Coal Handling Systems Operation And Maintenance Training

Objectives:
• Understand the overall layout and components of a coal handling plant.
• Identify key safety regulations and procedures relevant to coal handling.
• Recognise different types of coal and their properties affecting handling.
• Describe the basic flow of coal from delivery to storage.

Topics:
• Overview of coal handling systems: purpose and components.
• Coal characteristics: types, moisture, size, and calorific value.
• Safety in coal handling: lockout/tagout, dust control, fire prevention.
• Personal protective equipment (PPE) requirements.
• Plant layout: conveyors, crushers, stockpiles, reclaimers.
• Introduction to relevant SANS and OHS Act regulations.

Objectives:
• Identify conveyor components and their functions.
• Perform pre-start checks and start-up procedures for belt conveyors.
• Monitor belt alignment, tension, and tracking.
• Understand basic conveyor controls and interlocks.

Topics:
• Conveyor belt types and construction.
• Drive systems: motors, gearboxes, pulleys.
• Idlers, rollers, and belt support structures.
• Belt tensioning and tracking adjustments.
• Start-up and shut-down sequences.
• Safety devices: pull cords, belt sway switches, speed sensors.

Objectives:
• Describe the operation of primary and secondary crushers.
• Adjust crusher settings for desired coal size.
• Monitor screen performance and prevent blinding.
• Perform routine inspections on crushing and screening equipment.

Topics:
• Types of crushers: jaw, impact, and roll crushers.
• Crusher setting adjustment and tramp iron protection.
• Vibrating screens: types, deck configurations, screen media.
• Screen efficiency and troubleshooting.
• Dust suppression systems for crushers.
• Lubrication and maintenance schedules.

Objectives:
• Explain stockpile formation methods and their impact on coal quality.
• Operate stacker and reclaimer equipment safely.
• Manage coal blending and segregation in stockpiles.
• Monitor stockpile temperature and prevent spontaneous combustion.

Topics:
• Stockpiling methods: cone, chevron, windrow.
• Stacker operation: slewing, luffing, travel.
• Reclaimer types: bucket wheel, portal, bridge.
• Blending strategies and quality control.
• Temperature monitoring and fire prevention.
• Dust control during stacking and reclaiming.

Objectives:
• Operate dust collection and suppression systems.
• Maintain magnetic separators and metal detectors.
• Inspect and operate sampling systems.
• Understand the role of weigh feeders and belt scales.

Topics:
• Dust collection systems: bag filters, cyclones.
• Water spray systems for dust suppression.
• Magnetic separators: overhead and drum types.
• Metal detectors and tramp iron removal.
• Coal sampling: mechanical samplers, sample preparation.
• Weigh feeders and belt scales: calibration and accuracy.

Objectives:
• Develop preventive maintenance schedules for coal handling equipment.
• Identify common faults in conveyors, crushers, and reclaimers.
• Perform basic troubleshooting and corrective actions.
• Apply condition monitoring techniques (vibration, temperature).

Topics:
• Preventive maintenance planning and checklists.
• Conveyor belt splicing and repair.
• Bearing replacement and alignment.
• Crusher wear parts inspection and replacement.
• Troubleshooting conveyor jams, spillage, and slippage.
• Condition monitoring: vibration analysis, thermography.

Objectives:
• Interpret basic electrical schematics and control logic.
• Operate PLC-based control systems for coal handling.
• Respond to alarms and fault indications.
• Perform emergency stop procedures and resets.

Topics:
• Motor control centres (MCCs) and starters.
• Variable frequency drives (VFDs) for conveyors.
• Programmable logic controllers (PLCs): inputs/outputs, logic.
• SCADA interfaces and operator panels.
• Alarm management and fault finding.
• Emergency stop circuits and safety interlocks.

Objectives:
• Conduct shift handover with clear communication of plant status.
• Coordinate start-up and shut-down of the entire coal handling system.
• Demonstrate competence in a simulated operational scenario.
• Complete a written assessment covering all course content.

Topics:
• Shift handover procedures and logbook entries.
• Start-up sequence coordination between sections.
• Shut-down procedures and post-shutdown checks.
• Emergency response drills (fire, spill, injury).
• Simulated plant operation exercise.
• Final written assessment and practical evaluation.