conveyor instalation training module.pptx

this module is guidance for instalation and maintenance of conveeyor belt

1. STRINGER AND FRAME Stringer and frame were assembled on site by several type of frame ( type 1 to type 5 ), each type can be see on arrangement drawing. Quantity of each type were state on the table below. Each parts were connected by bolt, make sure the correct bolt was installed. Bolt material properties were High Tension Bolt with Hot Dip Galvanised Finish Conveyor arrangement as drawing below

2. STRINGER AND FRAME STRINGER ALIGNMENT Trusses and channel frame conveyor stringers must be installed parallel, straight, square, and level to allow proper belt training. There are four tolerances as guidelines for design/manufacture to facilitate proper idler and belt alignment: A. Parallel A maximum tolerance of ± 5 mm shall be allowed for the back to back dimension in channel frame or angle stringers. Similarly, ± 5 mm shall be allowed between webs of I-beams, wide flange beams, or tees when used as truss chords. B. Straightness The maximum allowable lateral offset in conveyor stringers shall be ± 5 mm in 10 meters of length.

3. STRINGER AND FRAME STRINGER ALIGNMENT C. Square- ness A check on square-ness can be made by comparing diagonal measurements between idlers Line A and B must be within 5 mm to assure conveyor frame square-ness. Return idlers should be installed level and parallel to the head and tail pulleys D. Level The two idler support members shall be level within 5 mm regardless of belt width. In addition, the elevation of stringer above support shall be held within ± 5 mm

4. STRINGER AND FRAME RAILWAY ALLIGNMENT Railway for tripper must be installed parallel, straight, square, and level to allow proper tripper travel. There are tolerances as guidelines for design/manufacture to facilitate proper railway alignment as table below:

5. IDLERS AND TRANSOM (BRACKET IDLERS) Transition Carrying Idler Spacing and positioning : before Head Pulley there’s must be minimum 2 sets of transition idlers and after tail pulley there’s must be minimum 2 sets of transition idlers. The recommended spacing distance is 0.4 – 0.7 x carry idler spacing. With maximum allowable distance is same as installed carry idler spacing Carrying Idler Carrying idler spacing was 1200mm between each set of carrying idler, Bolt Hole Tolerance of deviation within 5 mm Return Idler Carrying idler spacing was 3000mm between each set of return idler, Bolt Hole Tolerance of deviation within 5 mm Impact Idler Carrying idler spacing was 300mm – 500 mm between each set of impact idler, Bolt Hole Tolerance of deviation within 5 mm Note for Transition Idler:   Always use steel made roller for transitioning area. Since, the tension of the belt will be greater in transitioning area. Always design material dropping point on full angle idler (never drop material on transition point) Half through transition models can be used for dropping point designed on transition ( based on CEMA reference )

6. IDLERS AND TRANSOM (BRACKET IDLERS) Self Aligning Cary Idler ( SACI )   Self Aligning Cary Idler designed to automatically train the conveyor belt on top side while running. Spacing 30 – 50 meter distance between each aligning idler. For total length below 30 meter can be installed 1 set. The distance between before and after of the self aligning carrying idler to the regular carrying idler is following the regular caring idler spacing Self Aligning Return Idler ( SARI ) Self Aligning Return Idler designed to automatically train the conveyor belt on bottom side while running. Spacing 30 – 50 meter distance between each aligning idler. For total length below 30 meter can be installed 1 set. The distance between before and after of the self aligning return idler to the regular return idler is following the regular return idler spacing. Note for Self Aligning Idler:   Do not place the self aligning idler within 1 meter distance from pulley Do not place the self aligning idler on vertical / horizontal curve Do not place the self aligning idler on transfer / dropping / loading / impact point.

7. IDLERS AND TRANSOM (BRACKET IDLERS) IDLER ALIGNMENT The aim idler alignment is to achieve settings which are square and in line to the conveyor centerline and parallel to each other. Idlers shall be set from a previously squared and leveled terminal pulley. The recommended is to use laser alignment techniques to establish a datum line . The other way, use a tight wire on the centerline or offset to it, stretched to form a true centerline reference , at least 30 meter long and referenced to the squared starting pulley. Idlers shall be placed at design spacing and square to the line. After a span of a about 15 meter has been filled with the idlers, the 30 meter line shall be relocated so that there is a 15 meter overlap on the first position. Repositioning of the laser or tight wire should continue until the entire conveyor length is filled with idlers

8. PULLEYS PULLEY INSTALATION Move pulley from storage area to installation location. Move the pulley by using a "webbing sling" which is wrapped around the pulley body as shown below (Figure 1.) Another way to move the pulley can be done by hanging the webbing sling on the shaft. By placing the "webbing sling" as close as possible to the pulley shell as shown below (Figure 2.) Follow the manufacturer's instructions for installing a plummer block for pulleys that have not been installed with a plummer block. If the plummer block has been installed, make sure the hole spacing is appropriate. Re- grease when storage has exceeded 3 months. Put the pulley in place. When installing a pulley for replacement, clean the installation area before installation. Install the plummer block in the designated area, pay attention to the breaking load that can be accepted by the housing according to the recommendations from the plummer block manufacturer . ( see attachment ) Place the bolts in the holes and tighten them by hand. The diameter of the bolt is adjusted according to the hole in the plummer block provided. The bolt recommendation is ASTM A325 grade Do the alignment to ensure that the pulley is seated 90 degrees to the gallery. Check bearing holder aligment , give steel plate as 'shim' if it is found that both bearing housings are not level. Do the tightening with the torque as requested.

9. PULLEYS Give a mark on the foot plate bearing housing to find out if one day you find the bearing housing shifted. End the tightening with a torque wrench according to the torque value allowed. Paint on the part of the shaft that is visible from the outside. When the first application of grease may come out a little, clean it so it does not contaminate the belt. Re-grease if necessary. Create an installation report to record the history of the pulley. Create a maintenance card for routine maintenance   ATTENTION!! DO NOT move Pulley with wire rope directly touching the pulley lagging DO NOT move Pulley by hanging it from the plummer block. Be careful with the end disc. The end disc area is very sensitive to welding, drilling, and other treatments. DO NOT do any work on the end disc

10. PULLEYS Belt Tension & Alignment The tension on the belt is adjusted according to the pulley design that is installed. excess tension received by the pulley can cause damage to the pulley and plummer block. Centerline belt must be straight and parallel to pulley, to avoid misalignment Pay attention and check the alignment of the plummer block with the centerline shaft pulley using the following methods:

11. PULLEYS If there is a misalignment in the plummer block against the centerline shaft, make corrections to prevent overheating and premature damage to the plummer block sealing system. The supplyed Vortex pulley is assembled with Plummer block, already fully filled with grease to avoid condensation and rust on the internal parts of the plummer block, bearing and shaft during storage. When running for the first time, the grease inside the plummer block is full so that the plummer block temperature will rise. Run between 15-30 minutes until the grease inside the plummer block comes out by itself (purging / bleeding) and the temperature drops to normal operating temperature. If after 30 minutes the plummer block temperature is still high. check the alignment plummer block against the center line shaft pulley and make corrections. ATTENTION:   Use appropriate personal safety equipment before work is carried out such as gloves, helmet, goggles, body hardness, safety shoes, etc. Be careful when moving the V Pulley from storage location to installation location Make sure the system has been turned off before starting the V Pulley installation DO NOT touch any part of the V Pulley while operating or commissioning DO NOT make adjustments to the V Pulley while the conveyor belt is operating   Move away from the V Pulley during commissioning and operation of the conveyor belt

12. Position Trackers SELF ALLIGNMENT IDLERS

13. Below is another technique used to help aid belt tracking. This is unbiased to a particular side. This technique cannot be used on bi-directional conveyors. SELF ALLIGNMENT IDLERS The picture Above shows which direction the conveyor belt will track towards once rollers have been shifted from square to stringers. The angle has been exaggerated for demonstration and should not exceed 2 degrees in the field.

14. INITIAL FIRST RUN INSPECTION The next step is inspection process when the belt run in loaded condition (operation condition), and the check list for operating the conveyor belt when loaded: Tail pulley : Turning freely without bearing noise, product build up or carry back, belt tracking satisfactorily Load area spillage : Spillage Carry side idlers : Turning freely and parallel steady movement on horizontal sight Carry side self- trainers : Functioning and move freely to drive belt direction both side Secondary loading station : Spillage Tripper area : Tracking & Spillage Head pulley and Drive pulleys : Smoothly running, Slippage when starting or turn, Belt cleaners – functioning, Belt tracking Head snub pulley : Turning freely without bearing noise and clean Return Idlers : Clean and turning freely Bend pulleys : Turning freely without bearing noise and clean Take-up pulley : Turning freely without bearing noise and clean, moving freely in the frame

15. INITIAL FIRST RUN INSPECTION The next step is inspection process when the belt run in loaded condition (operation condition), and the check list for operating the conveyor belt when loaded: Tail pulley : Turning freely without bearing noise, product build up or carry back, belt tracking satisfactorily Load area spillage : Spillage Carry side idlers : Turning freely and parallel steady movement on horizontal sight Carry side self- trainers : Functioning and move freely to drive belt direction both side Secondary loading station : Spillage Tripper area : Tracking & Spillage Head pulley and Drive pulleys : Smoothly running, Slippage when starting or turn, Belt cleaners – functioning, Belt tracking Head snub pulley : Turning freely without bearing noise and clean Return Idlers : Clean and turning freely Bend pulleys : Turning freely without bearing noise and clean Take-up pulley : Turning freely without bearing noise and clean, moving freely in the frame Return side self- trainers : Functioning General belt tracking : belt tracking freely swing Plow or Scraper : Functioning

16. MAINTENANCE ROLLERS Vortex rollers are pre-lubricated at the factory and are ready for operation. Since it designed for seal for life it does not need relubrication Roller maintenance is necessary, even though Vortex Roller’s is designed for heavy duty use. Dirt and any other foreign material will affect exposed and bearing area. That will be resulting in overall performance reduction and increasing risk of downtime / failure. Reliable operation and long service life of Vortex roller depend upon the care taken during installation and operation. Periodic inspection and maintenance are required. A “walking inspection” of a belt conveyor system is a good method to detect potential problems for any unusual sounds made by such components as transom, roller shell, shafts, bearings, or other items. Excessive build up on roller surface will cause damage to the belt. Shut down the conveyor, locking out the power switch and clean up, repair, or replace immediately. Review the type of material being conveyed and type of rollers being used. Accumulation of materials must not interfere with roller rotation or training transom from pivoting. Clean up any material that could restrict pivot arms. A stalled roller will cause excessive roller shell and belt wear. Remove and replace any stalled rollers to prevent belt damage from a worn roller. Though impact rollers were designed to minimize belt and roller damage due to impact condition, the roller should be observed carefully and may require replacement due to some applications. Observe the edge of the belt for any wear. If such a condition is observed locate the area of contact and misalignment and adjust the transoms or install a self-aligning transom.  

17. MAINTENANCE Recommended Roller Maintenance Interval during Use Maintenance of roller is done by cleaning the shell surfaces of the roller using flexible nonmetallic scraper. High density plastic is recommended for this application. Scratch the surfaces until all foreign material or dirt is peeled off. Scratch the entire surface evenly following the counter direction of roller rotation. Foreign material should not be allowed to become entrapped between the belt and roller rim. Material build up on the roller face should be avoided. If this occurs scrap it immediately.  Please follow and fill the maintenance guidance (refer to maintenance interval) for maximal performance and optimum lifetime of Vortex Rollers. Regularly scheduled inspection of conveyor systems are the best preventive maintenance possible. Problems area can be detected and corrected before damage occurs to the belt or equipment. A check of the loading area is the best place to start. Loading chutes should be delivering material to the belt evenly and centre on the belt. Uneven or off-centre loading is the greatest cause of problems of any belt conveyor. Noticeable vibrations should be located and eliminated as this may loosen mounting bolts and cause the transom and roller to shift. Misalignment problems must be corrected at once. Check transom and roller alignment and adjust if required, remember to retighten mounting bolts. If off-centre loads occur, make correction to chute work. Watch for unusual wear patterns on the roller, which can be caused by off-centre loading or misalignment. Walk the length of the conveyor of the conveyor installation and verify that the rollers are turning freely and smoothly with no excessive endplay. Date of maintenance activity is must recorded and documented to ensure the manufacturer warranty is valid.

18. MAINTENANCE It may sound obvious, but the first rule of thumb with cleaners is to remove any debris from the blade and tension springs. Cleaners will shed most of the carryback into the chute or onto the receiving belt but sometimes it will come to rest on the cleaner itself. Tensioners can’t do their jobs with debris stuck in them and removing material build up from blades will make them much more effective. Plus, a dirt-free cleaner is much easier to inspect BELT CLEANER A simple visual inspection can do wonders for a cleaner. You can check to see that everything is in working order and replace any damaged components. When it comes to blades, inspect the visual wear lines to ensure that the blades have not reached the end of their lives. As you inspect the blades, make note of how close you are to complete wear and the approximate amount of time it took to get to that point. Tension the blade to accommodate the blade wear and to get optimal cleaning performance. In most cases, this is done quickly and easily by referencing the tension check decal on your cleaner and measuring the tension spring to ensure the blade is properly tensioned. If no decal is present, a simple check of the operations manual should provide the answers you need

19. MAINTENANCE Activity Checklist sample