LHS Training Manual

LIMESTONE & GYPSUM HANDLING SYSTEM
TRAINING MANUAL
REV.4 2017.09.25
CONTENTS
1.1 BIRD’s EYE VIEW PLANT

1.2 FLOW DIAGRAM(LIMESTONE & GYPSUM)
1.3 INTRODUCTION
1.4 BELT CONVEYOR
1.5 BUCKET ELEVATOR
1.6 PIPE CONVEYOR
1.7 PACKAGE ITEMS
1.8 BELT CONVEYOR COMPONENTS
1.9 SAFETY DEVICE
1.10 Euro Silo and Unloaders
1
1.1 BIRD’s EYE VIEW PLANT
2
1. 2 Flow Diagram
1.2.1 Limestone conveyor system
3
1. 2 Flow Diagram
1.2.2 Gypsum conveyor system

  
4
1.3 INTRODUCTION
The purpose of this training manual is to describe the Limestone & Gypsum Handling System
Material Handling System consists of ;

- Ship Unloader (continuous type ship unloader, Grab type ship unloader)
- Belt Conveyor & Bucket Elevator & Pipe conveyor
- Package Items (Vibrating Feeder, Bin Activator, Belt scale, Truck scale, Magnetic Separator,
Sampling system, Dust collection system, Crusher, Metal Detector, Flap gate etc.,)
- Components (Motor(Geared motor),Coupling, Back stop, Reducer, Belt cleaner, Brake, V-

scraper, Pulley, Idler, Belt, etc.,)
- Safety device
- Transfer Tower & Limestone Shed or Silo & Gypsum Shed or Euro silo
5
1.4 BELT CONVEYOR
1.4.1 BELT CONVEYOR DETAIL
• Components
- 7. Drive Unit(Motor, coupling, reducer)
- 7. 2. 11. 12 Pulley (Head, Tail, Snub)
- 4.15.3.5 Idler (Carrying, Return, Impact, Transition, Self
Aligning)
- 14. Belt
- 9. 10. Belt Cleaner
- 1. Chute(Liner, )
- 12. Take-up Device( Bent pulley, weight box)
- Support Structure 6
1.4 BELT CONVEYOR
1.4.2 STRINGER TYPE
Conveyor frame is steel channel and stringer with suitable supports and framework for
attachment of supporting bents
7
1.4 BELT CONVEYOR
1.4.3 GIRDER & GALLEY TYPE
Conveyor frame is steel channel and stringer with suitable supports and framework for
attachment of supporting bents, including necessary truss work, bracing.
1.5 BUCKET ELEVATOR
The bucket elevator is complete with motor, reducer, coupling, bucket, chain or belt, pulley, head and
tail casing.
The bucket elevator is vertical self supporting structure with continuous discharge type.
50-100m/min
10-14m/min
15-40m/min
9
1.6 PIPE CONVEYOR
10
1.7 PACKAGE ITEMS
1.7.1 Vibrating Feeder
The Vibrating feeder is installed under

the limestone underground hopper.
The feeder control the limestone flow
from the limestone underground
hopper to the conveyor.
1.7.2 Bin Activator
The Bin activator is installed under

the limestone daye silo.
The activator control the limestone
flow from the day silo to Weigh feeder.
11
1.7 PACKAGE ITEMS
1.7.3 Discharge Machine
The Discharge machine is installed

under the limestone underground
hopper.
The machine control the limestone
flow from the limestone underground
hopper to the conveyor.
1.7.4 Apron Feeder
The Apron feeder is installed above

ground.
12
1.7 PACKAGE ITEMS
1.7.5 Belt scale & Truck scale
The belt scale is installed on conveyors for recording delivery receiving limestone quantities.
The Truck scale is installed on ground for recording Truck weight limestone quantities.
13
1.7 PACKAGE ITEMS
1.7.6 MAGENNTIC SEPARATOR
The magnetic separators is installed on conveyor for removal of metallic refuse from the
receiving conveyor
14
1.7 PACKAGE ITEMS
1.7.7 Sampling system
The sampling system is designed to take sample of received limestone delivered on limestone
conveyor
15
1.7 PACKAGE ITEMS
1.7.8 DUST COLLECTION SYSTEM
The dust collection system is installed for dust removal system of discharge point conveyors.
16
1.7 PACKAGE ITEMS
1.7.9 CRUSHER
The Crusher is installed for crushing limestone.(250mm -> 20mm)
Roll Impact Hammer mills Jaw crusher
17
1.7 PACKAGE ITEMS
1.7.10 METAL DETECTOR
The metal detectors is installed on conveyor top for detect of ferrous metal or nonferrous metal
18
1.7 PACKAGE ITEMS
1.7.11 FLAP GATE
The flap gate is installed for limestone conveyor’s stream to change another conveyor line.
flap rotate
left or right
19
1.7 PACKAGE ITEMS
1.7.12 SCREEN
The Screen is installed for screening limestone size before a crusher
20
1.7 PACKAGE ITEMS
1.7.13 Plough system / Travelling Tripper
The Plough system is installed on conveyor top for discharging limestone to silo or Shed
21
1.8 BELT CONVEYOR COMPONENT
- Electric Motor - Fluid Coupling - Back Stop

( For Inclined Conveyor)
- Reducer
- Gear Coupling - Belt Cleaner
- Geared Motor - Thrust Brake - V-scraper

(For 30kW under)
22
- Pulleys - Return Idler
(Drive/Head/Tail/Snub/Bend) (Every 3m spacing)
- Carrying Idler - Self Aligning Idler

(Every 1m spacing) (Every 24m spacing)
- Impact Idler - Transition Idler

(Loading Part)
(Head & Tail Transition Part )
23
- Rubber Belt(Multi-ply) - Side wall Rubber Belt
- Rubber Belt(steel core)
24
1.9 SAFETY DEVICE
Belt Misalignment S/W

(Belt sway S/W)
Pull-cord S/W
Zero speed S/W

Belt Break Chute S/W
Limit S/W
25
1.10 Euro Silo ( for Gypsum) and Unloaders( for Limestone)
Euro Silo Continuous Ship Unloader (CSU)
Grab Type Ship Unloader (GTSU)
26
END

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LIMESTONE & GYPSUM HANDLING SYSTEM

1.1 BIRD’s EYE VIEW PLANT

1.2.1 Limestone conveyor system

1.2.2 Gypsum conveyor system

Material Handling System consists of ;

- Belt Conveyor & Bucket Elevator & Pipe conveyor

- Components (Motor(Geared motor),Coupling, Back stop, Reducer, Belt cleaner, Brake, V-

The Vibrating feeder is installed under

1.7.2 Bin Activator

The Bin activator is installed under

The Discharge machine is installed

1.7.4 Apron Feeder

The Apron feeder is installed above

Roll Impact Hammer mills Jaw crusher

- Electric Motor - Fluid Coupling - Back Stop

- Geared Motor - Thrust Brake - V-scraper

- Carrying Idler - Self Aligning Idler

- Impact Idler - Transition Idler

- Rubber Belt(steel core)

Belt Misalignment S/W

Zero speed S/W

Grab Type Ship Unloader (GTSU)

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