Vibrating Screen and Ring Granulator Presentation

PRESENTATION ON
VIBRATING SCREEN & RING
GRANULATOR
BY
ABHIJIT CHAKRABORTY
(E&I-F&A)
Lighting up Lives…. Serving Humanity

CONTENTS
INTRODUCTION
TECHNICAL SPECIFICATION
DIFFERENT PARTS OF SCREEN & CRUSHER
FUNCTION
OPERATION SEQUENCE
SCOOP SYSTEM
LOGIC/INTERLOCK
ALARM/TRIP SETTING
PROTECTION
MAINTENANCE SCHEDULE
 CASE STUDY

INTRODUCTION
What is Screen ?
Screen is the equipment where different size of coal can be
segregated or screened ,generally used to separate feeds
containing solid & crushed coal down to 20-26mm
What is Crusher?
Crusher is the equipment used to reduce the size or change the form
of large size solid/coal up to 20mm

TECHNICAL SPECIFICATION
VIBRATING SCREEN
• MAKE- TRF
• TYPE- TM-16 Double Deck
• CAPACITY:-800TPH/960 TPH
(RATED/DESIGNED)
• RATING-37KW/415V/67A/1470 RPM
• VIBRATING FEEDER RPM-660 RPM
• INPUT/OUTPUT COAL SIZE:-300MM/
80MM- top deck /26MM bottom
deck
• STROKE- 12.7 MM
CRUSHER
• MAKE:- ELECON
 TYPE:- RING GRANULATOR
 CAPACITY:- 800TPH/960TPH
(RATED/DESIGNED)
• RATING-550KW/6.6KV/64A
 SPEED-739 RPM
 INPUT/OUTPUT COAL SIZE:- 300/20
MM TOLERANCE 10%
 HAMMER:- 4 ROW PLACED AT 90 deg
 FLUID COUPLING- SCOOP
• ROTOR DIA- 1200 MM
 ROTOR LENGHTH-1263 MM

VIBRATING SCREEN

GENERAL ARRANGEMENT

GENERAL DESCRIPTION
DESCRIPTION:
Coal feed from Upstream Conveyor BCN-7A/7B directly to the Vibrating
Screen .The Chute gap kept between 600-700mm for smooth discharge
of coal to crusher followed by Vibrating Screen. Double deck type
Vibrating Screen used in our plant with capacity of rated 800TPH.
Generally coal feeding contains various size of coal. So there are two
deck 1. Top deck 2. Bottom deck (Screen cloth). Preliminary level of
screening done by top deck plate from where <80mm size of coal can
pass & fall direct to the bottom deck plate or screen cloth from there
<26 mm coal pass & fall direct to downstream conveyor BCN-8A/8B
through bypass chute & > 80mm size of coal directly pass to Crusher
by screen to Crusher chute. Vibrating Screen Inclined Slope kept
between 17 to 21 deg. NOW SET AT 18 DEG. Screen to Crusher
discharge chute gap kept 600 mm, discharge chute width 2920mm &
feed chute width 2120 mm

DIFFERENT PARTS OF VIBRATING SCREEN
HALF DECK PLATE FULL DECK PLATE
Screen Upper (top) deck plate contains 2 nos. half deck plate & 8 nos. full deck plate the
opening on both deck plate kept at 80mm x 80 mm. from there <80 mm size of coal passes &
directly fall on bottom deck plate or screen cloth. Coal feeding first directly fall on that half
deck plate . Deck plate dimension- 1400mm x 1200 mm

DIFFERENT PARTS OF VIBRATING SCREEN
BOTTOM DECK OR SCREEN CLOTH
80 mm size of coal directly fall on Screen cloth or bottom deck where secondary
screening done the opening kept at screen cloth is 26 mm x 26 mm from there <
26 mm coal directly fall to downstream conveyor through bypass chute & direct to
bunker. Screen cloth= 2000 x1200mm

TYPICAL DOUBLE DECK SCREEN

DIFFERENT PARTS OF SCREEN
THERE ARE FOUR NUMBERS (IN TOTAL) OF FRICTION CHECK PAD PROVIDED AT
BOTH SIDE OF SCREEN WHICH RESTRICT THE SIDE-WISE DISPLACEMENT OF
VIBRATING PART FROM ITS OWN POSITION . 100 MM CLEARANCE FROM VIBRATING
PART

DIFFERENT PARTS OF SCREEN
SCREEN MOTOR (37 KW/415V/67A/1470RPM)

CRUSHER & ITS DIFFERENT PARTS

CRUSHER HYDRAULIC DOOR OPENING MOTOR (1.5 KW)
HYDRAULIC PRESSURE-100 -120 bar, OIL (HLP-68)

INNER PART OF CRUSHER

TYPICAL CRUSHER WITH INNER PART

CRUSHER HAMMER (RING GRANULATOR)

BREAKER PLATE
• There are 4 nos. breaker plate inside crusher, 300mm & above size coal first fall
on breaker plate through screen to crusher chute & where hammer first strike on
big size coal & break into pieces. Material used in breaker plate-Carbon steel ,
thickness- 50-55 mm. Gap between hammer & breaker plate 130 to 150 mm
according to hammer thickness breaker plate adjusted.

SCREEN PLATE
There are 4 nos. of Screen plate inside crusher. After preliminary crushing at
breaker plate coal pieces come at screen plate from where 20 -25 mm coal
pieces fall directly to the downstream belt . Gap=20-26mm, Thickness- 35-
40mm

KICK-OFF PLATE
There are 4 nos. kick off plate inside crusher : upper kick off plate(2
nos.) , lower kick off plate(2 nos.). Material used
carbon Steel, Thickness- 25-30mm

RUSORKSHOW CRUSHER WORKS ?

FUNCTION:- 80mm & above size of coal first come to crusher through Screen to
Crusher chute & directly fall into the breaker plate where hammers strike on big size
coal & split into small pieces then those broken pieces of coal come into screen plate
& then from there 25-30 mm size of coal directly pass to conveyor from the small
gap of screen plate & if any metal or uncrushable come with coal by hammer’s
centrifugal force those metal pieces accumulated at trump iron pocket through kick
off plate & rest of broken coal pieces directly fall to the downstream belt through
the gap between screen plate & kick-off plate the gap between the same is approx
210mm.

CRUSHER ROTOR & CAGE ASSEMBLY

CRUSHER SCOOP

CRUSHER SCOOP POSITION DURING START/STOP

WORKING PRINCIPLE :-There are mainly two parts called Impeller and Runner, both
have a large number of straight radial vanes. The motor drives the impeller. The runner is
connected to the driven machine. In running condition, the working circuit of the scoop
coupling is filled with the oil and the impeller acts as a centrifugal pump, creating oil flow
radially outward, which crosses the gap to the runner, which acts as a turbine. The oil
flow given up power as it return to the impeller again and thus the cycle is repeated.
The output speed of coupling can be changed by varying the slip, which depends upon the
oil quantity maintained in the working circuit by changing the position of the scoop tube.
SPEED REGULATION :-The scoop tube position can be changed from 0% to 100% to
regulate the output speed of the coupling. In 0% position, the scoop tube is at FULL IN
position and does not allow oil level to build up in the coupling. At this position of scoop
tube, there is maximum slip and minimum torque transmission. In 100% position, the
scoop tube is at FULL OUT position at which maximum oil is in the working circuit. This
gives maximum torque transmission at minimum slip. For intermediate position of the
scoop tube, intermediate value of slip and torque transmission is obtained.

SCOOP OIL COOILING SYSTEM

SCOOP OIL COOLING FLOW DIAGRAM

SCOOP OIL FLOW CIRCUIT

OIL CIRCUIT FUNCTION:-The oil pump delivers oil from the sump (oil tank) to the oil
cooler through oil filter. From oil cooler oil goes into working circuit of the Scoop
Coupling. A small lube line is taken out from the main oil line that provides oil to
bearing.
After transmitting power, the scoop tube collects oil from working circuit and delivers
back to the oil tank. Also, some splashed oil in the coupling is collected in the
collection box located at bottom of the Scoop Coupling and returned to the oil tank.
The pressure switch, pressure gauge and temperature gauge are provided to monitor
the pressure and temperature of oil.
The pressure switch and temperature switch give an electrical trip signal to the control
panel in case of oil flow failure less than 0.8 kg/sqmm within 36 sec (T1) after starting
of pump .

SPECIFICATION OF CRUSHER SCOOP OIL CIRCUIT
Density at 15 deg C. : 0.873 to 0.879
Flash point : 210 deg C.
Pour point : 30 deg C.
Scoop Oil - HLP-46
Scoop Actuator Motor- 2.2KW
Oil Pump Motor:- 3.7KW
Oil Cooler Fan- 5.5 KW
Scoop Oil Tank Capacity- 510 ltr.

ELECTRICAL SENSORS

SCREEN & CRUSHER OPERATION SEQUENCE
START SEQUENCE:-
START
DOWNSTREA
M BELT 8A/8B
START CRS
SCOOP OIL
COOLER
FAN
START CRS
SCOOP OIL
PUMP
START
CRUSHER
MAIN
MOTOR
START SCREEN
MOTOR
SCOOP ACTUATOR
OUT COMMAND,
AFTER GETTING
SCOOP TUBE OUT
COMMAND
POSTION UPSTREAM FLAP GATE
& START FEEDING FROM
UPSTREAM BELT 7A/7B

STOP SEQUENCE:-
STOP
FEEDING
FROM
UPSTREAM
BELT 7A/7B
STOP
SCREEN
MOTOR
SCOOP
ACTUATOR IN
COMMAND
STOP
CRUSHER
MOTOR
CRS SCOOP
OIL PUMP
STOP
CRS SCOOP
OIL COOLER
FAN STOP
STOP
DOWNSTREAM
BELT 8A/8B

LOGIC & INTERLOCKS OF SCREEN & CRUSHER
SCREEN START LOGIC/INTERLOCK:-
1. SCREEN REMOTE SELECTION (FOR REMOTE OPERATION)
2. CRUSHER ON FEEDBACK
3. CRUSHER SCOOP FULL OUT FEEDBACK.
4. CRUSHER ZSS HEALTHY FEEDBACK
5. DOWNSTREAM BELT -8A/8B RUNNING FEEDBACK.
6. SCREEN LOCAL SELECTION (FOR LOCAL OPERATION)
7. MCC NOT DISTURBED
8. EPB NOT OPTD
9. NOT SELECTEC IN REMOTE.
CHUTE VIBRATOR START INTERLOCK (AT SCREEN BYPASS CHUTE):-
BCN-8A/8B RUN FEEDBACK & CR-A/B RUN FEEDBACK & UP STREAM FLAP GATE
POSITION FEEDBACK & BCN-7A/7B RUN FEEDACK= THEN EVERY 15 Mins
INTERVAL CHUTE VIBRATOW WILL RUN FOR 2 Mins.

LOGIC & INTERLOCKS OF SCREEN & CRUSHER
• SCREEN TRIP/STOP LOGIC/INTERLOCKS:-
1. BCN-8A/8B RUNNING FEEDBACK UNHEALTHY.
2. SCOOP OUT LIMIT FEEDBACK UNHEALTHY.
3. IF CRUSHER MOTOR GET TRIP WITH HIGH VIBRATION
4. CRS-A/B RUNNING FEEDBACK UNHEALTHY.
5. IF BCN-8A/8B GET TRIP ON ANY PROTECTION.
6. EPB PRESSED
7. SCREEN OVERLOAD/SHORT CIRCUIT
8. CRUSHER ZSS UNHEALTHY
9. MCC DISTURBED

CRUSHER START/STOP LOGIC/INTERLOCK
CRUSHER START LOGIC/INTERLOCKS:-
1.CRUSHER REMOTE SELECTION ( FOR REMOTE OPERATION)
2. BEARING TEMP/WINDING TEMP HEALTHY.
3. VIBRATION HEALTHY (DE/NDE SIDE)
4.SCOOP OIL PUMP RUNNING FEEDBACK HEALTHY .
5.CRUSHER SCOOP TUBE IN FEEDBACK.
6. PROTECTION (MASTER TRIP-86) NOT OPERATED.
7. BREAKER SPRING CHARGED FEEDBACK.
8. TRIP CIRCUIT HEALTHY FEEDBACK.
9. CRUSHER OFF FEEDBACK.
10. BREAKER SERVICE POSITION FEEDBACK.
11.CRUSHER LOCAL SELECTION (FOR LOCAL OPERATION)
12. EPB NOT PRESSED
13.NOT SELECTED IN REMOTE
14. SL NO:-2 TO 9

CRUSHER STOP/TRIP LOGIC /INTERLOCKS:-
1. HIGH BEARING/ WINDING TEMPERATURE
2. HIGH VIBRATION (MOTOR ONLY)
3. CRUSHER SCOOP OIL PUMP RUN FEEDBACK UNHEALTHY.
4. LOS PRESSED.
5. PROTECTION TRIP
6. MCC DISTURBED
SCOOP OPERATION INTERLOCK:
1. SCOOP LCP KEPT IN REMOTE MODE.
2. SCOOP OIL TANK LEVEL HEALTHY (BYPASSED/FOR FUTURE INTERLOCK)
3. SCOOP OIL TEMP HEALTHY ( TEMPARATURE SWITCH BYPASSED NOW)
4. COOLER FAN START FIRST THEN OIL PUMP WILL GET RUN PERMISSIVE.
5. OIL PUMP DISCHARGE PRESSURE HEALTHY (0.8 KG/SQCM RISING ,36 SEC ON TIME DELAY T1) IF
NOT THEN SCOOP TUBE OUT COMMAND WILL NOT BE EXECUTED & IF IN RUNNING CONDITION
OIL PUMP DISCHARGE PRESSURE GETS UNHEALTHY THEN SCOOP OUT FEEDBACK WILL GET
UNHEALTHY & SCREEN WILL BE TRIPPED.
6. CRUSHER MOTOR ON FEEDBACK
7. SCOOP TUBE OUT PERMISSIVE. ( ON TIME DELAY 25 SEC T2 SCOOP TUBE OUT FEEDBACK
HEALTHY SHOULD COME IF NOT THEN AGAIN SCOOP OUT COMMAND WILL NOT TAKE THEN PRESS
RESET & SCOOP IN COMMAND TO BE GIVEN FIRST THEN SCOOP OUT COMMAND WILL BE
EXECUTED

ALARM & TRIP SETTING OF IMPORTANT PARAMETERS OF
SCREEN & CRUSHER
SCREEN:
O/L ALARM:- 60 Amp @ 800 TPH
O/L TRIP:- 80 Amp @ Above 900 TPH
CRUSHER:-
MOTOR BEARING TEMP ALARM- 75 deg. C TRIP- 85 deg. C (DE OR NDE), 3SEC DELAY
TOTAL RTD -4 ( 2 NOS FOR MOTOR DE/NDE & 2 NOS FOR CRUSHER DE/NDE)
MOTOR WINDIND TEMP ALARM= 100 deg.C, TRIP- 115 deg. C , (R OR Y OR B ) 3 SEC
DELAY
(TOTAL RTD- 6 FOR 3 PHASE)
CRS MOTOR VIBRATION ALARM- 350 micron ( DE X OR DE Y , NDE X OR NDE Y)
VIBRATION TRIP- 450 micron ( 3 sec delay) ( DE X OR DE Y , NDE X OR NDEY)
ZSS TRIP:-
SPEED:- 8 (80 % Total RPM), ITD (INITIAL TIME DELAY)- 4 Sec, NTD (NOMINAL TIME
DELAY)- 6 sec.

PROTECTION OF SCREEN & CRUSHER
SCREEN:-
THERMAL O/L & SHORT CIRCUIT
CRUSHER:-
1. OVER CURRENT
2. EARTH FAULT
3. UNBALANCE
4. UNDER VOLTAGE (FROM BUS PT BY BUS UNDER VOLTAGE)
5. THERMAL O/L
6. EXCESS LONG START
7. BLOCK ROTOR

SCREEN & CRUSHER MAINTENANCE SCHEDULE
• VIBRATING SCREEN:-
• MOTOR & MODULE RM – 90 DAYS INTERVAL
CRUSHER
MOTOR & VCB RM – 90 DAYS INTERVAL
SCOOP OIL PUMP & COOLER FAN MOTOR RM- 90 DAYS INTERVAL
HYDRAULIC DOOR OPENING MOTOR- 180 DAYS INTERVAL
SCOOP INSTRUMENTS ( PRESSURE GAUGE/PRESSURE SWITCH/TEMP
SWITCH CALIBRATION- 365 DAYS INTERVAL
CRUSHER MOTOR GREASING – 90 DAYS INTERVAL
CRUSHER & SCOOP PROTECTION SWITCH & LCP CLEANING – 30 DAYS
INTERVAL

CASE STUDIES IN SCREEN /CRUSHER
SCREEN:-
1. HOLE /CRACK IN SCREEN UPPER DECK DUE TO COAL LUMPS
2. SCREEN CLOTH CRACK DUE TO DAMAGE OF BUCKER UP STRIP
3. SCREEN V BELT TURNING/SNAPPED
4. SCREEN HIGH CURRENT AT NO LOAD DUE TO BEARING MISALIGNMENT.
5. SCREEN CHOCKING DUE TO STICKY COAL
CRUSHER:-
1. HAMMER CRACKING/BREAKING
2. SCOOP TUBE IN/OUT LIMIT MALFUNCTIONING.
3. CRUSHER BEARING TEMP HIGH DUE TO OVERGREASING.
4. KICK OFF PLATE /SCREEN PLATE BOLT BROKEN.
5. COAL LUMPS PASSED GAP BETWEEN SCREEN PLATE & BREAKER PLATE DUE TO REDUCING
HAMMER THICKNESS
6. SCOOP OIL PUMP DISCHARGE PRESSURE LOW DUE TO SCOOP OIL CIRCUIT FILTER
CLOGGING / SCOOP OIL TANK LEVEL LOW .

THANK
YOU……..

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