COMMISSIONING PLAN

PT BANGUN ARTA HUTAMA

COMMISSIONING PLAN FOR OVER

Number
Date

: BAMA-OLCS-CP-002
: 03.06.2014

Revision :
Page

LAND CONVEYOR SYSTEM

02

1 of 22

COMMISSIONING PLAN FOR OVER LAND

CONVEYOR SYSTEM
Acknowledgement

Prepared by,

Checked by,

Approved by,

AVU

Trevor Salter

Ediie Arsyad

PT. Bangun Arta Hutama

PT. Mitra Lingkungan Dutaconsult

PT. Media Djaya Bersama

1)

2)

Engineering Manager

Project Manager

Revision history

Revision No.

Date

Remarks

01

27.02.2014

Revised on comment

00

24.02.2014

First Published

3)

Director of Project Development

Number

COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA

Date

COMMISSIONING PLAN FOR OVER

LAND CONVEYOR SYSTEM

: BAMA-OLCS-CP-002
: 03.06.2014

Revision :
Page

02

2 of 22

TABLE OF CONTENTS
1. GENERAL

2. INTRODUCTION
3. PURPOSE

4. OVER LAND CONVEYOR SYSTEM

5. INSPECTION TEST PLAN FOR COMMISSIONING WORKS

6. CHECK LIST FOR COMMISSIONING ACTIVITIES

7. MANPOWER HISTOGRAM FOR COMMISSIONING ACTIVITIES

8. TYPES OF STAGES IN PERFORMING COMMISSIONING
9. PLC OPERATION

10. PROCESS FLOW CHART COMMISSIONING

11. PREPARATION FROM MDB & BAMA

12. COMMISSIONING PROCEDURE & FULL LOAD TEST OF THE SYSTEM

1. GENERAL
To carry out all duties in a professional, conscientious, responsible, healthy and safe manner.
All operatives shall be experienced and trained in their respective trades and will be fully

familiar with the correct method of installation of the Coal mining facility so that both short
term as well as long-term installation work and product warranties are in qualified
approach.

This document describe the detailed commissioning plan of the conveyor system and the

methods involved in the commissioning of overland conveyor system, in the Project North
Sumatra, MDB coal project, material handling facility.

Communication between Project team PT.BAMA and Project team of PT. MDB should be

defined after Kick of meeting. All communications between other members of the Project

teams shall copy both leads.

COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM

Number
Date

: BAMA-OLCS-CP-002
: 03.06.2014

Revision :
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2. CONVEYOR INTRODUCTION

Belting

Idlers rollers with frame

Pulleys (Drive & Non-drive)

Drives (Geared Motor, Couplings & Bearings)

Conveyor Gallery & Trestles

Stringers & Short Supports

Head Frame, Tail Frame & Drive Base Frames

Discharge Chutes & Interconnecting Chutes
Take-up

Skirt Board
Actuators

Moving trolley arrangement ( Using Bogies)

Safety control switches

Computer based control (Automation)

3. PURPOSE
This document describes how PT. BAMA intends to carry out erection, co-ordinate

commissioning and complete the Works and to fulfill all its contractual obligations and the
achievement of Milestones.

4. OVERLAND CONVEYOR SYSTEM CONSISTS OF,

Magnetic Separator

CV-05 Radial Stacker

CV-06 Transfer Conveyor

CV-08 Transfer Conveyor
Reclaim Feeder 3

COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER

Date

: BAMA-OLCS-CP-002
: 03.06.2014

Revision :

LAND CONVEYOR SYSTEM

Page

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4 of 22

5. INSPECTION TEST PLAN FOR CONVEYOR COMMISSIONING WORKS

Testing and commissioning of all belt conveyors shall be carried out according to the

standard testing and commissioning procedure. General Inspection report to be verified for
all components involved in system.

TESTING AND
COMMISSIONING

Pre commissioning checks

Number

After positioning

Visual and Measuring instrument

FI

N/A

Measuring instrument

FI

N/A

all items in place

Dry / Test run

Before start up
After start up

Performance Appraise

Every one hour

Visual & Measuring instrument

FI

N/A

Wet/ Test Run

Before start up

Visual & Measuring instrument

FI

N/A

After start up

Performance Appraise

Every one hour

Visual & Measuring instrument

FI

N/A

Final Quality / hand over

Upon Readiness

Visual & Measuring instrument

FI

N/A

DOCUMENTATION

As built drawings

As soon as system

To comply with the requirement

Completed

of the contract

As and when the

To comply with the requirement

items supplied and

of the contract

Manual & other documents

Installed

CSV : Contractor Supervisor

3rd

: Contractor's 3rd Party

W : Witness Point
SW : Spot Witness Point

H : Hold Point

ES : PT MDB Technical Dept

R : Document Review
FI : Full Inspection

O/P : PT MDB Operation Maintenance

N/A - Not Applicable

COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM

Number
Date

: BAMA-OLCS-CP-002
: 03.06.2014

Revision :
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6. CHECK LIST FOR CONVEYOR SYSTEM (PRIOR TO COMMISSIONING):

S.no

Check List for Conveyor Commissioning

1 Conveyor Structure Leveling

2 Pulley , Idlers mounting and free rotation of same

3 Take-up leveling and squaring

4 Ensure all safety switches are in on Mode and not in touch with conveyor
5 Greasing of all components and oil level to required level
6 Ensure Skirt Board fixing, not to touch with belt
7 Check to remove any items lying in conveyor
8 Ensure alignment drive components

9 Ensure sufficient tension is available in belt

10 Grade of oil and greasing to components

11 Ensure coupling bolts are unfastened to check rotation of drives

12 Ensure bolts are fastened in couplings

13 Ensure all rotating parts are perfectly guarded

14 Ensure fasteners are fully tightened

15 Ensure scraper is aligned and gentle touch with belt

Remarks

Number

COMMISSIONING PLAN

Date

PT BANGUN ARTA HUTAMA

COMMISSIONING PLAN FOR OVER

: 03.06.2014

Revision :
Page

LAND CONVEYOR SYSTEM

: BAMA-OLCS-CP-002

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6 of 22

7. MANPOWER-HISTOGRAM FOR OLCS COMMISSIONING

Site Manager-Selva

Commissioning
Specialist-Avu

Engineer Mechanical

Engineer Electrical

Engineer Instrumentation &

Waris/ujang

Roy

Automation - Myrsa

Supervisor Mechanical

Supervisor-Electrical

Onshore - Bambang

Onshore- Agung

Electrician & Helper

Electrician

Team Onshore -1
conveyors 8 NOS

Helper

Team Onshore -2
conveyor- 8 NOS

Supervisor Electrical
Offshore

Electrician

Helper

COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM

Number
Date

: BAMA-OLCS-CP-002
: 03.06.2014

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8. TYPES OF STAGES INVOLVED IN COMMISSIONING & OPEARTING HOURS

There are three stages of commissioning involved in the conveyor system, which are as
follows,

Pre-commissioning

Dry-commissioning

Wet-commissioning

COMMISSIONING

PRE-COMMISSIONING

CONSTRUCTION VERIFICATION

DRY-COMMISSIONING

No Load Test -Initial start & stop for 2 sec

Contracts, drawing

& documentation.

Standards

and

codes

CHECK CABLE

CHECK COMPONENTS
CONVEYOR

1.

Alignment

2.

Lubrication

3.
4.

If ok, run for 10 minutes

If system performs well run for an hour

TERMINATION

Lightings
Manufacture
requirements

Load test with 50%

for 2 hour

Run for 1 minute & then 2 minutes

WET-COMMISSIOINING

Run for 2 hours

Run for 4 hours

Run for 12 hours

Load test with

100% for 8 hours

COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM

Number
Date

: BAMA-OLCS-CP-002
: 03.06.2014

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Prior to being placed into service the conveyor system shall be subject to the following
commissioning activities,

STAGE 1 PRE COMMISSIONING / CONSTRUCTION VERIFICATION

All components within the conveyor system shall be inspected to verify that they have been
fabricated / manufactured, supplied, installed, aligned, and lubricated in accordance with;
1. Contract drawings and documentation

2. Standards and codes specified in this standard

3. Statutory Regulations

4. Manufacturers Requirements- (Vendor representative should be present for

inspection to certify their equipments installation- Quality check vendor).

5. Lightings commissioning

Tests and calibration shall be carried out to prove that all systems are operational,
including protective and measuring devices.
1. General Mechanical

2. Fabric carcass conveyor

3. Miscellaneous conveyor equipment

4. Idlers

5. Pulleys
6. Drives

7. Shaft Mounted Gear reducer

8. Base mounted Gear reducer
9. Chutes

10. Alignment Bogies

STAGE 2 DRY COMMISSIONING

This stage involves the actual running of the equipment under no-load conditions,

Mechanical testing shall only commence after motor rotational tests and electrical control
and all safety checks have been carried out,

1. No- load running testing shall include:

2. Checking and recording the motor amps

3. Checking the correct operation of the equipment

4. Checking for evidence of misalignment, over heating or abnormal wear;

5. Measurement of bearing and gear vibration

COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM

Number
Date

: BAMA-OLCS-CP-002
: 03.06.2014

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6. Adjustments and correction of all faults.

The plant shall be run for a sufficient length of time to establish that it is in a reliable and
serviceable condition. Following Test reports shall be used to test equipment under noload condition,

1. General Mechanical

2. Fabric carcass conveyor

3. Belt conveyor components like

Idlers

Pulleys

4. Shaft mounted Gear reducer

5. Base Mounted gear reducer
6. Bogies

7. Scrapers

8. Actuators
9. Motor

10. Couplings

11. Safety switches

12. Lubrication

13. Cable Termination

14. Reading voltmeter, Ammeter etc.

15. Fasteners

STAGE -3 WET COMMISSIONING

This stage involves the testing and adjusting the equipment, with the conveyor system

operating under loaded condition i.e. running material through the process equipment. All

the above mentioned stages of commissioning will be carried out under the supervision of
the commissioning specialist and his specified trained team.

With reference to the test reports from the dry commissioning, all the parts of the conveyor
system have to be inspected again to envisage the behavior of the system. From the above
observation, all the faults have to be rectified to make the system get ready for 100%
TEST running and commissioning.

COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM

Number
Date

: BAMA-OLCS-CP-002
: 03.06.2014

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9. CV-05 OPERATION FROM PLC, MONITORING USING SCADA

BLOWS 2 TIMES

NO

CHECK FEEDBACK

SET 1 MIN
INTERVAL

COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM

Number
Date

: BAMA-OLCS-CP-002
: 03.06.2014

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All conveyor operates from PLC, can monitor using the SCADA Programming software to

ensure the installed system is running properly according to the sequence made in the PLC.
Any error in sending the signal to the system will be highlighted in the monitor, with which
we can take corrective measures to resolve it.

We can take print, the performance of the system whenever required.

Number

COMMISSIONING PLAN

Date

PT BANGUN ARTA HUTAMA

COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM

: BAMA-OLCS-CP-002
: 03.06.2014

Revision :
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11. OLCS CONVEYOR STARTING & STOPPING SEQUENCE PROCESS FLOW CHART
CONVEYOR STARTING SEQUENCE

CV 06

CONVEYOR STOPPING SEQUENCE

CV 06

COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM
PROCESS FLOW DIAGRAM OF COMPLETE PLANT:

Number
Date

: BAMA-OLCS-CP-002
: 03.06.2014

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Number

COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER

Date

: BAMA-OLCS-CP-002
: 03.06.2014

Revision :

LAND CONVEYOR SYSTEM

Page

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11. PREPARATION FROM MDB

This commissioning involves, the performance testing of the OLC system for its designed
rating (4000TPH).
REQUIREMENTS:
Requirements From MDB
S.no

Item

required

2
3
4
5
6

Coal stock
Fuel

consumption
Coal Delivery to
Radial stacker
Equipments

required to dump
coal inside RF
Operators

Commissioning
Team

From RF-03
Yard

Genset

13,500 MT

hours

1st 2 hrs / 50%

Dry Run
12

Total
Wet run hours
10

Client scope Client scope

load

100% load / 8 hrs

Client Scope

Client Scope

Client Scope

Client Scope

1500 MT

Client Scope

12000 MT

13,500 MT
22 hrs

Client scope
Total

13, 500 MT

Client Scope

FROM BAMA
Commissioning team with specialist as mentioned in the Man Power Histogram should be

available in shifts during the load run of the OLCs system.

COMMISSIONING TOOLS

Tachometer

Temperature Gun
Hammer

Spanner 24mm size

COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM

Number
Date

: BAMA-OLCS-CP-002
: 03.06.2014

Revision :
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SAFETY

Fire Extinguisher ( Every 100 meters)

Proper PPE

HSE Officer

Walkie Talkie

12. COMMISSIONING PROCEDURE

Belt Starting
This is the most important aspect of belt conveyor erection. As a matter of fact, a good
erection eliminates to a great extent the difficulty in belt training while a bad erection
may cause untoward problems in training the belt.

Belt Tracking

When belt conveyors are installed within accepted conventional alignment limits with
idlers and pulleys parallel, belt spliced square and true and material loaded centrally
the belt will track correctly without the need of special training or tracking devices.
In practice, these ideal conditions are seldom achieved and corrective devices and
accessories are required to maintain satisfactory training.

Few common causes of poor belt tracking are set out below. Corrective action necessary
for each of these is readily ascertained when the particular cause (or causes) is
identified.

1. Misplaced or twisted components in the conveyor structure.

2. Driving and idler pulleys are not normal to the conveyor centre line and not parallel
to each other.
3. Carrying and return idlers are not set normal to the conveyor belt centre line (This
point is of particular concern for reversible belt conveyors).

4. Out-of-round or stiff idler rollers giving belt contact forces asymmetrical to the belt
centre line.
5. Poor belt splicing giving a transverse bend to the belt centre line at the splice.

6. Asymmetrical loading of burden.

COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM

Number
Date

: BAMA-OLCS-CP-002
: 03.06.2014

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7. Pulley diameters are not symmetrical about the centre line of belt.
8. Build up of material on pulleys, idlers and /or belt.

9. Transverse forces applied to belt such items as angled belt scrapers.

10. Excessive tensioning of belt which is precluding all idlers from assisting in belt
steering.
11. Under-tensioning of belt which precludes pulleys from controlling drift.

12. Belt take-ups not taking up slack effectively during running and acceleration.
13. Belt take-up not travelling in line with belt center line.

14. Belt take-ups giving different forces on opposite sides of the belt this can occur
during take-up motion and is prevalent with hydraulic take-ups.
15. Jammed idlers or extraneous jammed articles along the conveyor.

A newly installed belt must be lined up to run on centre of the pulleys and idlers. The tail
end, take up pulleys and all the idlers should be squared up so that they are at 90 deg. with
the centre line of the conveyor. Belt can be aligned properly, only by adjusting the carrying
and return idlers. Self-aligning rollers are supplied with an actuating swivel base, which
will be bolted to the bottom side of the idler frame and will tilt the idler in proper direction
to centralize the belt
Important Tips

a) When starting a new belt for the first time, run it slowly and intermittently and

check the entire length to ensure that it is not running off at any point to an extent
that it will damage the belt.

b) Do not attempt to train the belt by adjusting head end pulley.

c) The return run should be checked first for belt alignment. When a belt runs off a

return roller, the edges may get damaged. To train the return belt, start at the head

end. In general the adjustments are made 3 to 4 meters behind the point where the
belt runs off.

d) All troughing idlers are provided with slotted holes for the hold down bolts to

permit shifting of the ends for belt alignment. To adjust the idlers loosen the hanger
bracket bolts slightly and move the idler slightly forward or backward. The belt will
shift to the side where it touches the roller first.

COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM

Number
Date

: BAMA-OLCS-CP-002
: 03.06.2014

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e) For training the belt on carrying side start with the tail pulley and follow the
procedure as explained above.

f) Do not try to collect belt alignment by extreme shifting of one idler but rather by

slightly changing a number of idlers. Proper alignment of idlers at the head end will
train a belt to run on the centre of the head pulley.

g) If the belt does not run centrally after adjustment of idlers and take up screws, check
to ensure that the belt lacing is square.

h) Conveyor take up should be adjusted to provide enough tension for the belt to

operate under load without slipping. Correct belt alignment must be maintained

while tension adjustments are made. When correctly aligned and adjusted, the belt
will be centered on the tail pulley while the conveyor is operated. The amount of

tension is correct when the belt sags slightly between return rolls.

i) Do not apply excessive tension because it results in damaging the belt and bearing.
After the belt has been run in, tension should be checked at frequent intervals and
take up adjusted when necessary.

To operate the conveyor system we recommend one operator. This will take approximately
hour to start the system and Operation will be as follows:Estimated time required to start up the conveyor system:

a) Co-ordination between control room and field 2 min

b) Checking conveyor path for safety reason 15 min
c) Convey message to control room via radio 1 min
d) Check for barge location 2 min
e) Start of hooter 2 min
f) Start of feeder 2 mi

g) Feedback to control room 2 min

h) Start the sub-sequent conveyors one by one as programmed already 15

min

i) Back to control room to ensure proper operation 4 min

Number

COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA

Date

COMMISSIONING PLAN FOR OVER

LAND CONVEYOR SYSTEM
Total 45

: BAMA-OLCS-CP-002
: 03.06.2014

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minutes

SCHEME OF OPERATION:
There are two distinct mode of operation.

1. NORMAL MODE (With auto sequencing) 2. MAINTENANCE MODE

NORMAL MODE

a) Equipments are connected to the path selected will be Centralized, Automatic,

Sequentially interlocked.

b) NORMAL / MAINTENANCE Selector switch for the particular path should be on

NORMAL mode position.

c) All safety switches PCS, BSS, ZSS and CBS should be in healthy condition in local
push button station, stop push button should be in Normally closed position.

d) Emergency push button should be in healthy condition.

e) If the above mentioned conditions are not satisfied PATH READY prompt will
appear in control desk at annunciate window.

f) Now press the system start push button to energize the whole system

g) Plant start hooters which are provided along the conveyor will sound.
MAINTENANCE MODE

a) In this mode of operation equipments will not have sequencing timing and
interlocks

b) Each and every equipment shall be started from the respective local push button
stations independently by switching NORMAL / MAINTENANCE selector switch in
MAINTENANCE mode.

Belt Controls

The belt control involves the following:

Stop/start: At single or multiple stations.

COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM

Number

: BAMA-OLCS-CP-002

Date

: 03.06.2014

Revision :
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Start warning: Audible or visual signal for pre-start warning

Interlock: The sequence control between the master and slave conveyors.

Telemetry: Distribution of belt control and information over significant

distance.

Lockout: Physical lockout of the all motive power sources

Loading of Conveyor belt

To ensure maximum life, the following Cdns for loading of the conveyor should be met.

The material should be fed in the same direction in which the belt travels. Also material
should be loaded at an angle, moving approximately at the same speed as of the belt,
whereby the cover wear is minimized. Conversely, if the material were loaded at an
angle of 90 deg. transversely to the direction of the belt travel, the wear of rubber

covers would be maximum. Also if the material has no velocity in the direction of the
belt travel or has negative velocity cover wear would be maximum.

Free fall of the material on the belt should not be more than 500 mm. A properly
designed loading chute and closely spaced impact idlers, also reduced free fall,
minimize cover belt.

Loading area of the belt should be horizontal or should have a slope of not more
than 8 deg. If the slop were more than 8 deg. cover wear would be high.

For very abrasive materials, grizzly screen should be used so that fines are placed
on the belt first and provide a bed for larger lumps.

Cover wear for general purpose belt is minimum i.e. where the material conveyed
does not react chemically with the belt and has a maximum temperature of 70C.
For reactive material or hot material, special covers are provided but their wear
resistance is relatively lower.
By means of skirt board, spillage on the return side of the belt may be prevented.

BELT CONVEYOR TROUBLE SHOOTING

(The number refers to the list below the table.)
Complaint

Cause

Complaint

Cause

In order of

In order of

probable

probable

occurrences

occurrences

COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER

Number
Date

pulley

Entire belt runs off

at all points of the
line

7 15 14 17 21
26, 17, 15, 21, 4,
16

One belt section runs 2, 11, 1

off at all points of the
line

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LAND CONVEYOR SYSTEM

Belt runs off at tail

: BAMA-OLCS-CP-002

Page

Excessive wear,

including rips, gouges,

02

20 of 22

12, 25, 17, 21, 8, 5

ruptures, and tears

Excessive bottom cover 21, 14, 5, 19, 20, 22

wear

Excessive edge wear,

26, 4, 17, 8, 1, 21

broken edges

Belt runs off at head

15, 22, 21, 16

Belt hardens or crack

8, 23, 22, 18

Belt slip

19, 7, 21, 14, 22

Covers become

8, 18

Belt slip on starting

19, 7, 22, 10

Longitudinal grooving

14, 21, 22

pulley

Excessive belt
stretch

Belt breaks at or

behind fasteners;

fasteners tear loose

Vulcanized splice
separation

13, 10, 21, 6, 9

2, 23, 13, 22, 20,
10

13, 23, 10, 20, 2, 9

checked or brittle
or cracking of top
cover

Longitudinal grooving
or cracking of bottom
cover

Fabric decay, carcass

cracks, ruptures, soft

spots in belt(gouges)
Ply separation

14, 21, 22
12, 20, 5, 10, 8, 24
13, 23, 11, 8, 3

1. Belt bowed: Avoid telescoping belt rolls or storing them in damp locations.

2. Belt improperly spliced or wrong fasteners: Use correct fasteners. Retighten

after running for a short while. If temporarily spliced remove belt splice and
make new splice. Set up regular inspection schedule.

3. Belt speed too fast: Reduce belt speed

COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM

Number
Date

: BAMA-OLCS-CP-002
: 03.06.2014

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4. Belt strained on one side: Allow time for new belt to break in. If belt does not
break in properly or is not new, remove strained section and splice in a new
piece.

5. Breaker strip missing or inadequate: When service is lost, install proper breaker
strip ( Breakers are woven fabric of nylon &/or polyester placed above the
carcass to dissipate impact energy and to prevent belt puncture)

6. Counterweight too heavy: Recalculate weight required and adjust

counterweight accordingly. Reduce take-up tension to point of slip then lighten

slightly.

7. Counterweight too light: Recalculate and adjust or screw take-up accordingly.

8. Damage by abrasive, acid, chemicals, heat etc: Use belt designed for specific
purpose. Repair cuts. Use enclosure where needed.

9. Differential speed on dual pulleys: Make necessary adjustments

10. Drive under belted: Recalculate maximum belt tensions and select correct belt.
Determine if extension is feasible or another belt to be installed. Check the
carcass is rigid enough for load, replace if service is lost.

11. Edge worn or broken: Repair edge. If the edge is out of square or badly damage
replace the worn portion of the belt.

12. Excessive impact of material on belt or fasteners: Use correctly designed chutes
and baffles. Make vulcanized splices. Install impact idlers. Where possible load
fines first. Where material is trapped under skirts, adjust skirt boards to

minimum clearance or install cushioning idlers to hold belt against skirts.

13. Excessive tension: Recalculate and adjust tension. Use vulcanised splice within
recommended limits.

14. Frozen Idlers: Free idlers. Lubricate. Improve maintenance. Dont over lubricate.
15. Idlers or pulleys out of square with centre line of the conveyor: Realign. Install
limit switches for greater safety.

16. Idlers improperly placed: Relocate idlers or insert insert additional idlers
spaced to support belts.

17. Improper loading, spillage: Feed should be in direction of belt travel and at belt
speed, centered on the belt. Control flow with feeders, chutes and skirt board.

COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM

Number
Date

: BAMA-OLCS-CP-002
: 03.06.2014

Revision :
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18. Improper storage or handling: Refer to the manufacturers instructions for

storage and handling.

19. Insufficient traction between belt and pulley: Increase wrap angle with snub
pulley. Lag drive pulley. In wet condition use grooved lagging. Install correct
cleaning devices for safety.

20. Material between belt and pulley: Use skirt board properly. Remove
accumulation. Maintain properly.

21. Material build-up: Remove accumulation. Install cleaning devices, scrapers and
inverted V decking. Improve housekeeping.

22. Pulley lagging worn: Replace worn pulley lagging. Use grooved lagging for wet
conditions. Tighten loose and protruding bolts.

23. Pulleys too small: Use large diameter pulleys.

24. Radius of convex vertical curve too small: Increase radius by vertical
realignment of idlers to reduce excessive edge tension.

25. Relative loading velocity too high or too low: Adjust chute or correct belt
velocities. Use impact idlers.

26. Side loading: Load in the direction of belt run and at the centre of the belt.

27. Skirts improperly placed: Use adjustable skirt boards and check that it does not
rub the belt.