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PARTIAL LIST

OF COAL
HANDLING
PRESTART
CHECK

COAL HANDLING PLANT PRE START CHECK


Task: Conveyor Pre-Start Check
PROCEDURE

ACTION BY

Ensure that all maintenance works


are done before starting the conveyor
system.

FIELD

The conveyor is ready for use and is


not tagged out.
Confirm that all maintenance work
permit issued is returned
Confirm that no alarms are present
prior to conveyor starting

CCR

It does not have people working on it.

FIELD

Check guards in place to prevent


access to all dangerous areas during
the conveyor systems operation.

FIELD

Lubrication systems are working and

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CCR
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oil levels have been checked (if


necessary).

Dust extraction points are secure and

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inspection hatches are closed.

Safety lanyards have been reset.

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Make sure that guards either


permanently or securely fixed to
ensure the guard cannot be altered
or detached without the aid of a tool
or key.
If a fixed barrier is not practicable and
access to dangerous areas is
required during operation, check if an
interlocked physical barrier used.
Tail and head drums are secure and
bearings appear intact.

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ACTION
CONFIRM

REMARKS

Check that nip points are guarded.

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Make sure that all stop/start control


and emergency stop switches clearly
marked.

Make sure that operators wear

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appropriate clothing: for example,


they avoid loose clothing, and keep
their hair controlled under caps

Ensure that all the belt splices are

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intact.

Ensure that all temporary


construction struts, stays and
steelwork are removed and that the
belt path is clear and free from
obstructions
Check that all additional steelwork,
plate work and attachments over the
conveyor are secure and that no
loose members can contact the belt
Check that belt travel (both carry and
return side) is clear from any sharp
edges on the conveyor structure
which may cause belt damage when
tracking conveyor belt
Ensure that all the idlers are properly
aligned and securely bolted and that
they can rotate freely, on both the
carrying and return strands
Check that all safety devices have
been installed and commissioning
prior to start-up. In particular, check
that speed sensing devices are
correctly installed
Check that all over-travel devices are
correctly located and are operational

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Check that all pulleys are securely

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fastened and aligned

Check that all bearings are correctly


greased
Check that the power packs are
securely fastened down and that the
reducers are properly lubricated with
the correct grade filling oil
Where the reducer is fitted with a
holdback, check that the unit rotation
is in the correct sense
Check that the holdback is correctly
lubricated.

Check that all couplings are correctly


aligned and that their transmission
systems ( such as driving pins, grids,
etc ) are in place
Check that the coupling all lubrication
requirements are met, for both high
speed and low speed locations
Check that all coupling covers and
guard covers are in place

Check the counter-weight. In


particular check that the
counterweight is correctly fitted with
the design mass and that the position
of the counterweight is in accordance
with the design
Check the condition of counterweight
carriage and take-up carriage

Check that belt sway switches are

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installed and commissioned

Check that zero speed switch is

installed and commissioned


Check the lubrication of following in
accordance with manufacturers
recommendations:

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1
All idler, rollers.
2
Gear Box.
3
Fluid coupling.
4
Gear Coupling
Check that there is no sag on the belt
in between the idlers

Check erection records for the


correct alignment of bolt idler
supports with respect to conveyor
centre line.
Ensure that all interlocks are meet
and no alarms are present before
starting the conveyor

FIELD
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CCR

Task: Ship Unloader Pre-Start Check


PROCEDURE

ACTION BY

Ensure that all maintenance works

FIELD

are done before starting the ship


unloader
The ship unloader is ready for use
and is not tagged out.
Confirm that all maintenance work
permit issued is returned

Check access to areas requiring


routine maintenance as well as stairs
and optional elevator to main areas
of the unloader
Check spud locks, tie downs, and rail
clamps for safe storage during
maintenance or adverse weather
conditions
Check operators cab safety restraint

It does not have people working on it

CCR

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ACTION
CONFIRM

REMARKS

Check guards in place to prevent


access to all dangerous areas during
the ship unloader systems operation.

FIELD

Check rope for wear and

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deterioration
Check correct rope angle from drums
and sheaves

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Check rope pattern between bucket

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and trolley that protects rope at


stress points and helps ensure
bucket stability
Ensure that all interlocks are meet
and no alarms are present before
starting the ship unloader

FIELD/CCR

Task: Tripper Pre-Start Check

PROCEDURE

ACTION BY

Installations are complete as per the


drawing
The Tripper is ready for use and is
not tagged out.
Confirm that all maintenance work
permit issued is returned
Rail tracks are level aligned a parallel

FIELD

Check both front and rear gear boxes


as per the standard check list

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Gear boxes front and rear alignment


is O.K

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Check that all the wheels are


coplanar

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ACTION
CONFIRM

REMARK
S

Check that electromagnetic brakes


on both driving motor and installed
and checked as per the check list
Check that the installation of rail
clamps is O.K

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Check the installation of flap gate

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Sealing belts installation is complete


with all its tensioning scheme

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Stoppers at the extreme and of travel


are provided

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Driving motors front and rear both


checked as per the standard check
list
Check that the cable reeling drum
installation is complete as per its
check list
Check the lubrication of following:
o Gear box front and rear.
o Run wheels bush bearings.
o Idler pulleys bearings.

FIELD

Ensure that all interlocks are meet


and no alarms are present before
starting the Tripper

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CCR

Task: Vibrating Feeder Pre-Start Check


PROCEDURE

The installation is complete in


accordance with approved drawings
and specifications
The Vibrating Feeder is ready for use
and is not tagged out.

ACTION BY
FIELD

CCR

ACTION
CONFIRM

REMARK
S

Confirm that all maintenance work


permit issued is returned
Clearance between the vibrating part
and fixed part is at prescribed
distance
Check that universal coupling joint
coincides with arrow mark on the fork
Check that all the 4 weights on two
fly-wheel segments of unbalanced
exciter are fully secured

CCR
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Check for the correct level of the


exciter base. Check the seating area
of exciter on its frame from the
erection checks records
Check that universal joint shaft is in
level with exciter shaft line or level
Check for the correct oil level in the
bearing housing of exciter
Check for correct lubrication of
universal joints
Check that the local control panel is
commissioned
Check that vibrating feeder motor is
tested as per the test procedure
Give the clearance for connection of
exciter with motor
Charge the vibrating feeder from
local panel and observe the
operation record the amplitude
Issue the initial operation certificate

FIELD

Ensure that all interlocks are meet


and no alarms are present before
starting the Vibrating Feeder

CCR

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Task: Storage/Hoppers Pre-Start Check


PROCEDURE

ACTION BY

ACTION
CONFIRM

REMARKS

Check that all maintenance works are


done and work permit issued are
returned
Check visually the structure of
hoppers for sign of damage

FIELD/CCR

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Task: Flap Gate Pre-start Check


PROCEDURE

Check installation is complete


according to the General assembly
drawing.
The Flap Gate is ready for use and is
not tagged out.

Confirm that all maintenance work


permit issued is returned

Check travel adjustment limit


switches for operation of flap gate in
both directions have been provided
Check that electrical actuator has
been installed
Ensure that all interlocks are meet
and no alarms are present before
starting the Flap Gate

ACTION BY

ACTION
CONFIRM

REMARK
S

ACTION
CONFIRM

REMARK
S

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Task: Belt Feeder Pre-Start Check


PROCEDURE

Installation is complete according to


general assembly drawing
The Belt Feeder is ready for use and
is not tagged out.

ACTION BY
FIELD
CCR

Confirm that all maintenance work


permit issued is returned
Check the alignment of bolt feeder
from erection records

CCR
FIELD

Check that all the roller supports


have been correctly tightened with
the correct size of nuts and bolts
Check the alignment of both sides
(Left & right gear boxes with the
driving and driven shafts)

FIELD

Check that both gear boxes have


been checked as per its standard
check list
Check the correct leveling of driving
pulley and tail pulley
Check that the screw take up has
been installed. Note the position of
take up pulley
Check that all the rollers have been
installed
Check that there is no sag on belt

FIELD

Check that both motors have been


checked as per the standard check
list
Check that lubrication of:
o All the rollers.
o Bearing of driving and tail
pulley
o Gear boxes.
Check that all the dust guard has
been fitted
Check the take up pulley position
and bolt sag
Adjust the take up pulling position its
adjusting screw if required
Following a satisfactory trial run
issue the initial run certificate
Ensure that all interlocks are meet
and no alarms are present before
starting the Belt Feeder

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