DPG Coal feeder
Paniman Palengai
Mechanical Engineer
PT. D&C Engineering Company
Email: paniman.palengai@gmail.com
Abstract - The power plant that is widely used in
Indonesia is Steam power plants, one of which is in
Jeneponto, South Sulawesi. 2x125 Jeneponto power
plant is a place where electricity is generated, the
electricity that will be generates needs an energy
that to be converted, which is heat energy that
produced from coal who is burned that subsequently
transfers its heat through the pipes that were in the
boiler. As one of the main components of the power
plant, the boiler has the means of supporting the
work in order to produce complete combustion.
Some of them is the coal feeder and pulverizer.
Pulvurizer is one factor supporting high efficiency
coal combustion since before the coal enters the
boiler, coal advance through the milling process in
pulvurizer. But before entering the pulverizer, the
amount of coal is regulated in coal feeder.
Coal feeder is the main equipment in PLTU that
serves to regulate the flow rate of coal coming into
the mill to be smoothed. Coal feeder is responsible
for managing how many coal required to be use, for
example the amount of power to be generated from
a PLTU system. The system contained in Coal
Feeder provides controlled flow rate of coal ranging
from Bunker to Pulverizer based on burning
requirements. Therefore, Coal's output varies
according to its needs. The clear coal flow
contained in the coal feeder provides information to
the operator about coal flow from bunkers and coal
feeder. Bunker outlet valve used to isolate coal from
bunker to coal feeder.
The faster the motor rotation and the heavier coal
that enter the coal feeder, the faster the flow rate of
coal entering the mill. This will make the power
generated PLTU system becomes larger, and also
apply vice versa.
The purpose of this study was to determine the
types of coal feeder, parts of coal feeder plant
Jeneponto, the technical components of the coal
feeder work, pulverized work process and especially
its maintenance in order to improve the efficiency of
pulverizer.
1. Introduction
2x125 Jeneponto power plant is a place where
electricity is generated, the electricity that will be
generates needs an energy that to be converted,
which is heat energy that produced from coal who is
burned that subsequently transfers its heat through
the pipes that were in the boiler. As one of the main
components of the power plant, the boiler has the
means of supporting the work in order to produce
complete combustion. Some of them is the coal
feeder and pulverizer. Pulvurizer is one factor
supporting high efficiency coal combustion since
before the coal enters the boiler, coal advance
through the milling process in pulvurizer. But before
entering the pulverizer, the amount of coal is
regulated in coal feeder according to the loads need.
In writing this paper i tried to introduce the coal
feeder, use and maintenance manual. It’s very
important because it will affect the amount of coal
that will enter the pulverizer and later will be burned
in combustion system. Based on the background, the
author choose to introduce the coal feeder. The coal
feeder can control the amount of the coal that will
enter the pulverizer.
Coal feeder is the main equipment in PLTU that
serves to regulate the flow rate of coal coming into
the mill to be smoothed. Coal feeder is responsible
for managing how many coal required to be use, it
determine the amount of power to be generated from
a PLTU system. The system contained in Coal
Feeder provides controlled flow rate of coal ranging
from Bunker to Pulverizer based on burning
requirements. Therefore, Coal's output varies
according to its needs. The clear coal flow contained
in the coal feeder provides information to the
operator about coal flow from bunkers and coal
feeder. Bunker outlet valve used to isolate coal from
bunker to coal feeder. Setting the output of coal
feeder can be done in two ways that is with a
rotating motor that can be set (variable speed motor)
or motor rotation is equipped with variable speed
drive.
To measure the flow rate of the coal feeder (kg / h),
the coal feeder has two sensors, a weight sensor
commonly called a load cell and a speed sensor
(tachometer). The weight sensor is placed in the
center of the conveyor, while the speed sensor is
placed on the conveyor drive motor. Coal from the
silo will be fed to the coal feeder so that the coal
feeder will measure the weight of coal entering with
a certain distance, ie until the weight sensor is Feeder data
placed so that we will get the weight of coal per DPG DPG DPG DPG DPG DPG
meter conveyor. 30 40 50 60 80 100
Nomina
Conveyor speed will be adjusted by using motor- l output 30 40 50 60 80 100
(t/h)
mounted speed sensor so it will be known how Range 5~35 4~46 5~55 5~70 18~90 25~1
much speed of conveyor in moving coal to mill. If of 15
output
the speed measurement of the conveyor drive motor (t/h)
is multiplied by the weight per meter of conveyor, it Accura
cy
will get the flow rate of coal with one kg / h. measuri
±0.5
ng (%)
The faster the motor rotation and the heavier coal Distanc
e of
that enter the coal feeder, the faster the flow rate of coal Determined by user ( recommended 1.8m~9m)
coal entering the mill. This will make the power supply
(mm)
generated PLTU system becomes larger, and also
Power
apply vice versa. of belt
driven 2.2 or 3.0 4.0
motor
(kW)
Power
of
0.25 or 0.37 or 0.55 (according to the distance
cleanin
g motor of feeder)
(kW)
Note: 1. Coal output in the table is in te case of coal
density 900kg/m3
2. the feeder with output over than 100t/h
and lower than 30t/h is not included.
The parameter of the coal
Coal type Bituminous coal, some lean coal
and some lean ignite coal
Figure 1. Coal feeder type belt feeder Moisture <20%
Granjlarity 0~60mm
Packing ratio 0.7~1.1 t/m3

3. structure introduction
DPG series coal feeder is mainly composed of
shell, conveying system, weighting system, cleaning
system, and control system. Conveying system
convey the material, measuring sytem weight the
material, to coal shell body at the bottom of the
cleaning system, at the bottom of the feeder shell
clean the fly ash and spilled material. There are
Figure 2. Coal feeder internal component observation windows at the door on the end of the
coal feeder and explosion-proof lights on top of the
In Jeneponto PLTU, coal feeder we use are the DPG feeder shell. You can observe the operation of the
series coal feeder. coal at anytime,without opening the door or
stopping the operation of the coal feeder.
Code and data of the feeder a. Feeder shell
The shell of the coal feeder is a sealing cylinder
D P G ___ welded by the steel plate. There are movable
doors on the shell ends with good sealing
Capacity (t/h) ability, also easy to install and repair it.
Conveying and measurement parts are fixed on
Geimeiji (in chinese)
the two sides of the Channel. Coal feeder has
Pidai (in chinese) good integral rigidity and good measuring
Dianzi (in chinese) performance.
b. Drive drum
The surface of the drum was machined with the
special technique. The rough surface can
 improve the driving force and prevent the belt
slipping. Also it has no damage to the belt.
c. Belt
The endless type o conveyer belt, specially
developed by Rubber Institute, has many
virtues: better belt elasticity; long service life
for using low extensibility frame, off tracking
prevention for guided rail bar in the middle of
the belt and high belt skirt both sides of the belt;
fire retardant belt.
d. Belt drive redactor and motor
The drive motor power is small, using the speed
ratio reducer to get the larger torque. The motor
uses frequency converter, the control cabinet
according to the given signal, the the motor
power source frequency, and the transmission
of the corresponding coal to the coal mill
e. Temperature Sensor
In the full coal store, self combustion may be
occurred because of the high temperature.
Temperature sensor will raise an alarm when
the temperature in the coal feeder above 75 c
for the high temperature self combustion coal in
the downward coal flux.
f. Load cell
The weighing sensor, bought from abroad, is
the key component of the measurement. The
computer processed weighing sensor's electric
signal can be displayed as data on the control
cabinet panel.
g. explosion-proof lamp
The lamp in the coal feeder is to observe the
running state of the equipment. In order to
extend the service life, a lamp with nominal
voltage with 36V is adopted instead of
operating voltage 32v.
h. Observation window
The coal feeder has four observation window s
in order to observe the running condition of the
components in the feeder body.
4. components of the Coal Feeder
a. Cleaning motor, serves to move coal cleaning
equipment scattered in the coal feeder, this
motor in the supply of MCC breaker boiler 380
V.
b. Driven motor, serves to drive the feeder belt,
this motor is supplied from the boiler breaker
MCC 380 V.
c. Belt feeder, serves to distribute coal from the
output of coal bunker outlets to the mill,
through the outlet of the coal feeder.
d. Clean out conveyor, scraper conveyor for
spilled coal cleaners and scattered under belt
feeder. Coal spills will be swept by clean out
conveyor into pulverizer through discharge of
chute coal feeder. This cleansing is to avoid any
disturbance that can occur in the belt and
remove any residual coal trapped inside the
feeder so as to cause an explosion hazard.
The material or coal trapped in the feeder may be
caused by the following:
~ Material falling from belt scraper.
~ Accumulation of dust.
~ Material falling from self take-up pulley.
~ The material blown by air seal due to the lack of
proper adjustment
Figure 3. Clean out conveyor chain
Continuous operation of clean out conveyor can
prevent the formation of corrosion on the connecting
or drive parts of the feeder that can occur over a
long period of time.
e. Pulley Head and Pulley Take-Up, serves as a
place to turn the belt feeder from top to bottom
and from bottom to top. Take-Up Pulley is
equipped with adjusting screw that serves to set
the belt position.
f. Belt V-Guide, serves as a guide so that the belt
operation is always in the center position. Belt
V-Guide is located at the center of the coal
feeder belt, which is mounted on the bottom
cover.
Figure 4. Belt v-guide
g. Local control panel, containing relays and
micro-processor keyboard that provides status
information, the mode used and alphanumeric
display to display the operating conditions.
h. Coal flow indicator is an indication that shows
the amount of coal that goes into Pulverizer.
i. Load Cell serves to read coal flow in coal
feeder in gravity.
j. Coal feeder protection:
• No Coal On Belt: protection for pulverizer
safety due to no coal in the feeder belt
(which goes into the pulverizer).
 • Coal Feeder Outlet Pluged: safety
protection for plugged in coal feeder
outlets.
• Motor Overload: protection for safety due
to over load.
Figure 5. Coal flow setting at coal feeder
The setting of coal in the coal flow feeder can be
done by two methods. The first method is
volumetric and the second is by gravimetric. Both
methods will generate how many tons per hour of
coal to burn in the boiler. Many factors determine
how much coal is needed, one of which is the load.
when the load is high, it will automatically require
high steam. Because it requires a high steam, then
the process of changing water from liquid to
produce steam must be faster. To speed it up, it
requires higher combustion and greater water flow.
To use the volumetric method then the steps that
must be done is as follows:
a. setting density
b. Setting cross-sectional area
c. RPM tacho drive pulley
To use gravimetric method then steps must be done
is as follows:
a. Signal Load cell
b. RPM tacho drive pulley
The calculation of flow in coal between volumetric
methods is different from gravimetric. The
calculations are as follows:
a. Volumetrik
Flow rate = SD (kg/m3) x A (m2) x V (m/s)
b. Gravimetrik
Flow rate = Lcell (kg/m) x V (m/s)
V is the speed with the unit m/s. If there is no speed
data in the unit m/s then it can be done by way of
conversion, that is by:
a) V can be extracted from multiplication between
angular velocity (ω) and rpm unit with point spacing
to rotation axis (r).
b) Where (ω) is 2 x phi divided by time period (T).
c) Time period (T) is one unity (1 / rpm).
In calculating the linear speed of the feeder belt, the
existing rpm is divided by the gear reduction ratio of
CF of 53.14: 1, thus:
V = ω x r = 2 x phi x r : T
V = (2 x 3.14 x rpm : GR ) x r (m/s)
In using of the methods that will be used, there are
several things to be aware of. when using of the
volumetric method, the real set of coal density used
at present will result in inaccurate measurement.
While the gravimetric method to note is, the
condition of the belt feeder (level flatness and
coefficient of elongation), so this deviation will
cause the load detected by Load Cell does not show
the value that represents the amount of coal
weighed.
5. Coal feeder maintenance
a. Inspection and adjustment of coal feeder
operation
i. Coal feeder checking project (every day)
1. Belt deviation
(Normal)
Through the observation window, check
whether the conveyor belt running position is
normal.
Belt is located in the center of drive roller and
the driven roller, not obvious to end.
(Explain)
The belt tensioning device (alignment) can be
used to correct running deviation.
Please pay close attention to the conveyor belt
in the first week after coal feeder hasjust
started to use or just replace the conveyor belt.
2. Belt tension
(Normal)
Checking the belt tension, not too loose or too
tight
(Explain)
The belt tensioning device (alignment can be
used to adjust)
3. Belt damage
(Normal) Check whether the belt is damaged.
Conveyor belt outside surface is damaged, and
the inner canvas exposed.
It has deep cut.
(Countermeasure)
If the inner canvas of belt was exposed or belt
cut deeply, please replace the belt immediately.
4. If there are attachments on belt inside and
outside surface
(Normal)
Check the internal and external surfaces of the
belt
The belt inside and autside surface must be
cleaning
(Countermeasure)
Zero adjustment or repair of coal feeder
sweeper
ii. Feeder adjust
5. cleaning system
(Normal)
Check the bottom of the coal feeder eleaning
system
cleaning chain has no damage.
(Countermeasure)
Replace the slider or cleaning chain.
6. Pulverized coal agglomerate and bypass
occur inside the shell
(Normal)
Check whether pulverized coal from the coal
mill was poured into the coal feeder pressure-
tight shell.
Under normal working state, there should be
no coal dust in shell
(Countermeasure)
If the pulverized coal within the feeder was
from the mill, the hot air will poured into the
feeder, then the environment temperature in
feeder will be rise and the pars of the feeder
will be destroyed.
The following measures should be taken:
- Repair coal mill to ensure that the coal
mill work under normal condition.
- Remove coal bypass.
- Check and repair parts of coal feeder
7. Internal pressure air leakage
(Normal)
Using visual and auditory to check.
Can't hear the air leakage noise.
(Countermeasure)
Tighten bolts and nuts,
8. Check instrument display data
(Normal)
By visual inspection
The instrument shows stability and accuracy
(refer to integrator instructions).
a. Rate showed : the current load rate
b. Instrument state monitoring show the
normal work, according to average failure,
fault code and information displayed
c. Information d display the current state of
weighing. set the content, the monitoring
content and ettor message. In the event of
failure, failure of series mumber or address
will be displayed.
d. Before adjusting instruments, please be
familiar with and understand the opetation
of books of integrator instrument
9. Abnormal sound or vibration
(Normal)
Check whether abnormal sound or vibration
occurred in the transmission and rotating parts.
Abnormal vibration and abnormal sound can
be finding by observation and hearing
1. Adjust belt deviation
[Target device]
Tension control screw
Belt tension adjustment device has two
functions as adjusting the belt deviation and
tensioning belt. The tension control screw
outside the feeder end door, you can adjust
screw with a wrench to adjust the belt tension
and correcting belt running deviation.
[Adjust method]
Please choose the appropriate wrench to turn
adjusting screw. Around every time
adjustment, adjust the rotation direction of the
rod must be instead, and number of turns must
be the same.
(1) When regulating, must observe the
operation of conveyor belt through the
observation window.
(2) When the belt running deviation left, the
left turn adjusting screw clockwise,
counterclockwise right regulating lever at the
same time. Every time adjustment must trace
adjustment, each adjustment rod rotation 13 to
1/2 turns
(3) on the other hand, when the belt running
deviation right counterclockwise to the left of
the regulating rod, at the same time clockwise
adjust lever on the right. Every time
adjustment must trace adjustment, each
adjustment rod rotation 1/3 to 12 turns.
(4) After each adjustment, must let the belt
running more than ten laps, identifying
whether belt running deviation phenomenon b
corrected. If there are runnin deviation
phenomenon, please repeat adjustment again.
Don't just rotating joint regulating screw,
otherwise you will change the belt tension,
which affect measuring performance and the
service life of belt and other parts.
 2. Adjust the belt tension
[Target device]
Tension control screw
Belt tension adjustment device has two
functions as adjusting the belt deviation a
tensioning belt. The tension control screw
outside the feeder end door, you can adjust
scrt with a wrench to adjust the belt tension
and correcting belt running deviation.
[adjust method]
Please choose the appropriate wrench to turn
adjusting screw
If the belt is in a state of relaxation, slowly
clockwise on the left side of the regulating
rod, at the same time slowly clockwise on the
right side of regulating rod, until the
appropriate location, belt tension adjustment
rod rotation laps around must be the same.
About adjustment, regulating rod rotation
number shall not be greater than 2 times.
If the belt is too tight, slowly
counterclockwise to the left ofthe regulating
rod, at the sa time slowly to the right to
adjust lever, counterclockwise until the
appropriate location, tension adjustment rod
rotation laps around must be the same. About
adjustment, regula rod rotation number shall
not be greater than 2 times.
3. Eliminate the blockage and bridging faults
at inlet and outlet
[Functional unit]
o If the clogging phenomena, wooden
hammer percussion coal drop pipe.
Don't damage the belt and cleaning system
parts.
b. Check and adjust the coal feeder downtime
i. Coal feeder stop processing requirements
1. Shut down a coal gate at the bottom of the
bunker.
2. Clean coal within the coal feeder
3. Stop coal feeder.
4. Close export coal gate.
5. Cut off the total power.
ii. Period inspection (annual)
1. Scraping the coal board inspection
(Normal)
Check whether coal scraping plate with old or
damaged.
scraping the coal board wear amount shall not
be greater than 5 mm.
Scraping the coal board must contact with the
outer surface of the conveying belt smoothly,
shall not be tilted.
(Countermeasure)
When cleaning the plate wear is greater than 5
mm, change clean the board.
cleaning the board must contact with the outer
surface of the conveying belt is not stable,
need to adjust the clean plate and fixed
installation.
2. The drive drum inspection
(Normal)
Clean the roller outer surface.
Whether need to carefully examine, the drum
shaft damage.
The drive drum shaft does not produce any
defects
3. Roller inspection
(Normal)
Clean roller surface. Roller rotates smoothly.
(Countermeasure)
If necessary, replace the roller.
4. Belt inspection
(Normal)
Confirm whether belt and on both sides ofthe
skirt bem damage or worn out.
If the belt is badly scratched and canvas layer
exposed, or belt worn seriously, please replace
the belt.
(Countermeasure)
If necessary, replace the belt.
5. Driven drum
(Normal)
Clean the driven roller surface is damaged,
need to check carefully whether the drum out
shaft damage. The driven drum shaft does not
produce any defects.
6. Cleaning the feeder shell
(Normal)
Cleaning the inside the feeder shell.
DANGER
Pay attention to safety, don't fall into the hole.
7. Metering device inspection
(Normal)
Cleaning load rollers and sensor.
Check the measuring roller rotating flexible
smoothly.
Check whether the sensor external corrugated
pipe and cable is damaged.
Metering rollers must be flexible rotation
smooth
Weighing sensor may not suffer any damage.
(Countermeasure)
If necessary, replace the load cell and load
roller
 8. Cleaning chain inspection
(Normal)
Confirm whether the blow links scratch or
deformation.
Confirm whether the link deformation or
damage.
Cleaning chain shall not damage or
deformation.
(Countermeasure)
if necessary, replace cleaning chain
Adjust the chain tensioning device, in order to
adjust the degree of tension of the chain.
9. Bearing unit
(Normal)
Check whether the bearing rotation is flexible
Bearings must be flexible rotation.
(Countermeasure)
If necessary, replace the bearing Use the grease
gun fill oil in bearing.
10. Sealing ring
(Normal)
Remove the seal fixed parts, check the seal
ring
Seal gasket and o ring must be flexible, cannot
have damage or hardening ofthe phenomenon
(Countermeasure)
If necessary, replace the seal gasket and o ring
11. Oil seal
(Normal)
Remove the oil seal is fixed parts, check
whether the oil seal is intact
oil seal must be flexible, cannot have damage
or hardening of the phenomenon
(Countermeasure)
If necessary, replace the oil seal
12. Motor
According to the requirement of the described
in the manual, check the motot performance
indicators.
13. Reducer
According to the requirement of the described
in the manual, check the technical
specifications of the reducer
c. Belt changing method
i. Shut off all the power
ii. Open both the front door and the back door
iii. a. Detach the power wire
b. Detach the head motor, reducer (one set)
iv. Disassembly
1. Unlock the tightening bolts. The two blots
should be unlocked in-step for preventing
the bending distartion of the bolts caused
by the leaning ofthe roller wheel.
2. Detach the flank blanks, then detach all the
carrier tollers from the flank apertures
3. Detach the reducer, unlock the tighten
screws on the bearings, detach the bolts of
the bearing houses, take down the bearing
houses, then unfix the blots of the inside
circula flanges, use the blots push the
flanges out, install a overhaul extend pipe
on one side, pus the active rotary drum out
slowly from the motor side after active
rotary drum was lifted.
4. Detach the tightening bolts covers and the
bolts of the blank, with which fixed rail, an
push the driven rotary drum out from the
body, then change a new belt.
v. Reassembly
1. Firstly, enter the belt into the coal handing
rack, put the driven rotary drum though th
belt, push the belt towards the active rotary
drum, then install the carrier rollers though
th belt from the flank apertures one by one,
pull the belt towards the active rotary drum
to th end, after that add a overhaul extend
pipe on one side of the active rotary drum,
lift the activ rotary drum and move it into
the coal handing rack slowly, install the
inside circular flange on two sides and
locked them with the bolts, then install the
beuring houses on two sides an locked
them with the bolts, after adjusting the
active rotary drum at the center positi
locked the tighten screws on the bearings
of two sides
2. Reassembly the planks with which fixed
rail, and locked with the bolts, install the
tighten bolt covers, revolve the tighten bolt
covers till the underside of the belt is
paralleled with the under surface of the
active and driven rotary drum
3. When the fixing bolts and the attachment
bolts of the coal handling rack are well
installed, the coal feeder can be put into
operation under the condition that the
running belt has no off tracking at least
10minutes. In order to observe and adjust
the running condition, the running machine
should be monitored on site in above half
an hour or every shift.
6. Conclusion
a. the working principle is to control the coal
flow from the bunker to the coal mill /
pulverizer. It varies the belt speed to
control the coal flow that enter the coal
mill.
b. Type of coal feeder used here DPG40 who
has nominal output 40 t/h and range of
output 4~46 t/h
 c. Coal feeder components are feeder cell,
drive drum, belt, belt drive redactor and
motor, temperature sensor, load cell,
explosion-proof lamp, observation window.
d. Maintenance and repair of coal feeder
consist of two kinds, internal inspection of
the feeder and external inspection of the
feeder.
7. Refferences
a. https://www.academia.edu/28860216/COA
L_FEEDER_PULVERIZER_DAN_COAL
_BURNER
b. https://id.scribd.com/document/358250120/
Coal-Feeder-pdf
c. https://instrumentasipembangkit.wordpress.
com/2017/02/07/equipment-pltu-coal-
feeder/
d. Beijing Power Equipment Group, Use and
maintenance manual of Raw coal weigh
feeder, manual book, 2017

Biography

PANIMAN PALENGAI

Currently working as a mechancal engineer at PT.

D&C Engineering Company

Graduate from State Polytechnic Of Ujung Pandang,

South Sulawesi, Indonesia on November 2014,
majoring in Mechanical Engineering