Crushing station diesel generator configuration

When a mine wants to increase shift production or add a new crushing and screening line, it usually first purchases a crusher, screener, feeder, conveyor belt, water pump or air compressor. The operating power on the equipment nameplate seems controllable, but the impact on the power supply system is greater at the moment of startup.

If the original units, low-voltage cabinets and cables on site are only configured according to the past load, the voltage may drop significantly as soon as the new equipment is started, causing protection tripping and even affecting other motors on the same line.

The most difficult thing for the person in charge of expansion to accept is that the equipment has been installed and a single piece of equipment can be started, but once it enters the linkage startup, it becomes unstable. The crusher trips when it starts, the conveyor belt and feeder interact with each other, and the voltage is pulled down as soon as the pump or mill is turned on.

Onsite personnel could only repeatedly adjust the startup sequence, temporarily stop some loads, or have electricians guard the control cabinet. The production line is not completely without power, but cannot start stably and run continuously as planned.

If the startup shock is not dealt with, the expanded production capacity will be stuck in the power supply system. Crushing, screening, conveying and pumping stations cannot be stably linked, shift output cannot increase, and equipment installation and debugging time will also be lengthened.

Even more troublesome is the judgment distortion. The site may think it is an equipment failure, control cabinet problem or operational problem, but the root cause is that the power generation capacity margin, parallel control, low-voltage power distribution and starting sequence were not reviewed together.

First split the motor list into three categories: continuous operating load, starting impact load, and auxiliary load that allows delayed start. Crusher, screener, feeder, conveyor belt, pump and air compressor should record the starting mode, rated power, voltage frequency, interlocking relationship and actual starting sequence.

When selecting, focus on the voltage drop and protection coordination at the start-up moment: whether there is a margin for single machine capacity, whether parallel machines need to be shared, whether the low-voltage cabinet and cables can withstand impacts, and which loads must be peak-shifted. Only in this way can the crushing line start up according to the adjusted rhythm, instead of relying on on-site trials again and again.

The first step is to establish a load table according to the equipment list, marking the direct start, soft start and variable frequency start equipment, as well as the conveying, feeding and dust removal loads that must run synchronously with the crushing host.

The second step is to estimate the risk of voltage drop according to the real startup sequence. When necessary, start large motors in batches, or use parallel control to distribute the starting impact to multiple units, and review the low-voltage cabinets, circuit breakers and cable margins at the same time.

The third step is to write the startup conditions into the debugging and handover list: which device should be turned on first, how long the interval should be, what kind of alarm needs to check the voltage and frequency first, and in which case the line needs to be shut down and reset. Even after the team is replaced, it can be started according to the same set of logic.

After completing the review, crushing, screening, conveying, pumping stations and auxiliary equipment have clear start-up queues, voltage fluctuations are suppressed within the acceptable range on site, and the unit will not repeatedly alarm or trip at the most difficult start-up moment.

When adding feeders, conveyor belts or pumping stations later, it can also be seen on site whether the bottleneck is capacity, parallel control, low-voltage cabinets or startup sequence. There is no need to rely on trial runs to find problems every time the production is expanded.