Published On: Thu, Sep 9th, 2021

Electrical Installations On Steel Structures – The Drive Station of Large capacity of The Belt Conveyor.

Electrical Installations On Steel Structures – The Drive Station of Large capacity of The Belt Conveyor.

Author of photos and text: Radoje Jankovic.

Practice of electrical installations of low and high voltage for:

– pupils

– students

– technicians

– electricians,

– electrical fitters,

– engineers,

– designers and constructors,

– Professor …

In this photo album I showed dozens of photos of practical implementation of electrical installation on steel structures.

In this case, it is the drive station of belt conveyor with large capacity intended for a new surface mine field “C” in the mining basin “Kolubara” Lazarevac, Serbia.

These are the kind of specific electrical installation, which many do not have opportunities, perhaps never to see or to work on their execution. Although for a professional electrician does not have any specifics; installation as well as all electrical installations. Just a little more or a lot more complicated than the standard electrical wiring in the classic buildings and buildings.

Many, and professors have not seen such an installation let alone worked on them, installed, connected equipment, interrogated, let up, maintain and even rarely any of them that has ever designed.

Such installations are performed highly professional workers, technicians and engineers with extensive work experience. Younger colleagues are experienced with these “wolves electrics” trained and taught the craft to such an installation.

Even in schools and at universities with these and similar installations do not study, and a special problem is that schools and colleges do not send students to practice in enterprises where this type or similar electrical installations are performed, at least to get familiar with the specifics of jobs is working on how to perform them.

Jankovic is a big part of their working life working on editing and execution of many types of electrical installation of the; the ordinary family houses, apartment buildings, industrial buildings, hospitals, schools, large production hall at hydro power plants, diesel power plants, separations materials, concrete factories, cranes, excavators of all types of belt conveyors and spreader devices, drilling towers, oil fields, the separation of oil and gas installations, cathodic protection, small photovoltaic solar power plants, heating plants, technological plants, administrative and factory buildings etc. and so on.

Because of his work in a very different electrical installations Jankovic has a large archive and project documentation with complete calculations, materials specifications, Bill of Quantities work …. and a large number of their own, original photo detail of electrical installation of the execution.

Especially documented his masterful work embodiment thereof.

In this, the first part, I will show only the details with photographs.

Each image shows clearly enough what is necessary to see and even to learn something new. With each picture gives a short description for a clearer perception and understanding of the photos and details on it.

Otherwise, all the equipment is designed for outdoor installation and the most difficult climatic conditions. A climatic conditions in opencast mines are very harsh and extreme, flying to 45 or more degrees Fahrenheit in the winter frosts, snow and temperatures down to minus 20 degrees Celsius.


Here we present details erection of electrical installation on steel structures, drive station a large belt conveyor for opencast mining of lignite coal.

In the later parts will be shown in many other details with different electrical equipment and devices both during installation and after completion, as well as details of installation in service after several years.


One view of the belt conveyor drive station during assembly on the assembly site. You can see the cable routes and the main switchyard at the top of the power station.
Recorded: Radoje Jankovic.
Photo # 1.
Jedan izgled pogonske stanice trakastog transportera u toku montaže na montažnom placu. Vide se kablovske trase i glavna razvodna kućica na vrhu pogonske stanice.
Snimak: Radoje Jankovic.
Foto #1.

Another view of the belt conveyor drive station where the cables laid along the cable racks as well as the connected drive motor can be seen, to the right.
Recorded: Radoje Jankovic.
Photo # 2.
Još jedan pogled na pogonsku stanicu trakastog transportera sa gde se vide položeni kablovi po kablovskim regalima kao i povezan pogonski motor, desno.
Snimak: Radoje Jankovic.
Foto #2.

Appearance of laid low-voltage cables with neoprene insulation and fine-wire cores.
These cables are designed for harsh operating conditions, just as in this case where there are high vibrations due to the transport of hundreds and hundreds of tons of coal or cubic meters of tailings.
Recorded: Radoje Jankovic.
Photo # 3.
Izgled položenih niskonaponskih kablova sa neoprenskom izolacijom i finožičanim žilama.
Ovi kablovi su predviđeni za teške eksploatacione uslove, baš kao što su u ovom slučaju gde su velike vibracije usled prevoza stotina i stotina tona uglja ili kubika jalovine.
Snimak: Radoje Jankovic.
Foto #3.

As in the previous picture. Low-voltage neoprene fine-wire cables laid on steel cable racks ready for connection.
Photo # 4.
Kao i na prethodnoj slici. Niskonaponski neoprenski finožičani kablovi položeni po čeličnim kablovskim regalima spremi za povezivanje.
Snimak: Radoje Jankovic.
Foto #4.
A simple pushbutton on the right and a mushroom red pushbutton known as “all stop”, which stops the belt conveyor in case of any danger or accident. When this button is pressed, the entire system is switched off, consisting of a rodent excavator at the beginning, several belt conveyors, sometimes up to ten kilometers long, with drive stations, reloading bandwagon, and finally a dredger with a sliding train that disposes of tailings, or, if is finally a coal loading station and it is switched off until the danger or fault has been rectified. Everything is regulated by time.
Recorded: Radoje Jankovic,
Photo # 5.
Običan taster desno i gljivasti crveni taster poznat kao “sve stop”, kojim se sve zaustavlja u slučaju bilo kakve opasnosti ili havarije. Kada se ovaj taster pritisne isključuje se čitav sistem koji se sastoji od bagera glodara na početku, više trakastih transportera, ponekad dužine i do deset kilometara, sa pogonskim stanicama, pretovarni bandvageni i na kraju bager odlagač koji odlaže jalovinu, ili, ako je na kraju utovarna stanica za ugalj i ona se isključuje dok se ne otkloni opasnost ili kvar. Sve je regulisano vremenski.
Snimak: Radoje Jankovic,
Foto #5.
Cable connection in the cubicle of switchgears.
The picture clearly shows that two cables were used due to high currents or high electrical load. The figure shows how the connection is made correctly.
Photo # 6
Kablovcki priključak u razvodnom ormanu.
Sa slike se jasno vidi da je upotrebljeno dva kabla zbog velikih struja ili velikog elektirčnog opterećenja. Slika prikazuje kako se pravilno izvodi priključak.
Foto $6

Low voltage cables on the right and high voltage cables on the left, neoprene – yellow, laid on vertical cable racks.
Photo # 7.
Kablovi niskog napona desno i visokog napona levo, neoprenski – žuti, položeni po vertikalnim kablovskim regalima.
Foto #7.
Display of correct installation and connection of one pushbutton for local command. The connection cable has a detailed number that tells where it is going and which drive is using it.
Photo # 8.
Prikaz ispravne montaže i povezivanja jednog tastera za lokalno komandovanje. Priključni kabl ima detaljan broj koji govori gde ide i koji pogon ga koristi.
Foto #8.
Detail of the cable connection of a three-phase low-voltage asynchronous motor. The lower cable is power, and the right ones are for the temperature control elements of the windings and ball bearings of the electric motor.
Photo # 9.
Detalj kablovskog priključka jednog trofaznog asinhronog nisko naponskog motora. Donji kabl je energetski, a desni su za elemente kontrole temperature namotaja motora.
Foto #9.
One look at the cable route under the lattice floor at the low and high voltage switchgear of the drive station. It is clear how the cables are laid properly.
Under no circumstances is improper cable laying allowed. All cables along the cable route must run parallel to each other.
Photo # 10.
Jedan pogled na trasu kablova ispod rešetkastog poda kod razvodnog postrojenja niskog i visokog napona pogonske stanice. Jasno se vidi kako se pravilno polažu kablovi.
Ni u kom slučaju nije dozvoljeno nepravilno polaganje kablova. Svi kablovi po kablovskoj trasi moraju da idu paralelno jedan pored drugog..
Foto #10.
Detail of mounting the outdoor luminaire on the drive station of the belt conveyor. Due to the high vibrations, the lamps must be mounted in such a way that they do not “shake” during the operation of the station. That is why they are mounted on special elastic supports that prevent the impact of vibrations.
Photo # 11.
Detalj montiranja spoljne svetiljke na pogonskoj stanici trakastog transportera. Zbog velikih vibracija svetiljke moraju biti tako montirane da se ne “tresu” u toku rada stanice. Zato su montirane na specijalne elastične nosače koji sprečavaju uticaj vibracija i potresa.
Foto #11. 
During my visit, the drive station was placed under a high voltage of 35 kV, 50 Hz, so detailed tests are performed on the so-called. “cold” and all checks on connections and correct operation. The picture shows the main contractor – a red helmet – otherwise my colleague Stepa, a top electrical expert for all mining machines from the smallest to the largest capacities, is retired, but he was invited to lead the installation of three power stations, excavators and bandwagon that are mounted on the same on this plot, the supervisory body – a yellow helmet and a representative of the station supplier in a white T-shirt – a young lady.
Photo # 12.
U toku moje posete, pogonska stanica je stavljena pod visoki napon od 35 kV, 50 Hz, pa se vrše detaljna ispitivanja na tzv. “hladno” i sve provere izvršenih veza i ispravnost funkcionisanja. Na slici je glavni izvođač – crveni šlem – inače moj kolega Stepa, vrhunski elektro stručnjak za sve rudarske mašine od najmanjih do najvećih kapaciteta, u penziji je ali su ga pozvali da vodi montažu tri pogonske stanice, bagera odlagača i bandvagena koji se istovremeno montiraju na ovom placu, nadzorni organ – žuti šlem i predstavnik isporučioca stanice u beloj majici – mlada dama.
Foto #12.
Another so-called “all stop” pushbutton mounted on the station.
Otherwise, there are several of these pushbuttons on the drive station in key places for immediate stopping of all drives in case of any danger or accident or overloading and burying the station with large amounts of excavated material.
Photo # 13.
Još jedan tzv. “sve stop” taster montiran na stanici.
Inače na pogonskoj stanici postoji nekoliko ovih tastera na ključnim mestima za trenutno zaustavljanje svih pogona u slučaju bilo kakve opasnosti ili havarije ili pretrpavanja i zatrpavanja stanice velikim količinama otkopanog materijala.
Foto # 13.

This figure shows the terminal box of a 35 kV / 10 kV high voltage power transformer.
See how well-done the work is on connecting the power three-phase power transformer.
Photo # 14.
Ova slika prikazuje priključnu kutiju visokonaponskog transformatora snage 35 kV/10 kV.
Pogledajte kako su kvalitetno izedeni poslovi na priključivanju energetskog trofaznog transformatora snage.
Foto #14.
Another look at the three-phase power transformer connection at the drive station.
Photo # 15.
Još jedan pogled na priključak trofaznog transformator snage na pogonskoj stanici.
Foto #15. 
Top view of the cable entry into the terminal box of a three-phase power transformer 35 kV/10 kV. All cables are marked with the appropriate numbers for identification.
Photo # 16.
Pogled odozgo na ulaz kablova u priključnu kutiju trofaznog transformatora snage visokog i niskog napona. Svi kablovi su obeleženi odgovarajućim brojevima radi identifikacije.
Foto #16. 
View of the power transformer, 35 kV / 10 kV  at the top of the drive station.
Photo # 17.
Pogled na transformator snage na vrhu pogonske stanice.
Foto #17.
View of a three-phase asynchronous motor for driving the belt conveyor with a connected connection using power cables. See motor data in the following figure.
Photo # 18.
Pogled na pogonski trofazni asinhroni motor sa izvedenim priključkom pomoću energetskih kablova. Podatke o motoru pogledajte na sledećoj slici.
Foto #18.
One of the two name plates of the drive three-phase asynchronous electric motor with speed regulation via frequency regulators.
Photo # 19.
Jedna od dve natpisne tablice pogonskog trofaznog asinhronog elektro motora sa regulacijom brzine preko frekventnih regulatora.
Foto #19.
A more detailed view of the cables to which the three-phase asynchronous motor of 1200 kW, 3 x 690 VAC is connected, the drive stations of the belt conveyor. Which is said “like a picture”.
Photo # 20.
Detaljniji pogled na kablove kojima je priključen trofazni asinhroni motor snage 1200 kW, pogonske stanice trakastog transportera. Što se kaže “k’o slika”.
Foto #20. 

The picture says it all clearly. See also the following connection figures for a three-phase asynchronous motor to drive a belt conveyor. The beauty of the artistic work of an electrician.
Photo # 21.
Slika sve jasno govori. Vidi i sledeće slike priključivanja trofaznog asinhronog motora za pogon trakastog transportera. Lepota od umetničkog rada montera – električara.
Foto #21.
And this picture says it all clearly, as do the upper pictures.
Recorded: Radoje Jankovic.
Photo # 22.
I ova slika sve jasno govori, kao i narednih nekoliko slika.
Snimak: Radoje Jankovic.
Foto #22.
One of the transit control cabinets at the belt conveyor drive station.
Photo # 23.
Jedan od prolaznih komandnih ormana na pogonskoj stanici trakastog transportera.
Foto #23. 
Another “all stop” pushbutton.
Photo # 24.
Još jedan taster “sve stop”.
Foto #24.
View of the cable entry from the vertical rack into one auxiliary passing cabinet at the drive station.
Photo # 25.
Pogled na uvod kablova sa vertikalnog regala u jedan pomoćni orman na pogonskoj stanici.
Foto #25.
View of oil heaters in the drive gearbox, belt conveyor drive stations.
The individual power of the heater is 2350 W, 230 VAC
Photo # 26.
Pogled na grejače ulja u pogonskom reduktoru, pogonske stanice trakastog transportera.
Pojedinačna snaga grejača je 2350 W, 230 V. A. C.
Foto #26. 

View of the terminal box of the electro-hydraulic brake for electric motor braking during stopping of the belt conveyor.
Photo # 27.
Pogled na priključnu kutiju elektro hidraulične kočnice za kočenje motora u toku zaustavljanja trakastog transportera.
Foto #27.

View of a reflector with a sodium light bulb for night lighting.
Photo # 28.
Pogled na reflektor sa natrijmskom sijalicom za noćno osvetljenje.
Foto #28.
View of the cable laying performed on the cable racks of the belt conveyor drive station.
Photo # 29.
Pogled na kablovski razvod izveden po kablovskim regalima pogonske stanice trakastog transportera.
Foto #29.
View of the three-phase asynchronous AC motor connection for the conveyor drive. Motor with VFD.
Photo # 30.
Pogled na priključak trofaznog asinhronog motora naizmenične struje za pogon transportera.
Foto #30.
Cables laid on racks and ready for connection.
Photo # 31.
Kablovi položeni po regalima i spremni za povezivanje.
Foto #31. 
One look at the cable racks with laid neoprene-insulated power cables.
Photo # 32.
Jedan pogled na kablovske regale sa položenim energetskim kablovima izolovanih neoprenom.
Foto #32.
The installer works on fixing the power cables laid along the vertical rack.
Photo # 33.
Monter radi na fiksiranju energetskih kablova položenih po vertikalnom regalu.
Foto #33

High-voltage and low-voltage cables brought to the transformer cubicle for another power converter.
Photo # 34.
Visokonaponski i niskonaponski kablovi dovedeni u trafo polje za drugi transformator snage.
Foto #34. 

Another look at the converter transformer from the previous picture.
Recorded: Radoje Jankovic.
Photo # 35,
Još jedan pogled na trafo sa prethodne slike.
Snimak: Radoje Jankovic.
Foto #35, 

Name plate of three-phase converter power transformer. The table shows-mirroring the connection cables from the second three-phase transformer.
Photo # 36.
Tablica sa podacima trofaznog transformatora snage. Na tablici se ogledaju priključni kablovi sa drugog trofaznog transformatora.
Foto #36. 

Shelving cables for connection of three-phase power converter transformer.
Photo # 37.
Kablovi uz regal za priključak trofaznog transformatora snage.
Foto #37.
Cables for other power converter transformers at the belt conveyor drive station.
Photo # 38.
Kablovi za drugi transformator snage na pogonskoj stanici trakastog transportera.
Foto #38. 
Radoje Jankovic at the drive station of the belt conveyor.
I apologize to my fellow installers, I did not take the protective helmet even though I worked on the assembly for many years and wore it. I violated the rule of safety at work.
Photo # 39.
Radoje Jankovic na pogonskoj stanici trakastog transportera.
Izvinjavam se kolegama monterima, nisam uzeo zaštitni šlem iako sam mnogo godina radio na montaži i isti nosio. Prekršio sam pravilo zaštite na radu.
Foto #39.
Supplied cables for connection of three-phase asynchronous motor for belt conveyor drive, motor power 1200 kW, 690 V AC. The voltage supplying of the motor is done via frequency regulators.
Record: Radoje Jankovic.
Photo # 40.
Dovedeni kablovi za priključak trofaznog asinhronog motora za pogon trakastog transportera, snaga motora 1200 kW, 690 V AC. Puštanje u pogon motora se vrši preko frekventnih regulatora.
Snimak: Radoje Jankovic.
Foto #40.
Jankovic besides of connected three-phase asynchronous motor for belt conveyor drive.
Photo # 41.
Jankovic kraj priključenog trofaznog asinhronog motora za pogon trakastog transportera.
Foto #41.
One look at three drive stations for new belt conveyors for transporting tailings or coal at a surface mine.
Video: Radoje Jankovic.
Photo # 42.
Jedan pogled na tri pogonske stanice za nove trakaste transportere za transport jalovine ili uglja na površinskom kopu.
Snimak: Radoje Jankovic.
Foto #42.


Autor: Radoje Jankovic.

Praksa izvođenja električnih instalacija niskog i visokog napona za:

– učenike,

– studente,

– tehničare,

– električare,

– elektro montere,

– inženjere,

– projektante i konstruktore,

– profesore …

U ovom foto albumu prikazao sam nekoliko desetina fotografija praktičnog izvođenja električnih instalacija na čeličnim konstrukcijama.

U ovom slučaju, radi se o pogonskoj stanici jednog trakastog transportera velikog kapaciteta namenjenoj za novi površinski kop Polje “C” u Rudarskom basenu “Kolubara” u Lazarevcu.

Ovo su u neku ruku specifične električne instalacije, koje mnogi nemaju mogućnosti, možda nikada da vide ili da rade na njihovom izvođenju. Mada za električara profesionalca nema neke specifičnosti; instalacije kao i sve električne instalacije. Samo malo više ili mnogo komplikovanije od standardnih električnih instalacija u klasičnim zgradama i građevinskim objektima.

Mnogi, i, profesori nisu videli ovakve instalacije a kamo li na njima radili, montirali, povezivali opremu, ispitivali, puštali u pogon, održavali pa i retko koji od njih da ih je ikada projektovao.

Ovakve instalacije izvode visokostručni radnici, tehničari i inženjeri sa velikim radnim iskustvom. Mlađe kolege se uz ove iskusne “vukove elektrike” obučavaju i uče zanatu za ovakve instalacije.

Ni u školama a i na fakultetima sa ovakve i slične instalacije ne izučavaju, a poseban problem je što škole i fakulteti ne šalju učenike i studente na praksu u preduzeća gde se ovaj tip ili sličan električnih instalacija izvode, makar da bi se upoznali sa specifičnostima poslova koji se rade na izvođenju istih.

Janković je veliki deo svog radnog veka radio na montažama i izvođenjima mnogih vrsta električnih isntalacija; na običnim porodičnim kućama, stambenim zgradama, industrijskim halama, bolnicama, školama, velikih proizvodnih hala, na hidro elektrnama, dizel elektranama, separacijama materija, fabrikama betona, kranovima, bagerima svih tipova, trakastih transportera i presipnim uređajima, bušaćim tornjevima, naftnim poljima, separacijama nafte i gasa,

instalacijama katodne zaštite, manjih fotovoltaičnim solarnim elektranama, toplanama, tehnološkim pogonima, administrativnim i fabričkim objektima itd. itd.

Zbog svog rada na veoma različitim električnim instalacijama Janković raspolaže velikom arhivom i projektnom dokumentacijom sa kompletnim proračunima, specifikacijama materijala, predmerima i predračunima radova…. kao i velikim brojem sopstvenih, originalnih fotografija detalja izvođenja električnih isntalacija.

Posebno je dokumentovao svoj majstorski rad na izvođenju istih.

U ovom, PRVOM DELU, prikazaću samo detalje pomoću fotografija.

Svaka slika dovoljno jasno prikazuje sve što je neophodno da se vidi pa i da se nauču nešto novo. Uz svaku sliku dat je kratak opis radi jasnijeg sagledavanja i razumevanja fotografije i detalja na njoj.

Inače sva oprema je predviđena za spoljnu montažu i najteže klimatske uslove. A klimatski uslovi na površinskim kopovima su veoma surovi i ekstremni, leti do 45 pa i više stepeni Celzijusa a zimi mrazevi, sneg, temeprature i do minus 20 stepeni Celzijusa.


Ovde su prikazani detalji izvodđenja električnih instalacija na čeličnim konstrukcijama, pogonske stanice jednog velikog trakastog transportera za površinski kop uglja lignita.

U kasnijim delovima biće prikazano mnoštvo drugih detalja sa različitom elektro opremom i uređajima kako u toku montaže tako i po završetku, kao i detalje instalacija u eksploataciji posle više godina.


About the Author

- Radoje - Rade Jankovic Electrician, Electrical Technician, Electrical Engineer, PhD, Ecologist, Environmentalist, Designer, Educator, Investigator... Today PROFESSIONAL TECHNICAL WRITER AND DOCUMENTATOR Massive practical experience in almost all fields of electrical engineering over 40 years. My International education group in Facebook: EEEW - ELECTRICAL & ELECTRONIC EDUCATION WORLD where published more than 8000 small or bigger articles, lessons, technical advice, projects, technical calculations, test questions with and without answers, illustrated test questions with and without answers; all my original works and few thousands of may original photos from practice, drawings, circuit diagrams, environmental lessons and examples from everyday practice etc., etc.

Displaying 3 Comments
Have Your Say
  1. Jed Hanses says:

    Good post. I learn something totally new and challenging on websites I stumbleupon on a daily basis. It will always be exciting to read through content from other authors and use a little something from their websites.

  2. I got what you mean ,saved to bookmarks, very decent internet site.

  3. It is truly a great and helpful piece of information. I am satisfied that you simply shared this helpful info with us. Please stay us up to date like this. Thank you for sharing.

Leave a comment

XHTML: You can use these html tags: <a href="" title=""> <abbr title=""> <acronym title=""> <b> <blockquote cite=""> <cite> <code> <del datetime=""> <em> <i> <q cite=""> <s> <strike> <strong>

Electrical Installations On Steel Structures – The Drive Station of Large capacity of The Belt Conveyor.