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AEP Overland

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AEP Overland

Text of AEP Overland


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    2,50O lon3 of cool per hour feed huge 2.6.million-kilowstt focility near Cherhire, Ohio,from lwo minea locoted lO ond | 5 miles owoy, respectively


    wl." 1-"':": . Erecrric ^ P,,wer

    l ion k i lowat l GeneralJames M. CavinPowr Planr near Cheshire. Ohio, ilimmcdiately facd a coal tran sponar ionproblem. Th problm was simply thalthe two new mines, Meiss I a.d 2.planned for developmenr a\ the prima-ry fuelsupply for the nw facihy. werelocaled respectively l0 and I5 miles

    This new major powr genraringplant . which would add 14 to 15 peFcenl to AEP\ total generating capac'ity. *ould requir. morc than eighi mil-lion lons ofcoal per year. The sazablecoal dcmand for this imporlant planldictal.d thar thc delivery method f.omlhc mines had to be .xrremly reliablewhile sdll cconomical, both a. initial

    . rp i r !1 . , ,s t . a \ wel la \ f tn ! re ing

    AEP \ manr8emenr rnd engineerinSarm. the AEP Scrv icc CorF. . srudiedthe pfu)blem and evahated rhe alrerna-t ives: l ruck haulage. ra i l haulage- andbell conveyor. After considerable in-venigar ion. a bel t conveyor \ysrem oiva( proport ion\ wa\de. ided upon

    The fesul ra. i huge mater ia ls han'd l ing \ tnem. de\ igncd and bui l t byRobins Engineer\ & (onstru. t rs . is

    raniNrt in ! coal r r rhe r r re of 2.500tons IJer hour frcm rhe lwo new deeptd ines in Meiss Counry When bolhmine\ are conplete ly devebped. the\ys lem wir l move more than E mi l l ionlons of co^ l annual ly to lhe new r iv-ersid senerrtins plant near Callipolas.Ohio.

    Col l \eam\ o*ned by AEP s OhioPower (o !nderlie some 56.00O acresin of Meigs. Vinton and cr l l iacoxni ies and are es l imated to conta in

    abov.. view lookin9loward mine No.2 portal-s'lo M2 in loreground ar righri b.eaketM1 and mine No 2 ponal in backoroundi also shown .re slope convsyor MSI (back-g rou nd) and conveyor M 12 {to silo). and seclion or M23 conveyor in exlreme toreg,ound

    E.lo*: Overall vrew laken lrom mrne No ? porlal showr.g slope conveyor MS1 wrthsc . loupto breaker bu i ld inoMl : i iom lhe 'e , conveyor M12 a lso w| rh sca te . to raw co . lsiroM2 rhen, indisra.ce. section ol conveyor M23 toward nineNo.l (nor inview)

    F.p.lnild trom F.bru.ry 1975 COAL l l G & PROCESSII{G

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    Vler l om top o t . l l o M6-gornq up l .om m ne No 1 s b reaker M7 to s i lo M6 s conveyo. M76 l lo reground) be low rs co l lec l ron ber lM6SP l rom bonom o t s r o lo sc feenrng p lanr to (9h t o l sc feen ng rs p rep p lan t beh 'nd prep p an l a re .onveyof MPG2 to s lo G2 andc leancoa s r oG2:conveyora lbor lomnqh l rsMST I e sopeconveyof l rom m neNo l lobreake ' M7

    ! )mc :90 mj l l i , ,n ,c(o\crrh lc r (J . \ . Thccor l . lno$n b lhe ( lnr tun 4.^ \erm.l ie \ .10{) lo l5{ ) n ht los lhc { | f i rceI h. f i r s l !en.r l ing unrr of the : 6 mi ! 'l i { )n ls powg thnr heran .pcrr t i ( )nl r \ t !ear . The rccond uni l $ i l l So on\ t rearn ia ler in l9?5. Ho$ever. eor l forborh unnr i t bc ins sk,ckpi led now

    Ihe l5 mr le conleyd syned conr i \ t \ o i a nve mi le uni r conne. l in8 thcconnanv s two ne* deet mrne\ and a

    l ( l mr lc \ r rc r .h t ( ) . in ) $ r \hc( l r . rl iom hoth mrne\ ro Ih r nos t r thnrI h . in leFmin t \ ! \ rem conr r r i \ c \ r f r i lo l : l / : m r l c r . n \ . \ o . \ $ h , i c r l r cl0 mi le \ ! \ rem cmt lo i \ r *o f r \c n rL l tl l8h t \ over Rr l lng 1e ' ra in

    Longest overland syslem

    In re ! iew inS lhe t i rametcr \ wh j .hhad ro be mer td th i \ rys rem. RE&( l

    ru [ /ed rh . ] r . ( )nvenrnrnn l .on \ rvo lr ._ .hno l ( )s \ $Lr l l nor !o rh . r (Jb Ihe\ r \ rcm $ou ld h . rh r lo rg . \ r In rhec o r i r r \ : t h c l . r r r i n $ r \ r ( { r u o r \ . r . dlhc rc \u l In8 c r . rhs . r l ! . \ l $ou ldhnvc k , b . m in ih i /ed In i r l r l . rp i ta lr . \ l h rd l . hc los ' rnd lhc rv r i l !b i l i t to f rhe \ ! \ tem hrJ to he ver ! h igh .

    Onc o f rhe 'n , , id eo \ r \ borh In cap i ta lou t l ! ! lnd mr in lenr .cc on an over land!ysrem 3re rhe conve!or .omNnent \

  • rn! \xpnol . l $hr(h inc lude convt !o 'id lcr \ . \ r rur lurc\ . fouodar jon\_ bel l inS

    Al lo l lhc{ ' tuekrr \ i rc in l luenccr i h tr h c s , d r h o l r h e \ y \ r e h s h i ( h $ , i t t v ! r ,drr .c l l ! t r i lh lhe \peed of lhe hehWhi l . eon!ent ionr l design\ $ould d ieta le ! ie . t l \ rn rhe order o i 600 f t /min.our r inr l rc lccr ion {a\ 950 l i /nr in re,\u l l rn ! in ! bel t width of only 48 in . rorchreve a.onservat ive del iver t r r tc oflJ00 rph

    In ovedand conveyor systems. i t isde\r rable l rom both the in i l ia l con \ landpornts to use a\ fe*

    f l rghl r (con!etors) as pors ib le In turn-thr \ d icr r te\ rhe l5ngc\r convetor \nrxcrreal ro the in \ la l la l ion.

    Conveyor design

    Al ier a lhorougb anr lysrs of lhe rerfu,n.ouplcd w' lh the object ive ofstandxrdizar ion of dr ives. each o!edandconveyor $as d iv ided into two f l igb ls .The f ive d i le system i r conpo\ed ofconveyor\ 10.000 and 10.847 fi long,phi le lhe f l ights on the lO-mi le synemare ?2.291 and 28.181 f t lons rspec,t ive ly . among tbe wor ld s largesl .

    Convent ional design would ur i l izeidlers spaced al5 ft on the carrying rideand l0 f l on the return. However. pre-vo!s rsearcb a.d p ioneer ing in con,ve!-or desisn bad prcven rh spacingcould he at least do!bled if rhe properid ler con{ isutat io . and deign concepls

    Af ter a lhorough re! iew. we ur i l izeda l0 tl \pacing on lbe troughers and a20 fi spacin8 on lh reiurns.

    A new hea!y duly id ler was desienedlor lh is appl ica l ion and uted an extrabea!y dury cenrer ro l lwi rh heary durye.d ro l ls ro mrrch the ro l ls * i th rhei r

    Ihe rc lur . id lers were of the Vee'tyFe to n in imize 1 'a in inB problems onthe re lurn \ t rand. Approximately 8000id lers we.e requ;cd. which permi edus b design and t ( t the id ler as an,ntegral parr of rbe idler srand. funhe.

    The final desisn also considered in-sra l l r r io6 cosls . The foundal ions for(he nand arc two cylindrical pierserecled by augering holes precisly lo,caled by special e.clion jigs and usiDSsonotube lype foms.

    Final a l ignnenl o i lhe id lrs em-ploycd laser beam sur ley inB tech-

    Belling & drivesThe cooveyor bel l ins i \ a s igniUcani

    parl of the cosr of a sysrem and thedes'gner must carefully consider fac-rom which wi l lextend i l t l i fe .

    The pr in. ipal in f luence in beh coverlifc ^ the wear occurinB at Ihe lran\ferpornls due to jmpacl and accelerarion

    Minimiz ing the .umber of lhe5epoinls by use of long flighls is a slep inlhe r ighl d i rec l ion. Ut i l izar ion of i .li.e lransfers essenlially of the beltto bell varieiy reduces the accelera-tion forces fur(her reducing belt cover

    Conveyor belc usually have a resi,due of male.ial on ihe carying side.Conventional conveyor consiructionhas lbe caffyin! sid in conhci with therel'rrn idlere. This *ould present sev.eral major problems on a long con-veyo.. Frrst, ihere *ould b undesi-rable wear on borh rhe beh ard rcturnid le6. In addi t ion, mater ia l tends iobuild up on the idlrs frequently cau$ine the belt to mi(rain. This .esulc inunnecessary marntenance and cleanup

    - E E I E - I f

    f , 3 A f [ I 3 E n J * f

    C lo3e- up rle, ol noro.ired t. ke-up ot co nveyo. M45 and I ran ster slation M 5

  • To aloid lhse problems. we used''lurn overs close 1o each rerminal topresenr the clean side oi lhe beli lorhe r ra in ins id lers. This h a . imple mechanicaldevicc us ing d l t to rurn overlhe bel t wi thout undue st ra int .

    The conleyom are undular ins, tend,in8 to fo l low lhe ier ra in o l lhecounlry. The final delermi.alion of lheprofiles considered bolh conveyor design and eanh movins con\ achieving

    The combinalion of lonc flighc andund!lating profiles requires a detaitedanalys is of rhe lensions in the btr u. ,der a vrnely of both sla jne and run-nrns condi l ions. The solu l ion was jnth conl ro l o f in i i ia l rensionscombinedwrrh rhe conrrolled applicnlion of torque and acceleralion. RE&C achievedthis by lhe use ofan electro-mechanicallensNnrng sys lem and oul r ip te dr ivesin which the motor rpeed and lorqueare eleclronically controlled by eddy

    The five-mile flights are drilen byfour l00O hp motors, rhree drivinB lheconveyo.s head end ard one dr iv inSthe ta i lend. A f i f lh noror reducer cou,plrng set\ acts as standby at lhe headend. The lwo and a hal f mi le Uirh lsemploy lhree mo1o.5 driling rwo put,leys at tbe head end of the conveyorwalh afour th as standby. Al lconveyorsare equipped wirh motd drive. len-s ioni .g e inches at the head end.

    Equlpment operationIn operation. here\ how rhis com

    binarion of equipment works: The fi 6ts lep is an in i t ia l lensioning cycte. Be-fore act ivat ing lhe dr ives. rhe winchta&e-up is enga8ed lo a pre-\el tevelwhich is auromal ica l ly sensed by n to.dcell which is an inregral pan of rhe

    Next . a l l o f rhe dr ive sysrem s motors arc brought ut ro synchronolsspeed (1750 rpm)and rhe eddy curenrc lu ich/coupl ings are enga8ed. The cou-plngs are provided wirh rwo \e(ings:pre-lensioning and acceleration. In thepre lension mod, the coupli.Ss followa fixed lorque romp from zero io tt25lb fi/min durins a lariable period up roa maximum of four minutes.

    A torque command signal is devefoped as a funcli

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