Field Operator Certification

Screw Conveyors
Learner Guide
 Screw Conveyors – Learner Guide

Introduction
This lesson on Screw Conveyors, as with your other lessons on Auxiliary Equipment, consists of two
main learning components  a self-directed/in-class component and an on-the-job component. You
are expected to complete both components as part of your Certification Program.

Review the remaining information contained in the Introduction section of this document prior to
beginning the Content section. If you have any questions about this information, speak with your
Instructor.

Objectives
Your learning objectives are broken down into two categories  learning objectives for the self-
directed/in-class portion of your learning; and, learning objectives for the on-the-job portion of your
learning. They are listed below for your information.

Self-Directed/In-Class Learning Objectives

1. State the purpose of a Screw Conveyor
2. Name the main components of a Screw Conveyor
3. Explain the principle of operation of a Screw Conveyor
4. Describe the classifications of Screw Conveyor flights and the configurations commonly used in
cement manufacturing
5. State the applications for Screw Conveyors
6. Describe the running and static inspections for Screw Conveyors
7. Describe the troubleshooting of common Screw Conveyor problems
8. State safety concerns related to Screw Conveyors

On-the-job Learning Objectives

 Perform a running inspection on a Screw Conveyor
 Perform a static inspection on a Screw Conveyor

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Lesson Outline
The first portion of the lesson, the self-directed/in-class portion, involves reviewing the following
information:

 The purpose and basic principle of operation of a Screw Conveyor

 A listing of the various components of a Screw Conveyor
 A discussion on the various Screw Conveyor flights and common configurations of flights
 Various applications of an Screw Conveyor
 Inspection points of a Screw Conveyor and basic troubleshooting
 Safety concerns related to Screw Conveyors
Pictures and graphics are included where appropriate to help you understand how a Screw Conveyor
functions. At the end of this section, there are a series of questions that you will be required to
answer and review with your Instructor.

The second portion of the lesson, the on-the-job portion, primarily involves the completion of
several inspections on Screw Conveyors, including both a running and static inspection. When you
are ready to perform these inspections, inform your Instructor.

If you are a new Field Operator, you will complete a series of steps in your OJT portion of this
lesson. These steps are listed below for your information.

 Step One
 Your Instructor will ‘walk through’ an inspection procedure with you. At that time
you can ask questions and take down any notes required.
 This walkthrough may be completed out in the field or during a meeting with your
Instructor.
 Step Two
 Your Instructor will demonstrate an inspection procedure in the field.
 Step Three
 You will conduct an inspection procedure in the field under the supervision of your
Instructor.
 Your Instructor will provide you with feedback about your performance during the
inspection.

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 Step Four
 You will complete a full inspection procedure without any assistance from your
Instructor.
 This inspection will be assessed against the inspection checklist contained in this
document. If you achieve 100% on the inspection, you will be certified on it. If you do
not achieve 100% your Instructor will provide you with further feedback and you will
have the opportunity to be re-assessed.
If you are an experienced Field Operator, you may already be quite familiar with inspection
procedures. Discuss this with your Instructor and you may only be required to actually complete
Step Four as discussed above.

Reference Material
 NA

Pre-requisites
 NA

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Screw Conveyors – Learner Guide

Screw Conveyor – Learning Content

Purpose
S CREW C ONVEYOR
 The purpose of a Screw Conveyor is
to transport material from one location
to another

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Components
S CREW C ONVEYOR
 Screw Conveyor Inlet Chute
 Screw Flights
 Coupling Shafts
 Drive Shafts
 End Shafts
 Support Bearings Types
 Friction (Hanger
Bearings)
 Antifriction (Roller Bearings)
 Shaft Seals
 Screw Trough
 Screw Conveyor Drive
 Screw Conveyor Discharge Chute

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Screw Conveyor Pictures

S CREW C ONVEYOR D RIVE

S CREW C ONVEYOR D RIVE

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H ANGER B EARINGS

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Principle of Operation
 The Screw Conveyor is comprised of flight sections that are typically fabricated from a
continuous helix mounted on a supporting shaft or pipe
 This assembly is then mounted within a stationary trough
 The material is introduced into the Screw Conveyor inlet chute where the face of the rotating
helix advances the material forward by shearing it between the bottom and sides of the screw
flights and the trough housing
 The rotation of the screw also lifts the material in the direction of rotation
 Each revolution of the screw advances the material one pitch length in a continuous shearing and
tumbling motion until the material is discharged out of the screw trough

S CREW C ONVEYOR

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Classification of Screws
C LASSIFICATIONS OF S CREWS
 There are two types of screw flight
classifications
 Left Hand Screws
 Have flights wrapped on the shaft
in a counter clockwise direction
 Right Hand Screws
 Have flights wrapped on the shaft
in a clockwise direction
 The determination of right or left hand
wrap of a screw can be seen from both
ends

Types of Screws
 Standard Pitch Single Flight
 Half Pitch Single Flight
 Variable Pitch Single Flight
 Double Flight Standard Pitch
 Single Flight Ribbon

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Standard Pitch Single Flight

S TANDARD P ITCH S INGLE F LIGHT
 Pitch equal to screw diameter (considered
standard)
 Suitable for wide range of materials in most
conventional applications
Graphic from source material

Half Pitch Single Flight

H ALF P ITCH S INGLE F LIGHT
 Similar to short pitch, except pitch is reduced to
½ standard pitch
 Useful for inclined applications, Screw
Conveyors or for handling extremely fluid
materials

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Variable Pitch Single Flight

V ARIABLE P ITCH S INGLE F LIGHT
 Flights with increasing pitch
 Used only in Screw Feeders to provide uniform
withdrawal of fine, free-flowing materials over
full length of inlet opening

Double Flight Standard Pitch

D OUBLE F LIGHT S TANDARD P ITCH

 Provide smooth, regular material flow and
uniform movement of certain types of fine
materials

Single Flight Ribbon

S INGLE F LIGHT R IBBON

 Excellent for conveying sticky of viscous
materials
 Open space between flights and pipe eliminates
collection and build up of the material
 Not used in feeder applications

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Applications
 Quarry Operation
 Raw Grinding
 Pyro-processing
 Finish Grinding
 Bulk Loading

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Inspection Points

Screw Conveyors – Running Inspection

Check For OK

 Inspect the drive motor for material build up on cooling fins and cooling fan inlet screen
 Remove build-up
 Palm test the motor casing temperature
 If too hot to touch, record temperature with hand pyrometer or contact thermometer
 Inspect drive motor electrical connections for damage or strain
 Palm test the drive reducer casing temperature
 If too hot to touch, record temperature with hand pyrometer or contact thermometer
 Inspect the condition of the final drive
 V-belt condition, tensioning, sheaves, direct coupling, chain and sprockets
 Listen for abnormal noise or vibration in the Screw Conveyor drive system
 Inspect the condition and support integrity of all safety guards
 Note general condition of Screw Conveyor, cleanliness, material leaks, lubrication leaks
 Inspect the discharge chute for proper material flow, build up or obstructions
 Inspect field control station for damage or cable strain
 Remove any obstructions for access
 Check that all access doors and inspection ports are closed and properly sealed
 Inspect the condition of Screw Conveyor protection devices, mounting, electrical connections, cable
strain
 Inspect the condition of Screw Conveyor shaft seals
 Inspect the Screw Conveyor trough for damage, wear, missing flange bolts

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Screw Conveyors – Learner Guide

Screw Conveyors – Static Inspection

Check For OK

 Inspect the drive motor for material build up on cooling fins and cooling fan inlet screen
 Remove build-up
 Inspect drive motor electrical connections for damage or strain
 Inspect the condition of the final drive
 V-belt condition, tensioning, sheaves, direct coupling, chain and sprockets
 Inspect the condition and support integrity of all safety guards
 Note general condition of Screw Conveyor, cleanliness, material leaks, lubrication leaks
 Inspect the discharge chute for proper material flow, build up or obstructions
 Inspect field control station for damager or cable strain
 Remove any obstructions for access
 Check that all access doors and inspection ports are closed and properly sealed
 Inspect the condition of Screw Conveyor protection devices, mounting, electrical connections, cable
strain
 Inspect the condition of Screw Conveyor shaft seals
 Inspect the Screw Conveyor trough for damage, wear, missing flange bolts
 Inspect the condition of hanger bearing brackets and bearing condition
 Inspect the screw flights for damaged, bent flights or worn flight sections
 Check coupling bolts and bolt holes for excessive play
 Inspect the drive reducer for oil leaks and oil level
 Inspect reducer mounting and torque arm condition if applicable
 Inspect Screw Conveyor roller bearing condition and mounting

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Troubleshooting

The following troubleshooting information has been prepared to help you resolve both material flow
and overloading problems associated with Screw Conveyors.

T ROUBLESHOOTING – L OSS OF M ATERIAL F LOW

Problem Test OK

Loss of material Flow

 Is the Screw Conveyor running?
 Is the discharge of the Screw
Conveyor clear of obstruction?
 What is the condition of the flights
on the screw?
 Check the breaker for blown overloads, disconnect
pulled
 Inspect the drive motor for signs of failure
 Inspect the Conveyor drive for signs of damage or
failure. Drive couplings, belts, belt tension, chain and
sprockets
 Are the screw section’s couplings or flight shaft intact?
Are both ends of the screw rotating when in operation?
 Is the Screw Conveyor overloaded or jammed with
foreign material?
 Inspect the discharge of the Screw Conveyor to assess
whether there is a physical blockage, material bridging
or build up
 Inspect the operation of downstream equipment to
ensure material is being evacuated effectively
 Inspect the Screw Conveyor for worn or bent shafts

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T ROUBLESHOOTING – S CREW C ONVEYOR O VERLOADING
Problem
 Has there been a process upset that
would explain an increase in material
loading in the Screw Conveyor?
 What is the condition of the flights
on the screw?
 What is the condition of the Screw
Conveyor’s support bearings?
16
Test OK
 Review process trends to determine if there has been an
upset in the system to explain an increase in material
loading
 Has the material density changed or been changed?
Aeration of material
 Inspect the Screw Conveyor for worn or bent flights
 Inspect the Screw Conveyor for failed hanger bearings
impeding material flow
 Inspect the screw’s rollers and friction bearings for
damage or wear
 Inspect the condition of the screw’s support hangers for
proper alignment, damage, support integrity
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Safety– Work Page

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Safety
 Always lock out Screw Conveyor prior to performing any service on the Conveyor
 Be aware that Screw Conveyors are controlled automatically and can start and stop at any time
 Be aware of all Conveyor nip points
 Never attempt to remove build-up off Conveyor components while operating
 Keep clothing, fingers, hair, and other parts of the body away from Conveyor drive components
 Never climb or step onto Screw Conveyor lids as they are not generally designed to support the
weight of an individual
 Inspect Conveyor guards for damage and support integrity
 Know the location and function of all control stations
 Keep all control stations free from obstructions to ensure access at all times
 Keep area around Conveyors clear of obstructions
 Report all unsafe conditions or practices immediately

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Lesson Review

1. State the purpose of the Screw Conveyor

2. Name 5 components of a Screw Conveyor

3. How far forward does the material move in 3 rotations of the screw if the pitch is 12 inches
long?

4. Describe 3 types of screw flights commonly used in cement manufacturing

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5. Describe 3 applications for Screw Conveyors in cement manufacturing

6. Describe 5 inspection points for a Screw Conveyor

7. Describe 3 conditions that could explain a loss of material flow

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8. State 3 safety hazards associated with Screw Conveyors

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