Coal Handling E-Learning Training Series

To help companies improve the knowledge and skills of workers and meet the demands of today's busy training manager, Global Training Solutions Inc. offers a practical solution with 20 Web delivered coal yard handling training units. This series addresses the most common coal yard operations.

Instructional Features

This new, self-paced and interactive Web-delivered series includes up-to-date, award-winning content, crisp audio, stunning graphics, and engaging discovery activities - all to stimulate and involve the trainee. This series is an Internet browser-based application with centralized learning management capabilities and global end-user accessibility. Each unit contains challenge questions within the web-based training module and an examination at the end each module.

Also includes:

High quality video of actual demonstrations from the field

Latest interactive instructional design methods to maximize learning

Graphical representations of coal yards and equipment components

Printable, online workbook

Materials available to support instructor-led training

Onboarding new staff or refreshing the knowledge base of your workforce

Increase retention and improve performance

Compliant with SCORM 1.2 and ADA 508(c) standards

Objective

This training series is designed to improve the knowledge and skills of coal yard workers by giving them an understanding of common coal yard systems and routine coal yard operating procedures.

Titles

Auxiliary Equipment

Auxiliary equipment is used to perform support operations in a typical coal handling system. Support operations, such as weighing coal and collecting coal samples, help provide important information for coal handling and other plant operations. This course explains why coal is weighed and sampled, and describes some of the auxiliary equipment used to perform these jobs. It also covers some of the preventative maintenance tasks that coal handlers may perform to keep auxiliary equipment in good working condition.

Subjects:

Introduction
Introduction to Auxiliary Equipment
Introduction to Stackers
Topic I Learning Objectives
Weighing Coal
Characteristics of Coal
Sampling Coal
Weighing Equipment
Topic II Learning Objectives
Truck Scales
Track Scales
Conveyor Belt Scales
Scale Operation and Preventative Maintenance
Topic III Learning Objectives
General Operation of Scales
Track Scales
Scale Calibration
Automatic Sampling
Topic IV Learning Objectives
Collecting Representative Samples
Automatic Sampling Equipment
Manual Sampling
Topic V Learning Objectives
Auger Samplers
Collecting Samples by Hand
Preventive Maintenance of Sampling Equipment
Topic VI Learning Objectives
Preventive Maintenance
Troubleshooting Sampling Equipment

Ash Handling

Ash is the solid residue that is produced when coal is burned. To keep a coal-fired plant operating, ash must be collected, removed from the plant, and properly disposed of. This course will provide a brief introduction to ash, including types of ash and systems used to handle it. It will also discuss methods of ash disposal.

Subjects:

Introduction
Learning Objectives
Introduction to Ash Handling
Topic I Learning Objectives
Ash Production
Ash Handling and Hazards
Bottom Ash
Topic II Learning Objectives
Bottom Ash Storage and Removal
Removing Ash from Dewatering Bins
Ash Piles
Fly Ash Systems
Topic III Learning Objectives
Wet Fly Ash Collection
Dry Fly Ash Collection
Silos
Drum Mixers
Topic IV Learning Objectives
Moving Ash to an Ash Conditioner
Drum Mixer Operation
Drum Mixer Maintenance
Bowl Mixers
Topic V Learning Objectives
Operational Checks
Bowl Mixer Maintenance
Ash Disposal
Topic VI Learning Objectives
Permanent Storage Sites
Ash Pongs
Commercial Ash Preparation
Ash Cleanup

Bulldozers

Bulldozers are used to spread coal out on storage piles and to reclaim coal from the piles when it is needed in the plant. Bulldozers are also used to manage coal piles to reduce the risk of fires and to minimize loss from erosion due to wind and rain. Coal handlers who use bulldozers must know how to operate them safely and correctly, and how to take care of them properly. This course focuses on the use of bulldozers in coal handling operations. Emphasis is placed on practical applications, inspection procedures, minor maintenance procedures, and basic operating procedures.

Subjects:

Introduction
Learning Objectives
Bulldozers
Topic I Learning Objectives
Functions of Bulldozers in Coal Handling
Major Types of Bulldozers
Major Parts of a Typical Bulldozer
Bulldozer Hydraulic Systems
Topic II Learning Objectives
Basic Hydraulic System Operation
Hydraulic Application in Bulldozers
Hydraulic System Inspection
Inspection and Minor Maintenance, Part I
Topic III Learning Objectives
General In formation
Bulldozer Lubrication
Inspecting and Maintaining the Cooling System
Checking the Electrolyte Level
Checking the Fuel Supply
Inspection and Minor Maintenance, Part II
Topic IV Learning Objectives
Inspecting and Maintaining the Air Cleaning System
Adjusting Track Tension on a Trade type Bulldozer
Checking the Tires on a Wheel-type Bulldozer
Operation, Part I
Topic V Learning Objectives
Bulldozer Safety
Bulldozer Instruments and Operating Controls
Starting a Bulldozer
Steering a Bulldozer
Slowing and Stopping a Bulldozer
Shutting Down a Bulldozer
Operation, Part II
Topic VI Learning Objectives
Avoiding and Dealing with Hazards
Bulldozer Reclaiming Techniques

Barge Unloading

Coal barges are generally loaded with coal dumped from trains. The loaded barges are taken to plants by tugboats, which also take the empty barges away to be reloaded. This course focuses on the operations involved in handling barges from the time they arrive at a plant until the empty barges are taken away. It examines in detail the components and operation of two types of barge unloaders: a bucket elevator unloader and a clamshell, or traveling tower unloader.

Subjects:

Introduction
Learning Objectives
Bringing in Barges
Topic I Learning Objectives
Barges and Tugboats
Make-ups with Cables and Lines
Bringing a Barge into a Dock and Tying It Up
Bringing in a Tow
Hooking up to a Barge Haul System
Safety
Bucket Elevator Unloaders
Topic II Learning Objectives
General Description
Unloader Components
Cab Controls
Operating a Bucket Elevator Unloader
Topic III Learning Objectives
Starting up a Bucket Elevator Unloader
Lining up and Unloading a Barge
Automatic and Manual Operation
Shutdown
Clamshell Unloaders
Topic IV Learning Objectives
General Description
Unloader Controls
Bucket Operation
Clamshell Unloader Operation
Topic V Learning Objectives
Prestart Checks
Operating the Unloader
Shutdown
Shifting and Taking Away Empty Barges
Topic VI Learning Objectives
Shifting Barges
Taking Away a Barge

Car Dumpers

Coal handlers operate and maintain the equipment used to transport and unload coal cars. This equipment may include rotary car dumpers, positioners, and retarders. To help coal handlers develop the skills needed to work safely with this equipment, this course describes how rotary car dumpers, positioners, and retarders work. It also explains how this equipment is generally operated during receiving operations, and how it is maintained.

Subjects:

Introduction
Learning Objectives
Introduction to Coal Car Unloading Systems
Topic I Learning Objectives
Receiving Operations
Scales, Dust Control Equipment, and Retarders
Coal Handling Responsibilities
Rotary Car Dumpers
Topic II Learning Objectives
Rotary Car Dumper Components
Dumper Platform
Cradle
Clamping System
Spill Truss
Drive System
Limit Switches
Mechanical Steps
Controls, Inspections, and Preventive Maintenance
Topic III Learning Objectives
Dumper Controls
Dumper Inspections
Preventive Maintenance
Receiving Operations
Topic IV Learning Objectives
Safety Considerations
General Receiving Operations: Separated Cars
General Receiving Operations: Rotarycoupled Cars
Positioning Systems and Retarders
Topic V Learning Objectives
Positioning Systems
Retarders
Receiving Operations Using Positioners and Retarders
Topic VI Learning Objectives
Positioner and Retarder Inspections
Receiving Operations

Coal Handling Overview

Coal handlers work with a variety of equipment designed to help them perform the job of keeping a plant supplied with coal. This equipment, known collectively as the coal handling system, provides an efficient way of carrying out basic coal handling operations. It is important for coal handlers to be familiar with the various types of coal handling equipment and with the jobs that they need to perform to keep a coal handling system operating safely and efficiently. This course explains how coal handling systems generally operate. It also describes equipment that carries out some of the major operations and support functions involved in coal handling.

Subjects:

Introduction
Learning Objectives
Receiving Operations
Topic I Learning Objectives
Coal Handling Systems
Receiving Coal
Transporting Coal
Outdoor Coal Storage
Topic II Learning Objectives
Stacking-out Coal
Storing Coal
Reclaiming Coal
Coal Preparation and Indoor Storage
Topic III Learning Objectives
Coal P reparation
Tramp Iron Removal
Indoor Coal Storage
Weighing, Sampling, and Dust Control
Topic IV Learning Objectives
Weighing Coal
Sampling Coal
Controlling Coal Dust
Ash Handling
Topic V Learning Objectives
Ash
Fly Ash Removal
Bottom Ash Removal Systems
The Coal Handler's Job
Topic VI Learning Objectives
Safety on the Job
A Coal Handler's Duties

Coal Pile Management

Plants that need to burn large quantities of coal also need to maintain large coal reserves. The most common way of storing coal is in large outdoor storage piles. Coal pile management involves moving coal to and from storage piles, and maintaining the piles to deal with coal pile fires and environmental factors such as rain and wind. This course will cover these topics, as well the equipment used in coal pile management.

Subjects:

Introduction
Learning Objectives
Introduction to Coal Pile Management
Topic I Learning Objectives
Coal Storage
Coal Pile Management Functions
Coal Pile Management Jobs
Coal Pile Management Equipment
Topic II Learning Objectives
Bulldozers
Front-end Loaders
Scrapers
Spray Vehicles
Coal Pile Lighting
Compacting, Contouring, and Grooming Coal Piles
Topic III Learning Objectives
Compacting Coal Piles
Contouring Coal Piles
Grooming Coal Piles
Reclaiming and Coal Pile Management Safety
Topic IV Learning Objectives
Reclaiming
Coal Pile Management Safety
Managing Runoff
Topic V Learning Objectives
Adverse Effects of Water on a Coal Pile
Dealing with Water in Coal Pile Management
Handling Runoff
Working the Coal Pile During or After a Rainstorm
Coal Pile Fires and Wind Erosion
Topic VI Learning Objectives
Coal Pile Fires
Wind Erosion

Coal Preparation Equipment

Coal preparation involves the use of special equipment that operators are often required to inspect, maintain, and troubleshoot. Operating coal preparation equipment properly can help prolong the life of the equipment and maximize the efficiency of the coal handling system. This course will provide an introduction to coal preparation equipment and its operation.

Subjects:

Introduction
Learning Objectives
Introduction to Coal Preparation
Topic I Learning Objectives
What is Coal Preparation?
Basic Methods Used to Reduce the Size of Coal
Major Types of Coal Preparation Equipment
Breakers: Principles of Operation
Topic II Learning Objectives
Major Parts of a Breaker
Basic Breaker Operation
Breaker Driving Mechanism
Auxiliary Breaker Components
Hammermills
Refuse P lows
Deflector Plates
Breaker Operation
Topic III Learning Objectives
Breaker Lubrication
Inspecting the Outside of a Breaker
Inspecting the Inside of a Breaker
Breaker Start-up
Conditions to Monitor During Normal Operation
Handling Breaker Operating Problems
Breaker Shutdown
Crushers: Principles of Operation
Topic IV Learning Objectives
Hammermill Crushers
Major Parts
Basic Operating Principles
Ring Crushes
Major Parts
Basic Operating Principles
Roll Crushes
Two-roll Crushers
Three-roll Crushers
Crusher Operation
Topic V Learning Objectives
General Crusher Inspection
Crusher Lubrication
Removing Uncrushable Material
Adjusting Crusher Clearance
Crusher Start-up
Conditions to Monitor During Normal Crusher Operation
Handling Problems in Crusher Operation
Crusher Shutdown

Coal Yard Maintenance

Coal is a heavy, abrasive, and corrosive material that can be difficult for equipment to handle. To handle coal, equipment must often run at high speeds and carry heavy loads. To do its job, coal handling equipment must be continually maintained to ensure it stays in good running condition. This course examines the maintenance jobs that are commonly performed on coal handling equipment and describes how coal handlers may be involved with equipment maintenance.

Subjects:

Introduction
Learning Objectives
Maintenance Principles
Topic I Learning Objectives
Basic Coal Yard Maintenance
Coal Handler Maintenance Responsibilities
Idler and Pulley Replacement
Topic II Learning Objectives
Idler Replacement
Pulley Maintenance
Changing a Belt, Part I
Topic III Learning Objectives
Belts
Preparations for Belt Installation
Belt Installation
Pulling the Belt
Changing a Belt, Part II
Topic IV Learning Objectives
Belt Change out Using Rope of Cable
Belt Splicing and Inspection
Training a Belt
Test Run
Idler Adjustment
Mechanical Splice
Topic V Learning Objectives
Mechanical Splice
Preliminary Steps
Splicing Equipment
Splice Installation
Vulcanized Splices and Repairs
Topic VI Learning Objectives
Vulcanized Splices
Preparing a Permanent Vulcanized Splice
Temporary Repairs
Permanent Repairs

Control Equipment

The components of a coal handling system are operated with control equipment. The proper operation of the control equipment ensures that the components are started and stopped in the correct sequence so that coal moves smoothly from one component to the next. If one of the components in the sequence is not operated properly, the entire system could come to a stop, and equipment could be damaged. This course describes how control equipment is used to operate coal handling components so that they work together smoothly as a system. Troubleshooting procedures that can be used to determine the cause of a coal handling system malfunction also are covered.

Subjects:

Introduction
Learning Objectives
Introduction to Control Equipment
Topic I Learning Objectives
Control Methods
Control Equipment Functions
Types of Control Equipment
Controlling Coal Flow
Topic II Learning Objectives
Coal Handling System Components
Component Motor Controls
Control Panels
Electrical Circuits
Monitoring Coal Handling Operations
Topic III Learning Objectives
Indicator Lights
Annunciators
Computer Graphics
Ammeters and Other Indicators
System Protection
Topic IV Learning Objectives
Sensing Devices
Interlock Systems
Start-up and Shutdown
Topic V Learning Objectives
Manual Control System
Manual Control System Start-up
Manual Control System Shutdown
Semi-automatic Control System
Automatic Control System
Automatic System Start-up
Automatic System Shutdown
Troubleshooting
Topic VI Learning Objectives
Coal Handling Troubleshooting Steps

Conveyors

Coal handlers operate and maintain the equipment used to transport coal to a plant for burning or to a coal pile for storage. This equipment includes conveyors, feeders, and chutes. Coal handlers must also inspect and maintain equipment such as magnetic separators and cleaning devices, which help transport operations run smoothly. This course explains how the equipment involved in transport operations works, and how it should be inspected and maintained.

Subjects:

Introduction
Learning Objectives
Conveyors
Topic I Learning Objectives
Coal Transport Systems
Conveyors
Belts and Idlers
Topic II Learning Objectives
Belts
Idlers
Pulleys and Drive Mechanisms
Topic III Learning Objectives
Pulleys
Drive Mechanisms
Safety Features
Feeders and Chutes
Topic IV Learning Objectives
Feeders
Chutes
Magnetic Separators and Cleaning Devices
Topic V Learning Objectives
Magnetic Separators
Cleaning Devices
Preventative Maintenance and Troubleshooting
Topic VI Learning Objectives
Preventive Maintenance
Inspecting Conveyors
Lubricating Conveyor Components
Inspecting Chutes
Inspecting Feeders
Troubleshooting

Dust Control Equipment I

When coal moves through a coal handling system, it produces a lot of dust, which can be harmful to those working in the plant. Coal dust can present a respiratory hazard to workers, cause fires, damage plant equipment, and cause air pollution. Coal dust must be controlled in order to reduce or prevent these harmful effects. This course focuses on the equipment that is commonly used to control coal dust in indoor locations, such as breaker buildings, tripper rooms, and car dumpers.

Subjects:

Introduction
Learning Objectives
Dust Suppression Systems
Topic I Learning Objectives
Spray Types
Activating Sprays
Checks and Minor Maintenance
Dust Collection
Topic II Learning Objectives
Systems Description
Operation
Maintenance
Baghouse Components
Topic III Learning Objectives
General Description
Typical Baghouse Components
Carbon Dioxide Fire Suppression System
Baghouse Operation and Maintenance
Topic IV Learning Objectives
Baghouse
Changing Bags
Fire Detection and Suppression
Indoor Vacuum Systems
Topic V Learning Objectives
Vacuum Systems
Vacuum System Operation
Maintenance
Dust Treatment Equipment
Topic VI Learning Objectives
Pug Mill
Pin Mixer
Pug Mill and Pin Mixer Operation
Briquetter
Dust Treatment Equipment Maintenance

Dust Control Equipment II

Dust from coal handling operations must be controlled to protect personal health, equipment, and the environment. There are many different types of equipment used to control coal dust, and operating it may be part of a coal yard worker's job. Dust control equipment is classified into two main groups: equipment used to control dust inside buildings and equipment used to control dust outside in the coal yard. This course focuses on the equipment used in the coal yard.

Subjects:

Introduction
Learning Objectives
Introduction to Dust Control II
Topic I Learning Objectives
General Description
Components and Systems
Hydraulic System
Pre-start Checks
Start-up
Spray Vehicles
Topic II Learning Objectives
General Description
Filling from a Hydrant
Filling at a Mixing Facility
Spraying
Minor Maintenance
Vacuum Loaders
Topic III Learning Objectives
General Description
Components and Systems
Pre-start Checks
Operation
Vacuum Trucks
Topic IV Learning Objectives
General Description
Components and Systems
Pre-start Checks
Operation
Wetting Dust inside a Truck Hopper
Dumping
Changing Filter Bags
Minor Maintenance
Street Sweepers
Topic V Learning Objectives
General Description
Pre-start Checks
Start-up and Sweeping
Dumping
Minor Maintenance

Dust Control Overview

Dust control is an important part of coal handling operations. This course looks at where coal dust is produced, how it can spread, and how it can be kept from spreading. Specific attention is directed to equipment and techniques that are commonly used to control dust in coal handling systems.

Subjects:

Introduction
Learning Objectives
Introduction to Dust Control
Topic I Learning Objectives
Sources of Coal Dust
Reasons for Controlling Coal Dust
Approaches to Controlling Coal Dust
Dust Reclamation
Dust Suppression
Topic II Learning Objectives
Suppression Methods
Foam Sprays
Dust Containment
Topic III Learning Objectives
Barge Unloading Operation
Dust Collection
Topic IV Learning Objectives
Baghouses
Cyclones
Dust Collection Systems
Dust Cleanup
Topic V Learning Objectives
Inside Cleanup
Outside Cleanup
Dust Reclamation
Topic VI Learning Objectives
Dust Reclamation Methods
Dust Treatment Equipment
Pin Mixer
Briquetter
Pug Mill

Handling Wet and Frozen Coal

Wet and frozen coal can create difficult problems for coal handlers, including clogging equipment and impeding or blocking coal flow. However, many of the problems resulting from wet or frozen coal can be greatly reduced, and sometimes entirely avoided by following certain precautions, by properly using specialized equipment, and, in some cases, by planning ahead. This course covers the types of problems caused by wet and frozen coal, as well as methods and equipment that are commonly used to avoid, minimize, or respond to these problems.

Subjects:

Introduction
Learning Objectives
Wet Coal, Part I
Topic I Learning Objectives
Wet Coal Problems
How Wet Coal Sticks
Wet Coal, Part II
Topic II Learning Objectives
Wet Coal, Part II
Preparing for Wet Coal
Detecting Wet Coal Problems
Dealing with Water Accumulation
Frozen Coal
Topic III Learning Objectives
Frozen Coal Problems
How Coal Freezes and Sticks
Handling Frozen Coal
Mechanical Treatment
Topic IV Learning Objectives
Frozen Coal Crackers
Travelling Hammermill Crushers
Thermal Treatment
Topic V Learning Objectives
Thawing Sheds
Torches
Chemical Treatment
Topic VI Learning Objectives
Applying Anti-freeze to Conveyor Belts
Treating Coal with Anti-freeze
Multiple Approaches to Handling Frozen Coal

Rail Yard Operations

Rail yards make it possible for a plant to receive coal by train. This course will start with a brief introduction to rail yards, and then continue to cover tracks and switches. It will also present information on coal cars, air breaks, and trains and locomotives. Finally, this course will also describe rail yard safety and communication.

Subjects:

Introduction
Learning Objectives
Introduction to Rail Yards
Topic I Learning Objectives
Rail Yard Equipment
Coal Handler Jobs
Tracks and Switches
Topic II Learning Objectives
Tracks
Switches
Coal Cars
Topic III Learning Objectives
General Features of Coal Cars
A Coal Car Braking System
Safety Procedures for Operating a Hand Brake
Air Brakes
Topic IV Learning Objectives
General Features of Air Brakes
Train Brakes and Automatic Brakes
Trains and Locomotives
Topic V Learning Objectives
Couplers
Locomotives
Safety and Communication
Topic VI Learning Objectives
Mounting and Dismounting Coal Cars
Isolating a Coal Car

Stackers

Plants that burn coal typically store their coal in outdoor piles. To move the coal to the storage pile, a machine called a stacker is often used. An important aspect of coal handling is operating a stacker, coordinating its operation with the rest of the coal handling system, and keeping it in good working condition by performing regular inspections and minor maintenance. This course will cover how to follow the procedures for each of these aspects of coal handling.

Subjects:

Introduction
Learning Objectives
Introduction to Stackers
Topic I Learning Objectives
Stackers: Basic Function
Major Types of Stackers
Telescopic Chute Stackers
Radial Boom Stackers
Stackers/Reclaimers
Stacker Control Systems
Operating Responsibilities
Drive Systems, Sensors, and Limit Switches
Topic II Learning Objectives
Stacker Drive Systems
Cable Drives
Hydraulic Luffing Systems
Slew Drives
Travel Trucks
Sensors and Limit Switches
Sensors
Limit Switches
Operation, Part I
Topic III Learning Objectives
Start-up
Positioning a Stacker
Setting up Operating Controls
Turning on the Stacking out Equipment
Stacking out Procedures
Operation, Part II
Topic IV Learning Objectives
Monitoring Operating Conditions
Operating Problems
Stacker Conveyor Trips
High Winds
Boom Problems
Shutdown
Inspection and Minor Maintenance
Topic V Learning Objectives
Stacker Inspection
Stacker Lubrication
Stackers/Reclaimers
Topic VI Learning Objectives
Stacker/Reclaimer Varieties
Start-up
Reclaiming
Monitoring Operating Conditions
Operating Problems
Shutdown
Inspection and Minor Maintenance

Trippers

As long as there is coal in the bunkers, the plant can keep running without having to get coal from the point of delivery or from the coal pile. Whenever there is an interruption or a breakdown in coal handling, having a supply of coal on hand in the bunkers allows the plant to continue operating while the problem is corrected. To ensure that the bunkers are filled with coal, plants need equipment designed for that purpose. In many plants, the equipment used to fill bunkers are machines called trippers. This course will review tripper operation and maintenance, as well as tripper room duties.

Subjects:

Introduction
Learning Objectives
Introduction to Trippers
Topic I Learning Objectives
Bunkers and Silos
Major Parts of a Tripper
Tripper Controls
Inspection and Maintenance
Topic II Learning Objectives
Inspecting a Tripper
Adjusting Belt Scrapers
Tripper Lubrication
Tripper Operation, Part I
Topic III Learning Objectives
Tripper Start-up
Filling a Bunker
Moving a Tripper from One Bunker to Another
Monitoring Tripper Conditions
Tripper Shutdown
Tripper Operation, Part II
Topic IV Learning Objectives
Stuck Coal in a Tripper's Discharge Chutes
Tripper Belt Running Off-center
Loss of Power to a Tripper
Tripper/Bunker Room Duties, Part I
Topic V Learning Objectives
Inspecting a Bunker
Bunker Problems
Stuck Coal
Fires
Tripper/Bunker Room Duties, Part II
Topic VI Learning Objectives
Checking Bunker Levels
Weighing Coal Fed to a Bunker
Taking Coal Samples
Cleaning the Tripper Room