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CONTENTS
1- Introduction
a) Handling and conveying of material
b) Material characteristics
c) Main processes in cement industry
d) Materials in cement industry
e) Conveying equipments in cement industry
f) Factors affect choice of conveying equipment

2-Belt conveyor
a) Advantages of belt conveyor
b) Belt conveyor in industry
C) Belt conveyor in cement industry
3- Basic design concept
a) Operation theory
b) configurations
c) Different lay out
d) Capacity

Material Handling
CONTENTS
Material handling includes all material
4- Components consideration except processing operations.
a) belt
b) idlers It includes :
c) pulleys
d) loading and discharge
• conveying
5- Maintenance and repair • feeding
a) installation
b) joining belts
• packing
c) alignment • storing
6- Safety • warehousing
a) hazard
b) accidents • loading
• unloading

Material Conveying ANGLE OF REPOSE

It is the angle of pile formed by free and

• Moving material continuously or
careful pouring of material
intermittently between two or
The lower angle of repose , the more
more points along fixed path
flowable material will be

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MAIN PROCESS IN CEMENT INDUSTRY

ANGLE OF SURCHARGE
 It is the dynamic angle of repose BLASTING
 It is edge angle of shacked pile
Angle of surcharge is less than angle of repose
CRUSHING

Material is shacked when :

 by truck over irregular land
 by belt of big sag

GRINDING
Shacking material results in :

 large lumps migrate upwards

 the pile moves latterly outwards
BURNING
CEMENT
GRINDING

MATERIALS IN CEMENT INDUSTRY FACTOR AFFECT CHOICE OF

CONVEYING EQUIPMENTS
TYPES SHAPE Physical
• Grain size
• Humidity
• Hardness
RAW Limestone
MATERIALS • Clay Material • small
•BLASTED Quantity • Medium
• Gypsum conveyed
• Others : - sand •CRUSHED • Big
• normal
- pyrite •GRINDED Temperatures • Medium
- Slag •POWDER • high
SEMI-PRODUCT CLINKER
Conveying • short
distance • Medium
FINAL PRODUCT CEMENT • long

WASTE •BY-PASS DUST Conveying • horizontal

• up vertical
MATERIAL •FILTER CAKLES direction • down vertical
OTHERS

BELT CONVEYOR ADVANTAGES LIMITATION OF CONVEYOR BELTS

 Require light foundation with minimum support
Structure
 Span up to 10 km
 Can cross over roads, railway and other obstructions
 Medium to large amount of material
 Variety of loading and unloading possibilities
 Can be loaded from one or more points simultaneously
 Mobile chute may be used
 movable belt tripper
 Many other functions can be performed with the
basic conveying like weighing, sorting, picking,
sampling, blending, spraying, cooling, drying etc.
• The loading and transfer points need to be
properly designed.
• Numbers of protective devices have to be
incorporated to save the belt from getting
damaged by operational problems.
• The belt needs higher initial tension (40-200% of
useful pull).
• Conveying of sticky material is associated with
problems of cleaning and discharge causing poor
productivity.
• Higher elongation of the belt (4% elongation may
take place at the working load).

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INFORMATION REQUIRED TO DESIGN BELT CONVEYOR TYPES

A BELT CONVEYOR
1. Length of conveyor from centre to centre of end pulleys.
2. Inclination-level or inclined. Either degree of inclination, or
distance to be lifted or lowered.
3. Average capacity per hour.
4. Maximum capacity per hour.
5. Material to be conveyed, and weight per cubic foot.
6. Average size of material.
7. Size of largest pieces and percentage in feed.
8. (a) Nature of material -dry or wet (moisture content).
(b) Abrasive or corrosive?
9. How material is to be fed to the belt and particulars of feed point
or points.
10. How material is to be discharged from the belt i.e. overhead
pulley or by trippers, and particulars of discharge points.
11. General indication of supporting structure.
12. Power available for driving.
• Permanent: This type of conveyors is installed for the life of the mine. They
are used in main line, slope, long overland installation, preparation plants
and stockpiles.
• Portable:These are characterised by relative ease of assembling and
disassembling to facilitate advances and recovery in development and
retreat operations in underground mining. Portable conveyors mounted on
crawler or wheels are also used in mechanised quarries and surface mines.
• Shiftable:Used in continuous surface mining this type of conveyor is
mounted on skid or supporting structures aligned together and the whole
can be shifted transversely to follow the advancing working face.
• High Angle Conveyor: These are special type of conveyor belt arrangement
used for negotiating steeper angle of inclination. Such belts can work in
slope up to 70-800. Sandwich belt conveyor is a type of such belt conveyor.
• Cable Belt Conveyor: Where the belt is carried on moving wire ropes and
the tractive force is applied through the rope to the belt is known as cable
belt conveyor. NALCO (in collaboration with France) is using such system for
long distance conveying of bauxite in their mines in Orissa

CONVEYOR BELTING FUNCTION AND

ARRANGEMENT
CONVEYOR LAYOUT
Belt conveyors are used to carry economically a greater
diversity of bulk material at higher capacity and for greater  Belt conveyors offer a large flexibility in lay
distances than any other. out arrangements.
 It can be used for material conveying the lump size, moisture
contend, chemical characteristics and temperature.  Belt can be manipulated in various ways to
 A belt conveyor carries material on the inclined plane and achieve its final destination using Straight belt
is discharges the load over the head pulley. The empty belt
running below is known as non conveying side.  Standard sections.
 A belt conveyor may be horizontal, inclined, declined or • Horizontal section.
follows a combination of these paths.
 Flat belts are generally used to carry bottle bags and • Inclined section.
packaged materials.
 Toughed belt increase the loading without fear of spillage of
the material and is suitable for handling bulk material in both
dry and semi wet conditions.

MAIN COMPONENTS OF CONVEYOR BELT

VARIOUS DRIVE ARRANGEMENTS
• number of driving pulleys
 DRIVE LOCATION
 NOS OF DRIVING PULLEYS
 Nos of drives per pulley
 Snub
• The belt that forms the moving and supporting
surface on which the conveyed material rides. It
number of drives per pulley
is the tractive element. The belt should be
any intermediate location in return selected considering the material to be
line transported.
• The idlers, which form the supports for the
Single
Dual
carrying and return stands of the belt.
• The pulleys that support and move the belt and
controls its tension.
one side
Two sides • The drive that imparts power to one or more
pulleys to move the belt and its loads.
Snub
No snub
• The structure that supports and maintains the
alignments of the idlers and pulleys and support
the driving machinery

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OTHER COMPONENTS OF CONV.BELT CONVEYOR BELT PROPERTY

• Loading chute or feeder chute that organises the flow of material and In general a conveyor belts has to meet the following basic
directs it on the belt conveyor. requirements,
• Take-up-device which is used to maintain the proper tension of the belt • HIGH STRENGTH
for effective power transmission. • LOW GROWTH
• Belt cleaner that keeps the belt free from materials sticking to the belt. • HIGH IMPACT RESISTANCE
• Tramp removal device, which is optionally used in case the conveyed • GOOD TROUGHABILITY
material bears the chance of having tramp iron mixed with it and
subsequent handling of the material, demands its removal. • NO BUCKLING
• Continuous weighing device for constantly measuring the load being • EFFECTIVE MECHANICAL SPLICING
carried by the conveyor belt. • GOOD ADHERING BETWEEN COMPONENTS
• Discharge chutes to guide the discharged projectile to subsequent • RESISTANCE TO ATMOSPHERIC CONDITIONS
conveyor or other receiving point. Other requirements for special application
• Surge hopper and feeder, which is essential for supplying material to the • FIRE RESISTANCE
conveyor at uniform rate when the supply of material is intermittent.
• ELECTRICAL CONDUCTIVITY
• Tripper arrangement to discharge material at different point or to other
device
• NO TOXICITY IN THE COMBUSTION GASES.
• OIL RESISTANCE.

BELT CONSTRUCTION CARCASS

Conveyor belts generally are composed of The reinforcement usually found on the inside of a
three main components: conveyor belt is normally referred to as the “carcass.” In
a sense, the carcass is in the conveyor belt since it must:
1. Carcass
2. Skims 1. Provide the tensile strength necessary
3. Covers to move the loaded belt.
2. Absorb the impact of the impinging
There are two types of belt available: material being loaded onto the conveyor
belt.
1.Rubber belt 3. Provide the bulk and lateral stiffness
2.Steel Cord required for the load support.

CARCASS
BELT CARCASS SELECTION • The most common carcass design is made up of layers or “plies” of
woven fabrics bonded together.
FOR SELECTION OF THE OPTIMUM PLIED BELT CARCASS, This “conventional plied” belt construction, generally employs a
FOLLOWING FACTORS NEED TO BE CONSIDERED, plain weave or twill weave carcass which is built up into as many layers as is
required to provide the necessary belt strength…usually bound together
with rubber.
1) THE BELT WIDTH.
Conventional plied belting constructions, employing all synthetic
2) THE SERVICE CONDITION UNDER WHICH THE BELT WILL carcasses and elastomer covers appropriate to the end use, are
OPERATE. particularly recommended for:
3) THE MAXIMUM OPERATING TENSION, BOTH STEADY AND I. Hard Rock Mining
PEAK CONDITION.
(A) Aggregate, sand and ore
4) THE MINIMUM NUMBER OF PLIES REQUIRED TO SUPPORT II. General purpose applications
THE LOAD.
III. Forest products
5) THE MAXIMUM NUMBER OF PLIESBEYOND WHICH
TRANSVERSE FLEXIBILITY IS REDUCED AND THE IV. Soft Minerals
TROUGHING EFFICIENCY IS AFFECTED. (A) Coal (B) Potash, Phosphates (C) Grain
V. Unit Handling
(A) Parcels (B) Baggage (C) Mail

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CARCASS
 The strength of fabric and the number of plies in the
carcass of the belt may be varied together to suit the
strength requirement.
 However if the belt is too tough, troughing of the belt
and bending it round the terminal pulleys will be very
difficult. Therefore the belt with lesser number of plies
with stronger fabric is generally preferred because it is
more flexible.
 Steel cord belting is used when good trough ability,
small specific elongation and higher operating tensile
forces are required.
 PVC belting is generally selected for underground
mining applications where fire hazard exists.
COVER GAUGES AND QUALITIES.
CONSIDERATIONS,
 FIRE RESISTANCE,
 RESISTANCE TO OIL,
 TEMP. OF THE OPERATING ENVIRONMENT/CONVEYED MATERIALS,
 RESISTANCE TO AGING, WHETHERING,
 THE TYPE OF MATERIALS TO BE CONVEYED,
 THE LUMP SIZE& SHAPE OF THE MATERIALS BEING CONVEYED,
 THE MIX OF LUMPS & FINES IN THE MATERIALS,
 THE ABRASIVENESS OF THE MATERIALS,
 THE METHOD OF LOADING THE BELT,
 THE FALL HEIGHT OF THE MATERIALS TO THE BELT,
 THE CYCLE TIME OF THE CONVEYOR FOR A SINGLE REVOLUTION OF THE
BELT,
 AVAILABILITY AND COST.
DIAMETER OF THE IDLER
Diameter selection is influenced by speed, weight of load, and
lump size and life expectancy.
 100 to 125 mm dia: 1.5 to 3 m/s belt speed (ball bearing of
16mm ID) 1600 kg/m3material flow
 150 to 175 mm dia: 4 to 5 m/s belt speed (ball bearing by 32
mm ID) more than 1600 kg/m3
CARRYING IDLERS
The most commonly used toughing idler has three rolls of
equal length with inclined rolls
usually of troughing angles of 20 deg. 35 deg & 45 deg.
35 deg are standard in most application.
RETURN IDLERs
Return idlers carry belt loads and operates against dirty side of
the belt.
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SKIMS
• The rubber, PVC or urethane between plies is called a “skim.”
Skims are important contributors to internal belt adhesions,
impact resistance, and play a significant role in determining
belt “load support” and “troughability.”
• Improper or marginal “skims” can adversely affect belt
performance in general and can lead to ply separation and/or
idler junction failure.
THICKNESS OF COVER
• In addition to selecting proper compounds for cover material, it is
also necessary to determine the proper cover thickness.
The thickness of a cover is influenced by the amount of abuse
and wear the belt will receive. The cover is usually the lowest cost
component of the belt. The severity of the wear depends on the
nature of the material and on the size, weight, shape and trip rate of
the Material conveyed.
• Sharp edges, particularly on large pieces, can quickly cut a cover
badly. On the other hand, if loading conditions are ideal, with the
material being loaded in the direction of travel of the belt, and with
only a slight impact onto the belt, even very sharp material may not
seriously cut or wear the belt surface.
IDLERS CONSTRUCTIONS
IDLERS are stationary roller over which belt travels between pulleys
Idlers construction
• outer shell
• shaft ( concentric with outer shell )
• bearing
• seal
The life time of Idlers depend mainly on life of its bearing
Factors affect idlers operation
• Effectiveness of seal
• Quality of bearing
• Shaft deflection
• concentric of bearing with shell
• lubrication
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• used on the top run of the conveyor

IDLER SPACING
Carrying idler • carry the weight of belt and material
• flat or troughed
• Weight of material and belt
FACTOR CONSIDERED • belt tension
• allowable belt sag

2–3%S
BASIC TYPES NORMAL SAG

• Load / each idle increase

• belt sag increase
LONG SPACING • material spill
• material vibration
• power loss
• used on the bottom run of the
Return idler conveyor
SHORT SPACING
• carry the empty belt on return run • cost wise

TRANSITION DISTANCE. CROWNING

It is distance a belt travels from being flat (over pulleys) to
becoming completely fully troughed (over idlers)
• crowned pulley has training effect on the belt
• forces affect on misalignment belt are unequal
• the difference acts on belt to resume the center position
• it is most effective when there is a long unsupported
approaching span

TWO TYPES.
 CUREVED CROWNING
• expensive
• large radius curve
• belt outer edges over stretched
TOO SHORT • Decrease belt life  TAPERED CROWNING
• less cost
Most common transition distance : 3 – 5 belt width
• normal taper : 1%
• Higher taper may damage belt carcass

Pulley size TYPES OF PULLEYS

1- Diameter Conveying belt system contain variety of pulleys
performing different tasks
• must be large enough to affect traction on the
belt
• provide the required belt speed
• matched to belt minimum bending radius
• should be matched to conveyor power train :
motor and reducer
2- Pulley width
Pulley must be slightly wider than belt. • head pulley • head pulley is on the discharge end
• tail pulley • tail pulley is on the feed end
Upto belt width 1 meter= 5cm • snub pulley
• tail pulley is often crowned to help in belt tracking

More than 1 meter= 8cm • bend pulley

• take up pulley

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FUNCTION OF PULLEYS TAKE-UP SYSTEM

 head pulley • head pulley is on the discharge end
 tail pulley • tail pulley is on the feed end
• tail pulley is often crowned to help in belt
tracking

Drive pulley Transmits force from motor to the belt

• the most common location is at head pulley
• could be located at tail pulley or any
independent site

 snub pulley • Smaller in diameter than head or tail pulley

• Increase wrap angle around drive pulley
• mostly crowed to aid in belt tracking • Adjust the proper tension
FUNCTION • Absorb any stretching along belt longitudinal axis
 bend pulley Direct the belt away from its path • Store a small amount of belt length as spare
Bend pulley • allow to release belt tension for maintenance and
repair jobs
Allow adjustment of belt tension • Manual
 take up pulley Take up pulley TAKE-UP SYSTEM • Automatic

PROPER LOADING SYSTEM LOADING SYSTEM COMPONENTS

Proper loading system feeds material to the belt in a way
such way that : Chute function
• uniform rate • contain and shape material
• centraly • adjust material direction and velocity
• in direction of belt travel
• velocity matched to belt speed
Chute types
• free of large pieces
• no impact • longitudinal chute
• transverse chute
Improper loading system can lead to :
• decrease belt life
• accelerate top cover wear
• seized idlers
• decrease idlers life Longitudinal chute
• belt mistracking
• clogging or jamming of conveyor
• spilled material
• dust generation

Tranverse chute LOADING SYSTEM COMPONENTS

Slide plate
To load material to transverse belt • give material forward velocity in belt direction
• help in shaping the load
Fall zone
• let material lose some of its velocity

Fine and lump mixer

Deflection plate Slide grizzly bars
• absorb some of material transverse velocity • spaced bars in melt direction travel
• direct material in appropriate direction • allow fine material to pass trough
• fine material act as cushion pad on belt

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SKIRTING
BELT CLEANING SYSTEM
• contain material on belt until it becomes settled
• it is parallel to belt Improper cleaning may lead to :
• commonly spaced to 2/3 of belt width
• commonly length1.3 m for every o.5 m/s belt speed
• only have light contact with belt • accelerate wear of idlers surface
• mistrack belt
• decrease bearing life

Types

• straight
• deflector
• continuous strips
• sectioned block

TYPES OF BELT CLEANER.

BELT CLEANERS BLADE OPTIONS
Precleaners Polyurethane
• Mounted to the head pulley • Easier on the belt
and below the material flow • Works well with mechanical
• Ideal for removing large pieces splices
of material typically about 60 - • Economical
70 percent of initial carry back • Specialty formulations for high
Secondary cleaners heat,
• Located just past where the belt chemical resistance, or water
leaves the head pulley and removal
anywhere else down the Tungsten carbide:
beltline
• Especially good at removing • Superior cleaning effi ciency.
fines, increasing cleaning Long wear.
efficiency to 90+ percent.

CRITERIA FOR SELECTION OF BELT CLEANER BELT SPLICES

1 Your belt speed and belt width
2 Whether the belt reverses VULCANIZING MECHANICAL FASTNERS
3 Your conveyor structure width
4 Your pulley diameter — typically, the larger the pulley,
the larger the required cleaner the stronger  not so strong
 suitable for  suitable for low tension
5 Your pulley condition — if the pulley is worn or
natural fibers and application
not perfectly round, a segmented blade may clean more effectively  less expensive
nylon carcass
6 Where you plan to position the cleaner and how much  sealed carcass  done by simple and
room there is to accommodate it away from standard tool
7 What types of splices are present and their condition  done in minutes
moisture
 needs no special cleaning
8 Any unusual characteristics of your load or environment  Does not affect precaution
(extreme heat, abrasiveness, mud, etc.) — a specialty belt scraper role  leave carcass exposed
cleaner that can withstand these conditions may be necessary  affect belt scraper role
9 The material’s path on the belt — matching the cleaner
to the material path reduces differential blade wear
10 Your desired level of performance and upkeep

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VULCANIZING INSTALLATION

COLD METHOD
Handling the roll of belting:
HOT METHOD
• Each rolls of belt is marked with an arrow that
The strongest one
• fairly strong bond
shown the direction of rotation on the
 needs specialized equipments
 needs well trained personnel
• use liquid cement and hardener
• needs moderate trained personnel
package.
 needs long time for curing
• Belt rolls should not be dropped from truck.
• For hoisting use a bar passing through the
hole in the centre of the roll.

INSTALLATION
(CONTD.)
Pulling the belt on the conveyor:
During mounting the rolls, the belt must load off the top of the
roll if it is being pulled onto the toughing idler but off the
bottom of roll if it is being pulled onto the return idlers.
In the mines, installation of the belt may be by pulling off the roll
and reefed to have large bends to avoid strain on belt.
In some underground application belt must make 90 deg truss
with turn table mounted spindle are often used.
Belt for replacement:
The old belt clamped off and cut, a new belt is spliced to the
leading end of the old belt by using plate fasteners. The
trailing end of the old belt is hooked to a tractor or other
means of providing traction.
The conveyor drive motor is used to pull on the used belt while
the towing device drags the old belt away.
.
INSTALLATION
(CONTD.)
Tensioning the belt:
The amount of tension required in a belt at splicing depend
upon the take-up and the average running tension in the
belt, the point along the conveyor where the splice is being
made, and whether the belt is tensioned by pulling in one
direction only or in both direction. If a belt is spliced at the
top of a slope, more splicing, tension is required than if
spliced at the bottom.
Training the belt:
Training the belt is a process of adjusting idlers, pulleys and
loading conditions in a
manner that will correct tendency of the belt to run other
than centrally

FACTORS AFFECTING TRAINING OF BELTS. BELT CONTROLS & SAFETY DEVICES

PULLEYS AND SNUB
Steering effect is obtained by crown of conveyor pulleys. The greatest advantage of
crowing is the centering the belt as it passes through the pulleys at load or tail &
take up.
CARRYING IDLERS
The belt can be trained with toughing idlers in two ways.
a) Shifting the idlers axis with respect to the path of the belt, known as KNOCKING
IDLER.
b) Tilting the troughing idler forward (not over 2 degrees) in the direction of belt travel
by putting shims under the rear leg of the idler stand produces self aligning.
RUTURN IDLERS
These idlers are pivoted about a central pin, results self aligning effect.
AUTOMATIC ALIGNING DEVICES
Centre pivoted return idlers are some times connected in group of two or three to
operate together and are actuated by a external mechanism that takes its action
from the beltposition. They have a very strong influence in centering the return, as
it approaches the tail pulley.
SIDE GUIDE IDLERS
They can be used to assist in training the belt initially to prevent it from running off
the pulley and damaging itself against the structure of the conveyor system.
POWER UNIT:
Belt conveyor is mostly universally driven by electric motor. The most common
electric motor for driving belt conveyor is the squirrel cage induction motor.
Small conveyor drives using a line start with low starting current.
Conveyor having high belt tension a high starting torque and low starting current
are considered.
In multiple unit conveyor progressive movement of the belt is done by sequence
starting rather than simultaneous starting.
COUPLING:
Various coupling between motor & gear box can be used to control the
acceleration of the belt independent of motor acceleration and to relieve
current in rush by getting the motor under way before loading it. Fluid coupling
are used to facilitate the start by allowing the motor to acquire some speed and
starting current inrush to fall, before The load is picked up.

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SAFETY DEVICES. BELT CONVEYOR MAINTENANCE

SAFETY DEVICES
In belt conveyor system safety devices are IN BUILT. There are two types of
safety Check list for operation & maintenance.
devices provided. 1. Grease periodically all grease point for pulley bearing.
· For operating personnel 2. Grease periodically all grease point for idler bearing.
· For belt & equipment 3. Grease periodically all grease points for other designed sealing activities.
PERSONNEL PROTECTION DEVICES 4. Check oil level for driving Gear Box.
a) Emergency stop switch (Pull cord) 5. Grease periodically Motor bearings.
b) Warning horns (are to warn the starting of the belt) 6. Check belt scraper
c) Light Signal 7. Check and clean all pulleys surfaces.
d) Belt crossover stair & walk ways (for crossing a conveyor belt safely) 8. Check and clean all Idler tube surfaces
e) Sequence protection (it is necessary to ensure in case a belt is stopped all 9. Check all bolts and nuts for entire conveyor
feeders or other belts loading arrangement onto it are also stopped) 10. Check rope clamps for tensioning devices
f) Over speed protection 11. Check Idler rotation and Work for correction
g) Pulley guards 12. Check all bearing for pulley about its free rotation
h) Lighting 13. Check all bearing for pulley about its free rotation

BELT CONVEYOR MAINTENANCE BELT CONVEYOR MAINTENANCE

(CONTD) (CONTD)
13. Check for free movement of self aligning Idler set and clean if necessary. 27. Check function of centrifugal switch.
14. Check pulley lagging and impact idler lining 28. Check for any material stickiness in chute and hopper
15. List and check important block bolts connection. Coupling bolts, bearing block. 29. Check function of Magnetic head pulley/over head magnetic separator/suspended
And other drive bolts. 30. Check function of Metal detector, if provided.
16. Check back stock (Hold back) 31. Check all seal leakage in gear drives.
17. Check brakes if provided. 32. Check for conveyor skirting rubber, its clamps and gap etc.
18. Check abnormal belt war & tear and belt wander and note for analysis 33. Check for central loading of material onto belt.
19. Check condition of splices for belt jointing. 34. Check motor current on load and without load for comparing with Tones per hour
20. Check wear pattern of Idler rolls. loading.
21. Check misalignment of drivers of low speed coupling and high speed coupling 35. Check for slippage of belt over pulleys and belt tension.
periodically. 36. Check for movement of take up trolley.
22. Check and note particular area for belt running off Centre and correct if required. 37. Check for wear/tear of chute/hopper liners.
23. Check for damaged Idler supporting structure. 38. Check for vibration level for drives and other connecting structure
24. Check for V-plug or return belt cleaning devices. 39. Check for belt swaying due to wind thrust.
25. Check function of pull cord switches.
26. Check function of belt sway switches
.

TROUBLE SHOOTINGS TROUBLE SHOOTINGS

ISSUES CAUSES CORRECTIVE ACTION ISSUES CAUSES CORRECTIVE ACTION
BELT RUN OUT ONE •One or more idlers not • Advance, the end of idler in
the direction to which the belt WEAR ON • Slippage on drive Increase belt tension.
SIDE AT A PARTICULAR square with the axis of
POINT belt. has shifted. PULLEY SIDE pulley. Improve loading
• Stretch string along edge to
BELT IS ERRATIC. • Conveyor frame or
determine extent & correct it. OF CONVEYOR • Spillage of material conditions to avoid
structure crooked.
• Sticking idlers, belt runs • Improve maintenance and BELT that is ground spillage.
of on terminal pulley. lubrication. •between belt & Improve maintenance
• One or more idler stands • Check terminal pulley pulley and lubrication.
not aligned alignment.
• Build up of material on •Check alignment of idlers • Sticking idlers. Adjustment of idlers
idlers. approaching terminal pulley. • Excessive tilt of should not be more
• Structure not level and • Install scrappers or other
cleaning device.
toughing idler. than 2 degree to the
belt tends to shift.
• Level structure. • Broken bolt heads. right angle with the
axis of belt.
Tighten bolts, replace
worn lagging on pulley.

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TROUBLE SHOOTINGS TROUBLE SHOOTINGS

ISSUES CAUSES CORRECTIVE ACTION ISSUES CAUSES CORRECTIVE ACTION
• Increase belt tension. • Increase speed, keeping
WEAR ON • Slippage on drive EXCESSIVE STRETCH •TENSION TOO tonnage at same.
PULLEY SIDE OF pulley. • Improve loading CONVEYOR HIGH • Reduce tonnage at same
CONVEYOR BELT • Spillage of conditions to avoid speed.
•spillage. • Replace worn out and frozen
material that is idler.
ground between • Improve maintenance • Decrease tension by improving
belt & pulley and lubrication. drive with
• Sticking idlers. • Adjustment of idlers • Lagging and / or increased
area of contact.
• Excessive tilt of should not be more • Counterweights take up of
toughing idler. •than 2 degree to the minimum amount.
right angle with the • Replace with lower elongation
• Broken bolt belt.
heads. •axis of belt.
• Tighten bolts, replace
worn lagging on
•pulley.

TROUBLE SHOOTINGS TROUBLE SHOOTINGS

ISSUES CAUSES CORRECTIVE ACTION ISSUES CAUSES CORRECTIVE ACTION
EXCESSIVE TOP COVER • Dir stuck or • Use more pliable seals (do GROOVING, GOUGING • Skirt board sheet too •Install cleaning devices,
WEAR misaligned return rolls. not use old belting). OR STRIPPING OF TOP stiff and pressed wash belt.
Cover quality too low • Adjust skirt rubber to COVER against belt. •Use rubber disc return
Pile up spilled minimum clearance. • Excessive space idlers repaired,replaced &
material at tail pulley. • Adjust to at least 25mm between belt and skirt. realigned.
Side loading or poor between metal and belt & • Metal side of chute • Replace with belt of
loading have gap increasing in skirts, too close to belt. heavier cover gauge or
Excessive sag between direction of travel so as to • Material under higher quality rubber.
idlers cause prevent material jamming at impact at loading point • Improve house keeping
load to work and this point. allowing material to be and loading
shuffle on belt as it • Install impact idlers to hold trapped against skirt. • Redesign chute to make
passes over idlers up against skirts • Jamming of material load feed onto belt.
• Improve loading to prevent in chute • Increase tension if it is low.
spillage or install baffles. • Reduce idler spacing.
• Widen chute

MONITORING OF CONVEYOR BELT MONITORING OF CONVEYOR BELT

• Due to the nature of bulk material conveyance, all belts
are subjected to damage from a wide range of sources.
• It is critical to detect the magnitude of damage as early as
possible to prevent further damage and minimize lost
production and downtime.
• Physical inspections by maintenance personnel are
generally time consuming, sometimes inaccurate, and in
most cases not able to detect internal damage to the belt
carcass. While regular physical inspections need to be a
part of all preventative maintenance programs, new belt
monitoring technologies are becoming available.
• Now the state-of-the-art protection systems,are
available which effectively monitor virtually all
aspects of the belt condition and operation on the
system. Cover wear, cover damage, carcass damage,
splice integrity, belt tracking and material build up are
just some of the systems’ capabilities.
• Immediate shutdown when predetermined parameters
are exceeded, while allowing for continuous
monitoring of potential problems and scheduled
manual shut down for inspection. PHOENIX offers the
most effective protection for your belt investment.

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MONITORING OF CONVEYOR BELT

MONITORING OF CONVEYOR BELT •
•
Key features of BELTGUARD:
Nearly maintenance-free
• Online image output
• Variable sensitivity problem classification
• The revolutionary one-for-all BELTGUARD system has a complete • Customized automatic incident response
range of capabilities that includes both carcass and cover • Provides belt maintenance schedule and scope
monitoring technologies. • Automatic detection and monitoring of:
• Belt cover damage, such as longitudinal cuts, cracks, grooves etc.
• Conveyor belts are subjected to constant impacts from material • Damage to belt edges
falling onto the belt. Foreign bodies, wrongly installed scrapers and • Fastener damage
chutes are also a risk for the conveyor belt. The earlier that damage • Opening of splices
is detected, the lower will be the repair costs. • Lengthening of splices
• BELTGUARD allows you to detect and monitor everything from • Excessive/abnormal cover wear
incremental damage to belt surface covers up to potentially • Cord misalignment
catastrophic damage due to pending splice failure or belt • Edge to outer cord dimension
• Belt tracking problem, leading to edge damage
penetration by foreign material. Belt alignment can be monitored • Cord corrosion due to moisture penetration at cuts, cracks, repairs or splices
along the conveyor length to ensure that the belt is not damaged • Condition of transverse cords
due to contact with structural equipment. • Failure of cords during service
• Entrapment of foreign objects
• Belt overlapping on pulleys
• Belt speed monitoring
• Insufficient belt cleaning

MONITORING OF CONVEYOR BELT SAFETY

• Key benefits of BELTGUARD:

• Avoids unplanned conveyor shutdowns Hazards
The main hazards involve moving belts.
• Necessary action can be taken before major This moving belt can catch body parts in pinch points and lead to
damage occurs entanglement and crushing.

• Increased belt service life Accident Types

Common types of accidents with conveyors involve personnel struck by
• Drastic cost savings due to reduced downtime. objects or caught in equipment.
The majority of these accidents occur when workers attempt to do repairs,
• Drastic reduction of maintenance costs installation or clean-up while the conveyor system is active.
• Monitors every cubic millimeter of belt
• Predicts remaining belt life time

SAFETY
Lockout SAFETY
- Determining the equipment or components to be worked on,
- Turning off and isolating all energy sources,
- Drawing off stored energy or potentially dangerous product,
- Installing tags and locks. Machine Guarding
- Equipment must be turned off and isolated even for short-duration adjustments or repairs. The use of guards on a conveyor system is not a recommendation,
- Procedures must be specified for each workplace and each piece of equipment to ensure,.
Checklist
it is a requirement .
- Guards on moving conveyor parts are often :
For inspection and maintenance purposes, a conveyor checklist is recommended.
- - non-existent,
• emergency stop pull cords
- - inadequate,
• start-up warning device (audible/visible )
- - improperly positioned, or
• guards on head, tail, drive, deflection, and tension pulleys
- - not replaced after repairs.
• guards on accessible pinch points
- - are not in place,
• guards protecting workers from overhead material
- - Not paint in bright contrasting colures. Legal Requirements
• means of safely applying belt dressing and lubrication to a moving conveyor
• fire suppression system
- no guards beneath a conveyor against falling materials
• guardrails
• access equipment (walkways, ramps, stairs, platforms, etc ).
• noise control .

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SAFETY GUIDELINES FROM CEMA

SAFETY REQUIREMENT
CEMA has a chapter on safety and gives the importance of design and operation for a
safe BC system. Here are some of the pointers:
When the BC system is towards completion, give a complete indoctrination to all
specific safety requirements for conveyors personnel in the use of the system
- pull cords at accessible locations for stopping the conveyor
* Do a 'safety check-up' before the commissioning
in emergencies
- a means of applying belt dressing while the conveyor is in *Conduct a formal training programme in safety for operation, maintenance and
motion supervisory personnel
- a start-up warning device when the conveyor is started : *Do not ever use the BC for a material other than the originally specified
- automatically or
- by remote control or *Only trained personnel will be authorised to operate the BC system
- where portions of the conveyor are not visible to the *Make known to all involved, the locations of the emergency controls and safety devices
operator
*Take a 'walking inspection' periodically. Trained personnel can, on hearing unusual
sounds, often detect potential hazards

*Do not allow anybody to ride on, step on, walk on or cross over a moving BC

SAFETY GUIDELINES FROM CEMA

BELT CONVEYOR SAFETY
*Any BC found to be unsafe must not be used before the repairs
*Some 'must' prerequisites for a BC safety: The main hazards related to belt conveyors are
Good housekeeping
*First class maintenance mechanical.
* Adequate lighting Other hazards are produced by :
*Barricades for unauthorized people entering the BC area - non-compliance with ergonomic principles
*Safety sign boards when workers operate near the conveyor
*Warning sign boards to alert people (operation station, control of the process,
*Free, easy and uncluttered access to all safety and emergency devices
CEMA has pointed out that diligence in safety considerations must be loading and unloading);
applied during manufacture, installation and establishing operation and - failure or malfunction or safety-related
maintenance policies and procedures. The system design has to take control systems; electrical
care, but safety has a psychological aspect too. People's behaviour and hazards; and thermal phenomena (such as
awareness have a bearing on safety. heat, fire or explosion).
"Safety is a matter of attitude”

The main mechanical hazards are related to: ACCIDENT FREQUENCY

- mechanical power transmission components (e.g., drive shaft, 1- According to conveyor location
reducing gears) that can cause damage by entrainment (by a belt or on
nip points), crushing or entanglement (human body entangled around Location Percentage
a rotating - Between the drive pulley, head pulley or tail pulley 48%
and the belt, inside one of these pulleys or between
- other moving components (e.g., idlers, pulleys, belt) that can cause one of these pulleys another pulley.
damage by entrainment in nip points, abrasion and burns;
- Between an idler or a return idler and the belt. 13%

- pinching zones (e.g., feeder, skirt-board, skirt-board seal) that can - Other locations (e.g., between electromagnets and 13%
cause damage by shearing and crushing; other components.)

- moving loads that can cause damage by shearing and crushing - Drum motor transmission mechanism. 7%
between the load and a fixed component, or an impact; - Between a take-up pulley and the belt. 5%
- Between a caught tool and the belt or the 2%
- moving subassemblies (e.g., ejectors, switches, transfer mechanism) conveyor frame.
- Not indicated or uncertain. 12%
that can cause damage by shearing and crushing;

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2- Worker Activity
- Cleaning a pulley or applying adhesive on a 24%
pulley or cleaning another component of a
conveyor (idler or return idler, frame).
- Maintenance work (other than cleaning
conducted on a moving conveyor.)
20% Remember –
- Normal work (e.g., sorting, packaging) performed
on or near a conveyor.
11%
The Best of Design
- Recovering an article caught in an unprotected nip 9%
point (7 of 8: between a pulley and the belt; 1 of 8;
between electromagnet roller and the belt).
Features May be Negated
- Cleaning under or around a conveyor.
- Maintenance work (other than cleaning) near
a moving conveyor.
7%
6% by Faulty Maintenance and
- Unjamming the conveyor or removing an
accumulation of material.
5%
Operating Practices
- Adjusting the belt tension or alignment. 4%
- Other activities (e.g., worker being transported 4%
by a conveyor).
- De-icing and unjamming a frozen belt. 1%
- Not indicated. 9 %

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