Explain how fly ash can be removed from flue gas and collected in a dry fly ash collection system.
• Describe the components of a typical ash silo. Drum Mixers
• Describe the operation of an air slide.
• Explain the operation of a typical drum mixer.
• Describe some maintenance tasks commonly performed on a drum mixer. Bowl Mixers
• Describe the general operation of a typical bowl mixer.
• Describe some maintenance tasks commonly performed on a drum mixer. Ash Disposal
• Describe how conditioned ash may be picked up and delivered to a permanent storage site.
• Explain the function of ponds at permanent storage sites.
• Describe how ash is removed from ash ponds.
• Describe one way that ash intended for commercial applications is loaded into trucks for transport.

Duration: 1.00 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

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 training program 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.

Learning Objectives

By the end of this course, you will be able to:

• State two reasons why coal must be weighed.
• Describe the general characteristics of coal.
• Explain the purpose of a representative sample.
• Give two reasons why coal should be sampled.
• Weighing Equipment
• Explain how truck scales are used to weigh coal.
• Explain how track scales are used to weigh coal.
• Explain how conveyor belt scales are used to weigh coal. Scale Operation and Preventive Maintenance
• Describe some of the general procedures involved in operating scales.
• Explain some of the preventive maintenance jobs that should be performed on scales. Automatic Sampling
• Describe some of the general principles that apply to collecting a representative sample of coal.
• Explain how an automatic sampling system generally operates. Manual Sampling
• Explain how an auger sampler can be used to collect representative samples of coal.
• Describe some of the general procedures for collecting a representative sample of coal by hand.
• Preventive Maintenance of Sampling Equipment
• Describe some of the preventive maintenance jobs that should be performed on sampling equipment.
• Describe problems that could prevent a sampler from operating properly and explain how these problems can be handled.

Duration: 1.00 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

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.

This training program 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.

Learning Objectives

By the end of this course, you will be able to:

• Name the three basics steps involved in receiving operations.
• Describe the general function of the following equipment: positioners, rotary car dumpers, scales, dust control equipment, and retarders.
• List some of the jobs that coal handlers generally perform during receiving operations. Rotary Car Dumpers
• Identify the basic parts of a rotary car dumper.
• Describe the function of the following dumper components: platform, cradle, clamping system, spill truss, drive system, limit switches, and mechanical stops. Controls, Inspections, and Preventive Maintenance
• Name the basic controls used to operate a rotary car dumper and explain the function of each control.
• Describe how to inspect a rotary car dumper.
• Describe some of the preventive maintenance jobs a coal handler should perform on a rotary car dumper.
• Receiving Operations
• Describe some of the safety procedures that coal handlers should follow during receiving operations.
• Describe general receiving operations at a plant that requires cars to be separated before they are unloaded.
• Describe general receiving operations at a plant where cars remain coupled during unloading.
• Positioning Systems and Retarders
• Describe the major components of a positioning system and explain how a positioner works.
• Describe the major components of a retarder and explain how a retarder works. Receiving Operations
• Using Positioners and Retarders
• Describe some of the inspections generally performed on positioners and retarders.
• Describe general receiving operations at a plant that uses a positioner and retarder.

Duration: 1.00 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

Coal preparation is an important aspect of coal handling. When coal leaves a plant’s coal handling system, it generally is sent to one of two places. Depending on the design of the plant, the coal may go directly to a boiler furnace to be burned, or it may go through coal processing equipment, such as a pulverizer, before it is burned. In either case, coal usually has to be prepared during coal handling so that the pulverizing and burning will be more efficient. 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.

Learning Objectives

By the end of this course, you will be able to:

• State the function of coal preparation.
• Describe the basic methods used to reduce the size of coal.
• Identify the major types of coal preparation equipment.
• Identify the major parts of a breaker.
• Describe the basic operation of a breaker.
• Describe a typical breaker driving mechanism.
• Describe the basic operation of a hammer mill.
• State the function of a refuse plow.
• State the function of deflector plates.
• Explain why breaker lubrication is necessary.
• Identify parts of a breaker and a breaker driving mechanism that typically require lubrication.
• Describe or demonstrate two ways in which a breaker or a breaker driving mechanism can be lubricated.
• Describe or demonstrate a general procedure for inspecting the outside of a breaker.
• Describe or demonstrate a general procedure for inspecting the inside of a breaker.
• Describe or demonstrate a basic procedure for starting up a breaker.
• Identify conditions that are typically monitored during routine breaker operation.
• Identify problems that may occur during breaker operation, and explain how these problems should be handled.
• Describe or demonstrate a basic procedure for shutting down a breaker.
• Identify the major parts of a hammer mill crusher.
• Describe the basic operation of a hammer mill crusher.
• Identify the major parts of a ring crusher.
• Describe the basic operation of a ring crusher.
• Identify the major parts of a roll crusher.
• Describe the basic operation of a roll crusher.
• Identify parts of a crusher and crusher driving mechanism that are typically checked during a routine inspection.
• Describe a basic oil bath system for crusher bearing lubrication.
• Explain the basic operation of a forced-oil system for crusher bearing lubrication.
• Describe inspection and maintenance procedures that are typically required for a forced-oil system for crush lubrication.
• Explain two ways in which tramp iron and other un-crushable material can be removed from a crusher.
• Describe or demonstrate the basic procedure for adjusting the clearance between a crusher cage assembly and crushing element.
• Describe or demonstrate a basic procedure for starting up a crusher.
• Identify conditions that are typically monitored during normal crusher operation.
• Identify problems that may occur during crusher operation, and explain how these problems should be handled.
• Describe or demonstrate a basic procedure for shutting down a crusher.

Duration: 1.00 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

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.

Learning Objectives

By the end of this course, you will be able to:

• Explain how an operator can control the components of a coal handling system.
• Summarize the purpose of the control equipment in a coal handling system.
• Describe three different types of control equipment.
• Name several types of indicators and controls commonly found on a typical control panel.
• Controlling Coal Flow
• Identify different types of coal handling components and describe how they help move coal through the system.
• Identify and describe different types of controls used to operate coal handling components, and explain how these controls are used to control the flow of coal.
• Explain how controls operate motor controllers to turn motors on and off. Monitoring Coal Handling Operations
• Describe how annunciators and computer graphics are used to indicate problems in a coal handling system.
• Explain how an ammeter is used to monitor operating conditions in a coal handling system. System Protection
• Identify several types of sensing devices and describe how they can be used with indicating devices to monitor and protect a coal handling system.
• Describe the operation of an interlock system.
• Describe a typical manual control system and explain the procedures for starting it up and shutting it down.
• Describe a typical semi-automatic control system and explain the procedures for starting it up and shutting it down.
• Describe a typical automatic control system and explain the procedures for starting it up and shutting it down. Troubleshooting
• Summarize the basic steps that can be taken when troubleshooting a coal handling system.
• Determine how to troubleshoot a coal handling system in which the system is running, but a control panel indication is not normal.

Duration: 1.00 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

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.

Learning Objectives

By the end of this course, you will be able to:

• Explain what a coal transport system is and identify its major parts.
• List four types of conveyors used to transport coal.
• Name the parts of a typical belt conveyor and describe the function of each part.
• Describe the parts of a typical conveyor belt and name three types of splices used to join the ends together.
• Identify the parts of a typical idler and describe the different types of idlers used in a coal transport system.
• Identify the different types of pulleys used by conveyors and explain how each type is used.
• Explain the function of a conveyor drive mechanism and describe its major parts.
• Describe the different conveyor safety features and how each feature is used.
• Name two types of feeders and explain how they work.
• Explain the purpose of chutes, wear plates, and skirtboards in a coal transport system.
• Identify the three types of magnetic separators and explain how each type removes tramp iron from coal.
• Describe the cleaning devices used to remove coal from conveyor components.
• Describe general procedures for inspecting and maintaining conveyors, chutes, and feeders.
• Describe general troubleshooting procedures for belt misalignment.

Duration: 1.00 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

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.

Learning Objectives

By the end of this course, you will be able to:

• Describe several ways in which coal dust is produced and spread.
• Explain why coal dust must be controlled. List several ways of controlling coal dust. Dust Suppression and Containment
• Define the term dust suppression.
• Describe ways that dust is suppressed while it is being transported in a coal handling system.
• Describe dust suppression methods used on a coal pile.
• Define the term dust containment.
• Describe several methods used for containing coal dust. Dust Collection, Cleanup, and Reclamation
• List several methods of dust collection.
• Explain how a baghouse separates dust from air.
• Explain how a cyclone separates dust from air.
• Describe methods used to clean up coal dust indoors.
• Describe types of vacuum devices used to clean up coal dust outside.
• Explain why coal dust should be reclaimed.
• State the reason for treating coal dust before returning it to the coal handling system.
• Explain how a pin mixer converts coal dust to granules or pellets.
• Explain how a briquetter converts coal dust to solid lumps.
• Explain how a pug mill converts coal dust to a thick sludge

Duration: 1.00 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

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.

Learning Objectives

By the end of this course, you will be able to:

• Explain why environmentally friendly chemicals, such as surfactants and foams, are used in dust-suppressing sprays.
• Describe the systems used to turn dust-suppressing sprays on and off, including a lever-activated system and a sonar-activated system.
• Identify the checks and minor maintenance procedures that an operator may have to carry out on a spray system. Dust Collection Systems
• Describe the general layout of a dust collection system.
• Explain how to operate a dust collection system containing a cyclone, an exhaust fan, and a dust valve.
• Identify minor maintenance duties associated with dust collection systems. Baghouse Components
• Describe a typical baghouse system, including the exhaust fan, bags, dampers, and dust valve.
• Explain how an air pulse bag cleaning system works.
• Explain how a typical carbon dioxide fire suppression system works.

Duration: 1.00 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

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.

Learning Objectives

By the end of this course, you will be able to:

• Identify the main components and systems found on a spray vehicle, such as a water wagon.
• Describe several important pre-start checks on a spray vehicle.
• Outline the startup procedure for a diesel-powered spray vehicle.
• Explain how to fill a spray vehicle from a hydrant and from an automatic mixing facility.
• List three general types of environmentally friendly chemicals sprayed on coal piles and explain what they do. State safety rules to follow when driving a spray vehicle on the pile.
• Discuss the minor maintenance procedures that an operator might have to perform on a spray vehicle. Vacuum Loaders
• Describe airflow through a typical vacuum loader.
• Explain how cyclone collectors and filter bags capture dust particles and how filter bags are cleaned.
• Outline the typical startup sequence for an electric-powered vacuum loader, including pre-start checks. Vacuum Trucks
• Explain how air and dust flow through the vacuum system of a typical vacuum truck.
• Identify the major components of the vacuum truck’s hydraulic and pneumatic systems.
• Explain how to check and start up a typical vacuum truck.
• Discuss the process of wetting dust down inside a vacuum truck hopper without clogging filter bags.
• Describe how to change filter bags in a typical vacuum truck.
• Explain how to perform minor maintenance on a vacuum truck. Street Sweepers
• Outline the flow path of air and dust through a street sweeper.
• Describe how a street sweeper collects dust and separates it from air.
• Identify one function of the hydraulic system in a typical street sweeper and one function of the pneumatic system.
• Explain how to operate and perform minor maintenance on a street sweeper.

Duration: 1.00 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

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 training program 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.

Learning Objectives

By the end of this course, you will be able to:

• Identify coal handling problems caused by wet coal.
• Explain how wet coal sticks to itself and to coal handling equipment.
• Outline procedures to prepare for wet coal problems.
• List methods and equipment for detecting wet coal problems.
• Describe how to respond to wet coal problems.
• Discuss ways of dealing with water accumulation.
• Identify coal handling problems caused by frozen coal.
• Explain how coal freezes and how frozen coal sticks to coal handling equipment.
• Outline procedures to avoid or minimize frozen coal problems.
• Describe mechanical methods of treating frozen coal.
• Identify the major parts of frozen coal crackers and traveling hammer mill crushers.
• Explain how frozen coal is broken up by frozen coal crackers and traveling hammer mill crushers.
• Describe how thawing sheds and torches are operated to heat frozen coal in railcars.
• State the reasons antifreeze is applied to conveyor belts.
• Outline a basic system for applying antifreeze to conveyor belts.
• Explain why coal is treated with antifreeze.
• Discuss how mechanical methods, thermal methods, and chemical methods can be used together to treat frozen coal in a coal handling system.

Duration: 1.00 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

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.

Learning Objectives

By the end of this course, you will be able to:

• Describe the functions of stackers.
• Identify the major types of stackers and describe the main parts of each type.
• Describe the general types of stacker control systems.
• Identify the major duties related to stacker operation.
• Identify the major types of stacker drive systems and explain their functions.
• Explain the function of stacker sensors.
• Explain the function of stacker limit switches.
• Describe the basic procedure for starting up a stacker.
• Explain how stackers are normally operated to stack out coal.
• Identify conditions that should be monitored during stacker operation.
• Explain how to detect and respond to the following stacker operating problems: stacker conveyor trips, high winds, and boom problems.
• Describe the basic procedure for shutting down a stacker.
• Describe or demonstrate a typical stacker inspection procedure.
• Describe or demonstrate how a stacker is typically lubricated.
• Identify the main parts of a stacker/reclaimer.
• Describe basically how a stacker/reclaimer is started up and shut down.
• Explain how a stacker/reclaimer is operated to reclaim coal.
• Identify conditions that should be monitored during operation.
• Explain how to detect and respond to operating problems.
• Identify inspection and minor maintenance procedures typically performed on stackers/reclaimers.