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Dngelhoff / Kosney: Betriebserfahrungen an Strebfrderern mit hydrodynamischem Abtrieb 1
Special Print: Operating experience with hydrodynamic drives
on armoured face conveyors at Prosper-Haniel Mine (Germany)
K. Dngelhoff & W. Kosney, Deutsche Steinkohle AG
3. International Symposium High-Performance Longwall Extraction, Aachen, 2003
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Dngelhoff / Kosney: Operating experience with hydrodynamic drives on armoured face conveyors 2
Operating experience with armoured face conveyors
with hydrodynamic drive systems
at Prosper-Haniel Mine
K. Dngelhoff & W. Kosney, Deutsche Steinkohle AG, GER
ZUSAMMENFASSUNG
Die Entwicklungsgeschichte der auf dem Bergwerk Prosper-Haniel eingesetzten Strebtechnologie
mit Turbokupplung wird beschrieben.
Die neueste Entwicklung der Turbokupplung mit einer Leistung von 800 kW wird hier zum Anlass
genommen, die positiven Betriebserfahrungen im weltweit ersten Streb mit dieser Technologie und
in dieser Leistungsklasse vorzustellen.
Whrend ihrer ersten Betriebsphase von 16 Monaten zeichnete sich die Kupplung durch ihre hohe
Verfgbarkeit von 99,7% aus.
ABSTRACT
The paper describes the history of applied longwall technology using a fluid turbo coupling at the
Prosper-Haniel mine.
The most recent development of the fluid turbo coupling with an installed power of 800 kW is being
used as a background for presenting positive operating experiences in the first longwall worldwide
with this technology and in this rang.
During the first 16 months in operation, the coupling has excelled by its high availability of 99,7%.
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Dngelhoff / Kosney: Operating experience with hydrodynamic drives on armoured face conveyors 3
STATISTICS OF THE PROSPER HANIEL MINE
Prosper-Haniel, a name that stands not only for a large mine, but also reflects a chapter in the
history of technical developments related to hydrodynamic drives in armoured face conveyors.
The entire mine covers an area of 165.4 sq km, of which 54.3 sq km are actively mined. The mine
itself consists of the pits Haniel West, Haniel Ost and Prosper Nord. The technically extractable
coal deposits amount to 233.5 million tv.
Technical dataLength of belt conveyor network 151 kmLength of main belt conveyor 15,1 kmMedium extraction speed 5,92 m/dAverage seam height w/wo faults 2,23 / 1,43 m
Output underground 6.969 kg/MS
EmployeesWorkers underground 2.770Workers above ground 877Admin personnel underground 369Admin personnel above ground 421Total 4.437of which trainees 267of which foreign employees 644
Productionusable annual output 3.905.495 tv/aaverage daily output 2000 14.565 tv/daverage daily output 2001 15.748 tv/d
In order to ensure the scheduled annual output, technologies had to be developed further. The
conveyor chains became ever heavier and bigger, the drives consequently had to be upgraded and,
eventually, the drive power also had to be increased.
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Dngelhoff / Kosney: Operating experience with hydrodynamic drives on armoured face conveyors 4
DEVELOPMENT OF THE TURBO COUPLING AND OPERATING
EXPERIENCES
Prosper-Haniel decided in the Nineties to equip the extraction systems with Voith Turbotechnology, in order to be able to utilize the increased powers efficiently.
The following reasons contributed to the decision to choose a hydrodynamic drive:
load-free start-up of motors sequential start of individual drives by timed variable filling of couplings automatic torque limitation during start-up, no stalling of the motor over pull-out torque rapid build-up of torque at the chain from zero torque build-up against blocked conveyor and holding of motor pull-out torque inherent protection of chain against rapid blockage
environmentally friendly operating medium water
The first application of this technology took place in the sections:
Seam Freya - Panel using a shearer
Seam P - Panel using a plough
These sections were equipped with 400 kW motors at the armoured-face conveyor. The 562
DTPPWL coupling was supplied via an external water control panel.
This kind of system is designated open circuit. Fresh water is continuously flowing through the
coupling. The throughput of the operating medium is determined only by the nozzles. These are
designed in such a way that slip heat generated during nominal operation is dissipated.
In order to reduce the water consumption, the newly developed system closed circuit was applied
in the subsequent panels. Here, the operation medium is utilized until a maximum allowable
temperature has been reached.
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Dngelhoff / Kosney: Operating experience with hydrodynamic drives on armoured face conveyors 5
The comfortable and versatile operating medium management of the closed circuit system combines
minimum water consumption with shortest start-up repeat times.
The water requirement is controlled in dependence on the temperature by timing the inlet and outletvalves. Here, water is supplied to the waste water removal system only once it has reached a
temperature of approximately 55 - 60 C.
The water removal consists of a container (collection tank) into which the water is directed. This
water is then used for dust suppression by the shearer. The amount of water required for this process
is extremely reduced. Comparable other drive solutions have equally high water requirements due
to motor cooling and longwall sprays.
The first coupling type was a fully self-supported 562 DTPPWL coupling with an external water
control panels. With his coupling type, outputs up to 630 kW could be achieved. The external watercontrol panels were prone to failure with a view to their tube and pipe system in running operation.
On the basis of existing operating experiences, DSK, in co-operation with the companies Voith and
Valvex, developed a new valve system the valve block which is mounted directly onto the
coupling and which has proven itself successfully in numerous installations (Fig. 1).
Fig 1: Coupling 562 DTPKWL with valve block
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Dngelhoff / Kosney: Operating experience with hydrodynamic drives on armoured face conveyors 6
The integration of the water-operated turbo coupling into the armoured-face conveyor drive
between motor and gearbox always results in a greater overall length of the drive unit. Depending
on the space available at the entrance to the face , the roof support design and the size of the
conveyor, but also depending on the operators philosophy of using two, three or four drives and
integrating them into the conveyor, the demand for short overall unit lengths is more or less strong.For this reason, the following coupling type was initially successful:
A fully self-supported unit that can consequently be easily transported and connected
underground through connecting couplings and guards with the motor and the gearbox. The
self-support unit carries the weight of the coupling runners and also takes up the
hydrodynamic axial forces.
The intended further development for outputs up to 800 kW aimed at a variation with a shorter
overall length, where only the output side is self-supported (Fig. 2.).
Fig 2: Coupling 562 DTPKWL2 for 800 kW
As a result of a special connection technology integrated into the coupling, separate and safe
transport underground as well as easy assembly on site are possible.
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Dngelhoff / Kosney: Operating experience with hydrodynamic drives on armoured face conveyors 7
Additionally, it was intended to fit the coupling with the intelligent coupler module (IKM) of DMT.
The reasons for the fitment with IKM can be summarized as follows:
1. Independently operating unit consisting of coupling + IKM (self-control)2. Considerable reduction of cables at the longwall
3. Availability of emergency operating mode
The IKM is a plc that is directly installed to the coupling. It controls all operating modes by
converting commands from an overriding master (valve control, temperature monitoring, etc.).
Each coupling features an operating IKM which controls and monitors the coupling and carries outthe selected operating modes. An overriding master IKM controls up to four operating IKMs from
the control panel at the main or tail drive. This master IKM which is linked to the longwall control
system which provides the operating modes of the conveyor of the individual drives . The master
networks and monitors the individual drives and forwards depending on the operating mode the
commands of the longwall control to the individual couplings.
Design of armoured-face conveyor with control device
Longwall control system
Connection box
Power supply
GearboxMotorcurrent
Coupling
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Dngelhoff / Kosney: Operating experience with hydrodynamic drives on armoured face conveyors 8
With the sensorics described earlier and the control elements, the following operating modes can be
ensured:
Load-free motor start with disposal of the remaining water from the coupling
Conveyor start-up by filling the coupling irrespective of the load condition.By utilizing the motor pull-out torque, the maximum amount of torque required for the
longwall can be supplied, in order to break away the chain swiftly even if the conveyor is
overfilled or blocked (Fig. 3).
Fig 3: Scheme of the start-up procedure
Nominal operation in closed circuit and water exchange only after operating temperature(T > 55 C) has been exceeded. In this case, the transmission of power is not impaired and
natural load sharing is ensured (Fig. 4)
Load sharing of the drives against each other (irrespective of whether there are 2 to 4 drives)occurs passively due to the hydrodynamic principle, i. e. precise control is not required in
nominal operation.
Operating mode creep speed is used for chain inspection and in plough operation forretracting the plough chain, as well as for safe material transport if the conveyor is otherwise
empty. The filling level of the coupling is automatically adjusted in line with a pre-set speed(stepless in the 50 100% range, e. g. 50% of the nominal speed).
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Dngelhoff / Kosney: Operating experience with hydrodynamic drives on armoured face conveyors 9
Operating mode chain tensioning is covered by the coupling function with partial filling.An additional (e. g. hydraulic) tensioning device is therefore not required (Fig. 5).
Fig 4: Commissioning of BH 475, start-up of empty conveyor and nominal operation
Fig 5: Commissioning, chain tensioning with pre-set load 70% of motor pull-out torque
Starting currents
Auxiliary drive (pink) alwaysrushes ahead of the maindrive (blue), hence noslacking chain
Load sharing
Water temperature
Pre-set load
Timing of filling valve
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Dngelhoff / Kosney: Operating experience with hydrodynamic drives on armoured face conveyors 10
The first application of the drive system described before took place at the Prosper-Haniel mine at
seam N, BH 475.
Height BH 475Extraction technology Sliding plough 5.7Length of longwall 360 mInstalled power 2 x 800 kWThickness of deposit 130 - 193 cmAdvance 2.227 m
2/d
Even during the preparation of the longwall, the Voith technology excelled by its easy handling and
assembly.
Interference factors that are normal for start-up procedures concerned primarily the fine adjustmentbetween the longwall control IKMs and the coupling.
In the ensuring 16 months (from 19 July 2000 to 16 November 2001), standstill times that were
originated by the coupling amounted to only 1600 minutes The availability of the coupling is
consequently 99,7 %. A great advantage in this context is that this drive component as a mechanical
unit is very robust, well known and easy to operate.
In the meantime, further longwalls that are successfully operated with this technology, have
followed.
Therefore, maintenance work mostly referred to peripheral systems. In this context, the purity of theused operating system needs to be mentioned; the water filters require regular cleaning.
An important aspect for the safe operation of the coupling is the water supply. The infrastructure of
the mine needs to ensure that sufficient water is available for the safe operation of the couplings (for
the 562 DTPKWL2 coupling, 240 l/min are required over a short period during the start-up
procedure).
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Dngelhoff / Kosney: Operating experience with hydrodynamic drives on armoured face conveyors 11
After the start-up procedure, the coupling operates in a closed circuit, so that additional water is
only required, when the coupling is cooled during the water exchange. This water exchange is
normally carried out at 15-minute intervals.
The operating medium water used in the couplings is used for several purposes. Prior to its use n
the coupling, it is used to cool motor and gearbox. The heated water drained from the coupling iscollected in a tank and used for dust control.
Conclusion
The above allows the conclusion that we have a very safe technology in operation with this type of
power transmission.
In the meantime, the 562 DTPPWL couplings (400 and 630 kW) have been fitted with IKM, in
order to be able to utilize the aforementioned advantages of this system for these couplings.When, as a next step, an output increase up 1000 kW is achieved, we would not hesitate to use this
proven technology again.
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Dngelhoff / Kosney: Operating experience with hydrodynamic drives on armoured face conveyors 12
Voith Turbo GmbH & Co. KGVoithstr. 174564 Crailsheim, Germany
Tel. +49-(0)7951-32-409Fax +49-(0)7951-32-480
startup.components@voith.comwww.startup-components.comwww.voithturbo.com