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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. An online glossary is available for ease of reference. In addition, to reinforce the audio medium of delivery, a closed captioning feature allows you to read the lesson word for word, in its entirety. The Learning Management System (LMS) keeps track of all trainee test scores, log times, and site-information access and provides custom reporting options.


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.
Auxiliary Equipment Ash Handling Bulldozers Barge Unloading Car Dumpers Coal Handling Overview 1 Coal Handling Overview 2 Coal Handling Overview 3 Coal Pile Management Coal Preparation Equipment Coal Yard Maintenance Control Equipment Conveyors Dust Control Equipment Dust Control Equipment II Dust Control Overview Handling Wet And Frozen Coal Rail Yard Operations Stackers Trippers


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.

Also includes:


P.O. Box 26067 3163 Winston Churchill Blvd. Mississauga , Ontario Canada L5L 5W7 (416) 806-5777 info@globaltrainingsolutions.ca www.globaltrainingsolutions.ca


Global Training Solutions Inc. provides compliance, workforce training programs and classroom instruction aimed at the development, training and safety of employees in many diverse industries worldwide. © 2020 Global Training Solutions
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 Compliant with SCORM


The benefits of Web-delivered mechanical training include: reduction of learning time, consistency of delivery, increase in mastery scores, automated recordkeeping, increased motivation, greater retention, privacy, and remedial or refresher training. Additional benefits include increased trainee interest and flexible scheduling. Also, training units accommodate all learning styles through a variety of media presentation formats.


The 20 units in this series represent some of the most common coal handling systems and components in the industrial market. Topics covered range from routine coal yard receiving operations to dust control and ash disposal.


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.


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 Scale Calibration 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 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.


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 Dry Fly Ash Collection Wet 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 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.


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


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.


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


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.


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: Rotary coupled 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 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.


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 Preparation 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


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.


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 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.


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 Plows 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 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.


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


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.


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


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.


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


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.


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 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.


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 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.


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


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.


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 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.


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


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.


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


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.


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 Chute 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