COMMISIONING MAUNAL

2018.01.26
 < CONTENT>

1. GENERAL DESCRIPTIONS

1.1 General
1.2 Equipment Specifications
1.3 Lay Out
1.4 Preparation for Commissioning
1.5 Progress Schedule Progress Schedule for Belt Conveyor(Unit)

2. COMMISSIONING CHECK SHEET

2.1 Flow Diagram for Commissioning

2.2 Method for Commissioning
2.3 Check Point for Commissioning
2.4 Check Sheet for Commissioning
2.5 Pulley Centering Check Sheet
2.6 Check Sheet for Drive Unit
2.7 Check Sheet for Take Up Unit

3. NOTE FOR COMMISSIONING

3.1 Check Point

3.2 Emergency Stop
3.3 Agreement for Stop
3.4 Belt Alignment in opening section of Tail & Head.
1. General Descriptions

1.1 General
This guide book is that describes the pipe conveyor and equipment.
This Project will be served as follows to guarantee the good efficiency.

1.2 Equipment Specifications

Capacity Width Speed Motor
No. LINE Material Q’ ty
(T/Hr) (mm) (m/min) (Kw x Pole)

1 CNV-801 1400 COAL 1400 180 160 x 4 2

2 CNV-802 1400 COAL 1400 180 110 x 4 1

3 CNV-803 600 COAL 900 200 75 x 4 1

4 CNV-804 600 COAL 900 200 15 x 4 1

1.3 Lay Out

1.3.1 Plot Plan

1.3.2 CNV-801A/B
1.3.3 CNV-802

1.3.4 CNV-803
1.3.5 CNV-804

1.3.6 TRIPPER CAR

1.4 Preparation for Commissioning

1.4.1 Cleaning the Check

① Between Pulley and Belt

② Inside of Chute, Gravity Cover, Skirt, Frame

1.4.2 Check the Oil Charge

Plummer Block, Motor, Reducer

1.4.3 Check the Bolt Connection

Coupling, Set Bolt, Rotating Part

1.4.4 Check the Balance of Tension

1.4.5 Check the Position

① Belt Guide Roller, Return Roller, P.S.K Idler.

② Belt location of Pulley (Head Pulley, Tail Pulley, Bend Pulley)
③ All Point Check for Interference
(Belt and Roller, Rubber of Skirt, Belt Cleaner, Scraper, Frame)

1.4.6 Method for Safety

① Control access to official notice board outside the lines.

(Authorized Persons Only)
② Operation of the facility in accordance with one command.
③ Emergency stop, protective equipment should be aware of location and method.
④ If you are having problems.
Personnel should contact command immediately.
 1.5 Progress Schedule for Belt Conveyor(Unit)

1.5.1 Main Schedule

Time(Day)
0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0
Item

Ready For Operation

No Load Test

Load Test

1.5.2 No Load Test

Time(hr)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Item

Individual Test

Adjust

Interlock Test

1.5.3 Load Test

Time(hr)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Item

Interlock Test

Adjust

Operation
2. COMMISSIONING CHECK SHEET

2.1 Flow Diagram for Commissioning

Check the Installation

Individual Test Drive Unit

Connecting Coupling Install the Cover

No Load Test Drive Unit

Alignment of the Belt

Twisting of the Belt

Pull-Cord Switch

Belt Sway Switch

Belt Speed Detector

Load Test Belt Alignment

Inspection Equipment
(Back Stop)
2.2 Method for Commissioning
① Adjust open / pipe part while short commissioning at 10~30 seconds period,
five times by commander of commission.
② After complete method ①, adjust twist of belt during another short
commissioning of 1~2 minutes (make belt proceed one cycle of line) by
judgment of commander.
③ After complete method ②, make a conveyor belt drive for 30~60 minutes
continuously. If there are any troubles, make the conveyor stop and adjust in
detail. Move to next step by judgment of commander.
④ After complete method ③, make the conveyor drive with 'no load condition'
and 'load condition'. And check driven time of each equipment in conveyor.
2.3 Check Point For Commissioning

BASIC CHECK POINT Allowable range remarks

HEAD PULLEY PART Check a belt is located in face

1
(CARRIER SIDE) of pulley.

TAIL PULLEY PART Check a belt is located in face

2
(RETURN SIDE) of pulley.

Check a belt has clearance with

3 GRAVITY PULLEY, BEND PULLEY PART
Gravity Frame.

Fifth idler located

at the position
CARRIER
from head pulley
SIDE
to tail pulley
direction.

GIRDER
4
PART

Fifth idler located

at the position
RETURN from
SIDE tail pulley to
head pulley
direction.
 2.4 Check Sheet for Commissioning
Inspection Time
Division Check Point No
Install Load
Load

Is there Oil in Reducer? ○

Are the Coupling connected well?? ○

Does the belt away from the Belt cleaner? ○

Is there foreign material Chute? ○

Is there foreign material on Belt? ○

Does gravity slide device is fixed? ○ ○

Have an obstacle in the direction of the belt? ○

Preparation

Is the tension is maintained for Take up unit? ○ ○

Is the grease into the bearings? ○

Is roller installed in the proper position?

○ ○
(Angle of inclination, Orientation)

Is belt located in the center of the pulley ? ○ ○

Is the tail Part Rubber stuck? ○ ○

Does the back stopper plate is fixed? ○

Pusher bolts of Pulley are installed? ○

Is the adjustment of the mounting bolt Carrier Roller

○
able?

Direction of rotation ○

Measure current value ○

Motor

Output measurement ○

Does the safety cover is installed? ○

 Inspection Time
Division Check Point Cold Hot
Install
Run Run

Does the safety cover is installed? ○

Couplings does it work? ○

Individual operation

Have an obstacle in the direction of the belt? ○ ○

Measure current value ○

Output measurement ○

Does not cause abnormal noise of Pulley bearing part ○

Do meandering a belt movement? ○

Does Belt Cleaner is operating normally? ○

Measurement of Vibration of Structures ○

Is there a strange sound? ○

Is there a problem with the sealed section? ○

Interlock operation

Check for blockage in Chute? ○

Measure current value ○

Output measurement ○

Is rubber located in Tail Skirt section well? ○

Set Bolt Re-Tightening, Bearing Block Part ○

Set Bolt Re-Tightening, Drive Part ○ ○

 2.5 Check Sheet for Pulley Centering

(Unit : mm)

Before adjustment After adjustment

Measurement
NO
A B Date A B Date
Pulley

#1 Head No load
1
Pulley Load

#2 Snub No load
2
Pulley Load

#3 Bend No load
3
Pulley Load

#4 Bend No load
4
Pulley Load

#5 Gravity No load
5
Pulley Load

#6 Tail No load
6
Pulley Load
 2.6 Check Sheet for Drive Unit

2.6.1 Speed, Output of Power, Electric Current

(Unit : mm)

Belt Output of Power Electric Current Belt Speed

Capacity(T/H)
Date Size (KW) (A) (m/min)
(mm) Spec. Check Rating Check Rating Check Rating Check
 2.6.2 Temperature of Bearing, Motor, Reducer

Ambient temperature : ℃

Time(Minute) Initial 10 40 60 100 120 180

A(Reducer)
Drive Unit
B(Motor)

#1 Head R

Pulley L

#2 Snub R

Pulley L

#3 Bend R

Pulley L
Bearing Part
#4 Bend R

Pulley L

#5 Gravity R

Pulley L

#6 Tail R

Pulley L
 2.6.3 Check the Vibration of Drive Unit

(Unit : ㎛)

Position 1 2 3 4 5 Remark

Motor
Condition Unloading
Loading
 2.7 Check Sheet for Take Up Unit

2.7.1 Tail Screw Type

(Unit : mm)

No.
A
Date

2.7.2 Gravity Type

(Unit : mm)

No.
A B C D
Date
3. NOTE FOR COMMISSIONING

3.1 Check Point

① Head Pulley Part : When you install the belt, must be installed in center of
pulley.
② Tail Pulley Part : When you install the belt, must be installed in center of pulley.
③ Checking the status of the interlock
④ Commissioning Check Sheet on the record after Check the direction of
motor.

3.2 Emergency Stop

① When there is damage to the Belt.
② When it seems that a disaster occurs.
③ When the facility is damaged by Belt operation

3.3 Agreement for stop

① When adjusting for meandering of the belt
② Skirt Part : Adjust the spacing of Rubber and Belt
③ Adjust the spacing of Belt Cleaner and Belt

3.4 Belt Alignment in opening section of Tail & Head

① Position of belt could be differ by no load/load while proceeding, adjust belt
alignment if it is needed.