Hendrina Power Station Training: Coal Plant Course

• Hendrina Power Station provides operating training for a coal plant course.
• Discipline: The unit standard number is 114456, and the learnership level is 3.
• The average time required is 80 hours.
• The course was prepared on 24/4/1992, last reviewed on 10/01/2008, revised on 22/02/2007, and accredited on 08/05/1995. The current revision is 3.
• The plant course includes safety, health and environment topics.

Course Content

• Introduction and Purpose: Pages 1
• Personal Safety: Page 1
• Origin of Coal: Page 9-93
• Plant Layout: Page 19
• Road Truck Weigh Bridge: Page 28
• Coal Plant Components and Equipment: Page 34
• Conveyor Belt Idlers: Page 44
• Transfer Chutes: Page 67
• Tripper Car: Page 77
• Pre-Start Inspections: Pages 94-128
• Operating: Pages 94-128
• Conveyor Belt System Operation: Page 101
• Abnormal Operating: Page 115
• Duties and Responsibilities: Page 118
• Boiler Bunker Lashing (a Roshcon requirement): Page 119
• Readings: Page 120
• Log Writing: Page 121
• Conveyor Belt Specifics (Eskom Belts & Isolations and De-isolations): Page 121

Module Focus

• The Unit Standard 114456 focuses on operating a Coal Handling Plant and monitoring plant operability.

Embedded knowledge

• Understanding the impact on energy conversion processes and being aware of the environmental impact of actions is vital.

Prior learning

• A foundation in Maths, Engineering Science, Electrical Trade Theory, and Power Plant theory at Pre-N1 / N1 level is assumed.

Objectives

• Safely and effectively operate the coal plant and associated equipment.
• Identify and describe coal plant components, and discuss normal/abnormal plant operation.

Given Conditions

• Classroom lectures and training manuals are given
• 80% must be achieved on written tests, 100% on practical ID, final criterion practical tests and safety tests, and 80% on self tests

Personal Safety

• Wearing personal protective equipment (PPE) is compulsory when working on the coal plant and includes hard hats, overalls, ear protection, safety boots, dust masks, eye protection, and short leather gloves.
• Personnel aren't allowed to clean machinery in motion, especially cleaning pulleys, drive motor units, and idlers.

Safety Measures

• Trip wires are installed on both sides of the conveyor belts and are there so workers can protect themselves from serious injury.
• Safety guards on motor couplings, fluid couplings, pulleys and shafts must be regularly inspected to be secure and in good condition.

Safety Precautions

• Compulsory PPE must be worn at all times whilst working on the plant.
• Don't wear loose hanging clothing when working on or near moving machinery.
• Safety protection covers on electrical and mechanical drives are essential.
• Smoking is not allowed and can lead to carbon monoxide fumes.
• Never cross over the conveyor belts by any means, unless the ladder walkways are provided.
• No persons shall ride on conveyor belts.
• Adhere to safety signs and safety devices.

General safety advice

• Never tamper with safety devices or signs.
• Be aware of slippery walkways or ladders, and report any hazardous conditions.
• Use the correct tools and ensure fire-fighting equipment is in position.
• Maintain correct correct steps should when isolating or de-isolating plant

Senses during operation near machines

• Sight
• Hearing
• Feeling
• Smelling
• Always handle equipment with care and respect.

Health

• Industrial diseases, such as deafness, poor eyesight, and tuberculosis, can lurk for years before discovery.

Environment

• Prevent chemical spills, report sources of pollution, and participate in waste recycling activities.

Housekeeping

• Maintain a clean plant prevent and accidents.

Confined Spaces

• Confined spaces are enclosed, restricted areas where hazardous substances may accumulate or oxygen deficiency may occur and access into these areas is strictly prohibited without the PSR arrangement requirements.
• Areas considered to be confined are boiler bunkers, staithe bays, and bilge sump pump sump pits.

Stray Cortex

• If a ± 4mm string is seen in the coal, remove it immediately as it may be a stray cortex (dynamite).
• If it's dynamite, trip out the belt to retrieve this and report this to a supervisor.

When operating the Eskom 'STAR' Policy should be adhered to

• Stop
• Think
• Act
• Review