Doc No: D108

Rev No: 00

STTAR ENGINEERING SERVICES

Write up on Control System Design for Side Scraper
Reclaimer
RAIN INDUSTRIES LTD.,

GENERAL WRITE UP ON
CONTROL SYSTEM DESIGN
FOR
SIDE SCRAPER RECLAIMER

Project

Side Scraper Reclaimer,

Page No.:

1/7

Client

Rain Industries Ltd.,

Date

25-Jan-07

Customer :

Mantakraf India Pvt. Ltd.,

Supplier:

Sttar Engineering Services.

Doc No: D108

Rev No: 00

1.0

STTAR ENGINEERING SERVICES

Write up on Control System Design for Side Scraper
Reclaimer
RAIN INDUSTRIES LTD.,

GENERAL DESCRIPTION
1 No. Side Scraper Reclaimer is used to reclaim the material from stock pile. The
stockpiles are situated on either side of these conveyors. There are land mounted buffer
end stops to positively limit overtravel. The electrical power supply to the machines is via
power Cable reeling drum. The cables are routed from a land mounted central anchorage.
The control signals are transfered to main PLC through control cable reeling drum.

2.0

PLANT PHILOSOPHY
The machine operates in conjunction with a unidirectional reclaim conveyor, which transports
material from machine, when required.
The control & sequential operation of drives and equipments of reclaimer shall be done by
using field proven programmable logic control (PLC) system. The programmable logic
control (PLC) system shall consist of CPU, I/O modules. The machine operations are
possible from the control desk in operator's cabin in Auto & Manual Mode and from Local
Control Station of respective drives in Maintenance Mode. The operator interface for control
& monitoring shall be via a control desk (CD).

3.0

CONTROL SYSTEM ARCHITECTURE

The PLC system will be installed in the machine E-house. It will be housing CPU panel and
Cater to the I/O requirements of MCC, field and control desk I/Os.

4.0

MODES OF CONTROL

4.1

AUTOMATIC MODE (AUTO)

The co-ordination of scraper chain conveyor and travel during operation is achieved
automatically in this mode. However, machine should be made ready, i.e., individual starting
of drives and positioning of machine and scraper boom (in slow speed) should be done in
manual mode only. Once the machine is ready, auto operation is initiated by auto start push
button on the control desk in Operators cabin. It stops whenever a fault occurs or auto stop
push button is pressed.

Project

Side Scraper Reclaimer,

Page No.:

2/7

Client

Rain Industries Ltd.,

Date

25-Jan-07

Customer :

Mantakraf India Pvt. Ltd.,

Supplier:

Sttar Engineering Services.

Doc No: D108

STTAR ENGINEERING SERVICES

Write up on Control System Design for Side Scraper
Reclaimer
RAIN INDUSTRIES LTD.,

Rev No: 00

4.2

MANUAL MODE (CABIN MANUAL)

The scraper hoist, scraper chain drive, and travel motion of machine are controlled
individually by the operator by push buttons provided on the control desk in control cabin.

4.3

MAINTENANCE MODE (LOCAL MANUAL)

This mode is generally used for maintenance of machine. No load operations are
recommended in this mode of operation. Hoist, scraper and travel drive are controlled
individually from the respective local control stations without sequential and only minimum
safety interlocks.

5.0

OPERATIONS OF MACHINE

5.1

RECLAIMING OPERATION

A.

Automatic Reclaiming:
The scraper is lowered at slow speed up to the presence of pile before
commencement of reclaiming operation manually to align the scraper along with the pile
already formed.
Reclaimer yard conveyor will be started first from the control room and upon receipt of
reclaimer running signal from CCR to machine PLC, siren will be initiated and then the
reclaimer scraper chain will be started with a time delay.
Based on the depth of cut programmed, the scraper boom will be lowered at every end point
Of the layer. This will continue up to reclaiming the total pile.
Once the pile is fully reclaimed, the scraper hoist will be run at full speed manually
and travel drive will also be run at full speed manually to ensure efficient and quick transfer of
machine from one pile to another.
CHECKS TO START AUTO RECLAIMING SEQUENCE
1.
2.
3.
4.
5.
6.
7.
8.

Emergency stop circuit healthy

Reclaim conveyor running
Travel drive healthy
PCRD healthy
CCRD healthy
Long travel not overtravelled
Depth of cut programmed
Travel set point programmed

Project

Side Scraper Reclaimer,

Page No.:

3/7

Client

Rain Industries Ltd.,

Date

25-Jan-07

Customer :

Mantakraf India Pvt. Ltd.,

Supplier:

Sttar Engineering Services.

Doc No: D108

Rev No: 00

STTAR ENGINEERING SERVICES

Write up on Control System Design for Side Scraper
Reclaimer
RAIN INDUSTRIES LTD.,

A fault occurs when any one of this condition fails.

B.

Manual Reclaiming:
In this mode the sequence of operation remains same as auto reclaiming mode. But
operator has to manually do the operations by pressing individual push buttons available on
control desk.
CHECKS FOR MANUAL RECLAIMING
Same as for Auto Reclaiming.

5.2

NORMAL TRAVEL OPERATION

This mode is used to travel the machine in Idle, i.e., no load condition. So no sequential
interlocks are required and only safety interlocks are provided in this mode.
NORMAL TRAVEL CHECKS a.
b.
c.
d.
e.
f.
g.

Manual mode selected

Long travel drive not overloaded
Long travel not overtravelled
PCRD healthy.
CCRD healthy
Local stop not pressed
Travel drive Brakes lifted

6.0

START-UP LOGIC FOR INDIVIDUAL DRIVES

6.1

SCRAPER CHAIN CONVEYOR

This is a set of scraper attached conveyor drive when it run scoops material and delivers to
the discharge chute of the machine and thereafter it is transferred to the main reclaiming
conveyor.
It can be started by the push buttons on control desk in auto / manual mode, if checks are
O.K. or through the LCS in Maintenance Mode.

a)

Scraper chain conveyor common checks

i)

Scraper chain conveyor stop push button

In CD not pressed.
Chain lubrication system healthy.

ii)

] For Auto and

] Manual modes only.

Project

Side Scraper Reclaimer,

Page No.:

4/7

Client

Rain Industries Ltd.,

Date

25-Jan-07

Customer :

Mantakraf India Pvt. Ltd.,

Supplier:

Sttar Engineering Services.

Doc No: D108

Rev No: 00

STTAR ENGINEERING SERVICES

Write up on Control System Design for Side Scraper
Reclaimer
RAIN INDUSTRIES LTD.,

iii)
iv)
v)
vi)

Scraper chain conveyor healthy.

Reclaimer conveyor running
Scraper chain conveyor not electrically over loaded.
Local stop push button not pressed.

b)

Scraper chain conveyor Running

i)
ii)

Scraper chain run feedback healthy

Scraper chain is not snapped

]
] Only Auto mode
] For all modes.
]

] For Auto and

] Manual modes only.

If any of these condition fails, it will trip the Scraper chain Conveyor.
6.2

SCRAPER CHAIN HOIST DRIVE

Scraper chain hoist drive is used to position the scraper boom onto the pile face for efficient
reclaiming. An Incremental encoder is fitted in the drive motor for closed loop torque control
and also for length of rope unwound measurement.
This is rope driven system with winches for winding and unwinding of wire ropes.
SCRAPER CHAIN HOIST CHECKS :
a)
b)
c)
d)

Scraper chain hoist not electrically overloaded

Emergency stop circuit healthy
Scraper chain hoist stop PB
on CD not pressed
Local stop PB not pressed

]
]
]
]
] For all modes.

BOOM RAISE CHECKS

a.
b.

Hoist not fully raised

Hoist running feedback

] For all modes.

]

BOOM LOWER CHECKS

a.
b.

Hoist not fully lowered

Hoist running feedback

] For all modes.

]

Project

Side Scraper Reclaimer,

Page No.:

5/7

Client

Rain Industries Ltd.,

Date

25-Jan-07

Customer :

Mantakraf India Pvt. Ltd.,

Supplier:

Sttar Engineering Services.

Doc No: D108

Rev No: 00

6.3

STTAR ENGINEERING SERVICES

Write up on Control System Design for Side Scraper
Reclaimer
RAIN INDUSTRIES LTD.,

LONG TRAVEL DRIVE

The Long travel of the machine is achived via 2 nos. Squirrel cage induction motors driven
by a common VVVF drive for smooth acceleration and deceleration.
During reclaiming the drives operate at slow speed for better reclaiming and during pile to
pile transfer, the drives operate at rated speed for swift transfer. Speeds are set in operator
interface mounted in the control desk.
The brakes of drive motors are designed as holding brakes, and are
a) Used to hold the machine at standstill, with normal decelaration
LONG TRAVEL COMMON CHECKS
a.
b.
c.
d.
e.
f.

Emergency stop circuit healthy

Long travel drive healthy
PCRD healthy
CCRD healthy
Travel drive brakes lifted
Local stop PB not pressed

For all modes.

CHECKS FOR RECLAIMING OPERATION

a.
b.
c.
6.4

Scraper chain conveyor running

Reclaimer conveyor running
Auto Start Operation initiated

POWER CABLE REELING DRUM DRIVES

Power is fed to Reclaimer machine through power reeling drum via trailing cables. The drive
motors are rated for continuous operation with machine stationary.
The reeling drums when energised maintain the cables at the correct tension and thus
they are laid correctly or picked up as the machine travels.
Provided that the checks are satisfied reeling drums are energised when long travel
drive gives a command to energise it.

Project

Side Scraper Reclaimer,

Page No.:

6/7

Client

Rain Industries Ltd.,

Date

25-Jan-07

Customer :

Mantakraf India Pvt. Ltd.,

Supplier:

Sttar Engineering Services.

Doc No: D108

Rev No: 00

STTAR ENGINEERING SERVICES

Write up on Control System Design for Side Scraper
Reclaimer
RAIN INDUSTRIES LTD.,

PCRD CHECKS
a.
b.

Power Reeling drums cable not electrically overloaded

Power Reeling drums cables not electrically overloaded

The drums operate in conjunction with the travel drive. In case of any fault of PCRD or
travel drive, the other drive will stop.
6.5

CONTROL CABLE REELING DRUM DRIVES

Control is fed to Reclaimer machine through control reeling drum via trailing cables. The
drive motors are rated for continuous operation with machine stationary.
The reeling drums when energised maintain the cables at the correct tension and thus
they are laid correctly or picked up as the machine travels.
Provided that the checks are satisfied reeling drums are energised when long travel
drive gives a command to energise it.
CCRD CHECKS
a.
b.

Control Reeling drums cable not electrically overloaded

Control Reeling drums cables not electrically overloaded

The drums operate in conjunction with the travel drive.

7.0
8.0

INTERF
ACE BETWEEN LAND PLC AND MACHINE PLC
The following Hard wired is transmitted via control cable reeling drum to Land PLC and the
Machine PLC for correct and safe operation of reclaimer.

7.1

FROM MACHINE PLC TO LAND PLC

1.
2.

7.2

Reclaimer Ready to start FB

Scraper Chain on FB
FROM LAND PLC TO MACHINE PLC
1. Reclaimer Remote ON
2. Reclaimer yard conv. running

Project

Side Scraper Reclaimer,

Page No.:

7/7

Client

Rain Industries Ltd.,

Date

25-Jan-07

Customer :

Mantakraf India Pvt. Ltd.,

Supplier:

Sttar Engineering Services.