Troubleshooting of CHP Equipments.

S Equip Defect Reason Impact Remedy

r ment
n
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1 Wagon
tippler
1)Table rail
&outer rail
Continuous in-out of loaded
wagons and engine on WT table
Wagon derailment 1)OTLS(Over travel limit
switch) setting to be
mismatch disturbing OTLS setting & or cup- adjusted and trial with
cone assembly empty wagon to be taken.
may get disturb/shifted. 2)cup cone assembly to be
repositioned and refitted.
2)Big lumps Hopper grills get damaged due to 1)vibrating feeder Timely repair or
passing through high impact of big lumps, stone liners damaged replacement of hopper
grills of wagon shells during unloading of wagon 2)lump, shells stuck up grills of required size
tippler hopper. contains raw coal into vibrating feeder
3)conveyor belt may
get damaged
4)Crusher components
like hammers ,rings
may get damaged .
3)Uneven/erratic 1)Poor cleaning ,wear out of 1)Wagon derailment 1)Timely and proper
operation of clamping pad, poor or no 2) Aggravates the cleaning by removing
wagon holding lubrication of rotating elements clamping system. debris of coal &coal dust
clamping system of clamping arrangements. 2) Lubrication of rotating
elements of clamping
arrangements.
crusher Excessive Unbalance of rotor due to 1) Damages to rotor, 1) Stone shells, big lumps
2 vibrations to damages to crusher elements like bearing of rotor, to be trap before entering
crusher hammer, ring due to stone shells, overloading of motor, into crusher.
big lumps. undesired coal size 2) Periodic monitoring of
may pass to bunker. vibrations and bearing
2)Wear out of grinding temperature.
plates. 3) Lubrication schedule to
be followed.
4)periodic inspection of
crusher elements and
grinding liners and
balancing of crusher
elements.
Transfer Reduction in 1)Continuous coal flow 1)Damaged the body 1)Timely inspection of
3 Chute thickness due to 2)Crack generated from the holes of crusher liner plates.
Liners, wearing of for fixing of bolts 2)Adding into 2)periodic replacements of
Grinding jib surface vibrations liner plates.
of crushers
Bearings 1)Development of 1)Improper or excessive loading 1)Damages the bearing 1)Periodic monitoring of
4 failure cracks in the race 2)Dust ingress into bearing. 2)Damages the shaft. bearing temperature and
2)Heating of 3)poor lubrication. 3)wearing out of shaft. measurement of bearing
bearing upto clearances.
abnormal level 2)preventive maintenance
3)Abnormal to be followed strictly.
 sound observed 3)Sealing to be done to
in bearing hub. avoid ingress of coal dust.
4)contaminated grease to
be removed before fresh
lubrication.
5 Conveyor 1)Due to End disc 1)Cyclic loading of conveyors. Failure of the weld 1)periodic inspection to be
pulleys failure 2)Frequent on/off of conveyor between the hub and carried out.
3)Failure of the end disc in welded- 2)Lock nut to be checked
locking assembly in hub designs. for its positioning and
tightness.
Drive Bolt failure, Cyclic loading of conveyors. A result of 1)Scheduled preventive
6 foundations Frame failure manufacturing maintenance of drive .
fabrication defects or 2)Nut bolt tightening of
localized damage in drive bearing
service, assembly ,gear box
foundation ,motor
foundation with proper
torque.