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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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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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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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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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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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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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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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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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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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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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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

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