M 02 - Belt Conveyors

PAGE 1
T P L07 OPERA nON MAINTENANCE OF

MATERIAL HANDLING EQUlPMENTS
Module 02 Belt Conveyors
Course Name OPERA nON MAINTENANCE

OF MATERIAL HANDLING
EQUIPMENTS
Course Number L07
Module Number 02
Module Title BeltConveyors including Magnetic

Separators Belt Weighers Table
Feeders Vibratory Feeders
Objective Participants will be able to
Identify different components ofBelt

Conveyors
Learn the operating principles
Learn maintenance aspects of belt
conveyors with respect to
a Routine Maintenance
b Preventive Maintenance
Troubleshooting of Belt Conveyors

CBT
Belt splicing and vuleanising Video
Safety aspects Video
Understand the operation and

working principle ofequipments like
Magnetic Separators Belt
Weighers Table Feeders
Vibratory Feeders
sruOENrS GUIDE
PAGE 2
OPERA TlON MAINTENANCE OF 1

T P L07
MATERIAL HANDLING EQUWMENTS
Duration 125 days Ten sessions of45 Min each
including video and CBT
Number of Pages 72
Oass Room
Necessary Facilities
TV
Necessary Instruments 35 mm Slide Projector VCR
Computer for CDT
STUOENrS GutOe
PAGE 3
3 P
T 07
1 OPERAnON MAINTENANCE OF
MATERIAL HANDLING EQUJPMENTS
Module 02 Belt Conveyon
Table of Contents
BELT CONVEYOR
Page
21 INTRODUCTION 4
2 2 BASICS
2 3 MATERIAL CHARACTERISTICS 7
24 CONSTRUcnON I
24 1 COMPONENTS AND ACCESSORIES C
25 OPERATION 4
26 MAINTENANCE 43
27 BELT SPLICING VULCANISING 49
28 SAFETY 60
29 AUXILIARY EQUIPMENTS 63
29 1 MAGNETIC SEPARATOR 63
29 2 ROTARY TABLE CONVEYOR 63
3
29 VIBRATORY FEEDER 67
29 4 OSCILLATING FEEDER 67
29 5 BELT WEIGHER 69
2 10 CONCLUSION 71
STUDENT
S GUIDE
PAGE 4
1
TP L07 OPERATION MAINTENANCE OF
MATERIAL HANDLING EQUIPMENTS
2 1 INTRODU TlON
In this session we shall cover theoperation and maintenance of Belt

Conveyors being used in cement plants The subject coverage in the
module shall be done in the following fashion
a
Types Conveyors in the Cement
of Belt Plant
b Various parts ofBelt Conveyor

c
Operation ofBeh Conveyor I I
J
u nance
Maiuu or iscit Conveyor
I e Belt Splicing and V ulcalising

f Inspection
g Safety aspects in the Belt Conveyor system
This module includes one video on Belt splicing and vulcanising and one
CBT dealing with of trouble shooting of belt conveyor system
Belt Conveyors have attained a

position in transporting bulk
dominant
materials due to economy safety of operation reliability versatility and

practically unlimited range of capacities They are suitable for
with their
performing numerous processing functions in cormection
normal purpose of providing a continuous flow of material between
operations
Low labour and low energy requirements are fundamental advantage with
belt conveyors as
compared with other means of transportation
2 2 BASICS
Belt Conveyor is an endless moving belt for transporting materials
inclination either up down

horizontally or on an or
STUDENT S GUIDE
PAGE 5

Module 02 Belt CODveyon
In a process Industry like Cement Plants

it is required to
transport
wide variety ofbulk materials from one place to another The distance
between two places may be ranging from few meters to
many kilometres
and they may be in different altitudes
Apart from their basic function
of moving materials belt conveyors are
equally adaptable to many other
operations such as stock piling blending sampling and weighing A
typical Belt Conveyor as shown in fig 2 I
22 1 Advantages of Bdt Conveyors
Bdt Conveyor has the advantages of simplicity of constuction high

efficiency and low frictional loss resulting in iow power requirement fhe
I
other main advantages are listed below
a Coaveying ofvariety ofMaterbls
Materials ranging from very fine dusty chemicals to large Lumpy stone
or Coal can be handled efficiently by Belt Conveyors The materials
being handled by Belt Conveyor in Cement Plant are Crushed Limestone
Coal Gypsm Clinker etc
b Wide range of Capacities
Belt Conveyors of handling

are capable capacities ranging upto 1000
tonslhr
t Adaptability to path of Travel
The Belt Conveyor system provides the means of conveying materials

through the shortest distances between the and
required loading un
loading points Belt conveyor can convey the materials from mines to
the plant directly crossing rivers Hill Terrains etc and also in all
weather
STUDENrS GUIOE
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T P L07 OPERATION MAINTENANCE OF
Module 02 BeJt Conveyon
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2 3 MATERIAL CHARACTERISTICS
23 1 Basic Properties
The Belt Conveyors are capable of transporting material generaJly

lumpsize upto 600 mm
Typically it can carry without any problem
some percentage of dust as well as size above 100 mm To decide the
Conveyor capacity and therefore the width of conveyor the following
characteristics of material have to be considered
r1
Angle of Repose It is the angle of the sloping surface of material

measured from horizontal under static conditions Details
given in table 1
Angle of Surcharge The angle of surcharge of a material is the

angle
to the horizontal which the surface ofthe material assumes while the
material is at rest on a moving conveyor belt
Table 1 of Surcharge
Flowability Angle Angle of Repose
Very free Free flowing Average flowing Sluggish

floing
50Angle of 100 Angle of 200 Angle of 250 Angle of 300 Angle of

Surcharge Surcharge Surcharge Surcharge Surcharge
10
00 190 Angle 200 290 3 0 340 350 390

Angle Angle Angle oo up Angle
of repose of repose of repose of repose of repose
Material Characteristicll
lJnilortn Size Rowlkd dry Irregular granular Typical Common Irregular stringy
1 mall rounJcO polished pw1ic1es or Iwnpy materi T1l1ls such lIS librous
mah interlocking
partcile of medium weighl als of medium 01 bituminous coal matcrilllsoch as
such liS lIioole such lIS lIlltluacite stone most ores wood chips
baglL
m coaI c1ave c f ffiP
k d foundry
fc
Clink
sand etc
I
SruOENrs GUIDE
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t
Flowablity of Material
the Material Institutions the ability

The term flowablity is defined by as
to flow from the Bett or in the chute easily
the material is classified

According to this property as
a
Very free flowing
b Free flowing
c Av age flcig
I d Sluggish
I
least and the sluggish materials
Very fine flowing materials will have the
will have maximum The details are given in Table 1
angle of repose
2 3 1 SELECTION OF BELT CONVEYOR
while choosing belt

The following precautions are to be observed
conveyors on slope for given material
1 Granular large lumps are likely to roll back on the belt without being
conveyed
Spillage of material both at feeding point and discharging point have

to
2
be prevented by proper design ofchutes Often in practice incorrect
design of chutes lead to poor performance of belt conveyor
to carrying side ofbelt and

Very fine sticky material will stick cause
3
damage to return idlers
STUOENrS GUIDE
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T P 17 OPERATION MAINTENANCE OF
4 CONSTRUCTION
2
24 1 BELT CONVEYOR COMPONENTS AND

ACCESSORIES
The essential components of Belt Conveyor are
I The belt to carry the material

2 Driving gear
3 RoDers or Idlers
4
Conveyor Pulleys Shafts Backups and Brakes
5 UDS to maintain Belt tension
Take
6 Loading and unloading chutes
I 7 Cleaning and protecting devices for belt
24 1 1 BELT
The belt consists of layers or plies of cotton deck impregnated with

rubber and protected by a rubber cover on both sides and
edges The
cotton deck supplies the
strength to withstand the tension created in
carrying the load while the cover protects the cotton carcass
The belt carcass carries the tension forces necessary in

starting and
moving the loaded belt absorbs the
impact energy of material loading
provides necessary stability for proper alignment and load support over
idlers
2 41 2 COVERS
Top and bottom covers of belting is made of rubber or rubber like

compounds This compound binds the various components of belt
carcass
The top cover will

generally be greater in thickness than the bottom cover
because the concentration of wear is
usually on carrying side
STUDENTS GUIDE
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T P 07
1 OPERATION MAINTENANCE OF f
24 13 BELT CARCASS
This is the tension element of a conveyor belt Most conveyor belt
carcasses are made of one or more plies of woven fabric Some high
single layer of parallel steel cables
I
tension carcasses employ a
Conveyor belt fabric is made ofwarp yarns which run

length wise and
which run cross wise
I
worsted yams or fitling
Four commonly used weave patterns are

I
I 1 Plain weave
2 Straight warp weave
1 3
4
Solid woven weave
Woven cord weave
I 2 4 1 4 BELT PLY
The different types of constructions are

given below
A Straight Ply Construction

B Stepped Ply Construction
C Breaker Ply Construction
D Skim Coated Ply
A Straight Ply Construction
width
This construction of Straight load plies extends across the whole
width This
ofthe belt and the cover thickness is uniform across the belt
is llIustrated in the Fig 2 2
This is available with two alternative edge icoonstrnuct They are
a Moulded Edge
In this construction the edges of the fabric carcass are fully enclosed
with rubber
STUDENTS GUIDE
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PAGE
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T P L07
OPERATION MAINTENANCE OF
MA TERlAL
HANDLING EQUJPMENTS
PKe eo
FIG 2
STRAIGHT PLY CONSTRUCTION
L 07 02 20
FIG 2 3
STEPPED PLY CONSTRUCTION
l 07 02 21
STUDENTS GUIDE
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TP 01
1 OPERATION MAINTENANCE OF
b Cut Edge
This construction consists offuU fabric reinforced fabric which improves

the resistance of the belt to edge wear
B Stepped Ply Construction
increased and the

1n a stepped ply construction the cover thickness is
carcassthickness is reduced across the belt width In thisconstructionthe
in the first and second at the carrying
gap is left in the first ply or plies
side the gap being filled with addiliooai rubber cover nus construction
where wear is
provides more rubber cover in the centre of the belt
thickness It also
normally very severe thus increasing the over aU
improves transverse by reducing the number of plies at the
flexibility
centre of the belt Atleast three straight ply arerequired toplies
stepped ply construction as lllustrated in the Fig 2 3
incorporate as
c Breaker Ply Construction
Under very severe condition bond between the cover and the carcass
is greatly improved This bond is increased by including the breaker
in the coverrubber It consists ofopen weave fabric made ofcotton
a
or nylon It is coated with cushion rubber softer than the cover rubber
The advantages are given below
the tear resistance ofthe rubber

Improving the cushion and cover
Protects tbe main carcass fabric from impact
The breaker can be placed in the belt in the following ways
a Breaker on face
In this construction the breaker strip rod is flush over the carcass face
as iIIutrated in the Fig 4

2
STUDENTS GUIDE
PAGE 13
T P 1
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Module 02 Bdt Cooveyon
b Breaker on eKe aDd back
This construction is used where the belt is

subjected to heavy driving
pulls such as suitable inclusion and geared tandem drives It is illustrated
in Fig 2 5
Ji1oatiDg
c Breaker
Intbis construction in addition to the breaker ply and its associated

cushion layer another layer ofthe resilient cushion rubber is interposed
between the breaker ply and the ca WlSS Thb is uSai where loading
impact is severe This cushion layer is nonnalJy 1 5 rom thick I
d Skim Coated Ply
When rvice conditions the ply may be skim coated

are severe
by
application of additional rubber
insulation between the plies Skim
coating involves an extra in which the friction operation is over laid
with a thin coating of rubber The additional
bond between plies
a more flexible carcass thanis
produces obtained with ftictioned plies and
thereby minimises the possibility of ply seperation where severe
flexing
is encountered
24 5 DRIVES AND CONTROLS FOR

1
BELT CONVEYOR
Normally Belt Conveyors are driven through electric motors through

a speed reducer The different
types of speed reduces that can be applied
for belt conveyor applications are
Reduction Gear Box

Chain Sprocket system
Belt Drive systems
S GUIlE
STUOENT
PAGE 14
T P 01
Module 02 t CODveyon
Cover
FIG 2 4 BREAKER ON FACE
L 07 02 22
FIG 2 5 BREAKER ON FACE AND BACK
L 07 02 23
STUDENTS GUIDE
PAGE 16
T P 07
2 4 1 5 1 Drive witb tion

Reduc Gear Box
The variOtts parts of a typical belt conveyor drive unit are
Reduction Gear Unit

Drive pulley Conveyor drive pulley
Drive Motor
Different arrangements of Drives are shown in

fig 2 6 a b
Normally the Motor shall be with aotirun back braking device for
conveyi B at an ascending l1glc The jXJWCI transmission to the belt
driV
1
depends on the drive pulley diameter the belt ten jQ I the angle of vrap
and the coefficient offriction between belt and
pulley The friction can
be increased by providing the drive
pulley with a covering that gives a
better grip Alternatively the belt may be driven
drive system are the take up pulley upper idler

by two pulleys around
which it is wrapped dual drive Theotberdementsofthe belt
conveyor
I
pulley and lower idler
pulley
2 4 55
1 Driving Gear
BeltConveyor drive equipment nonnaIly consists of Motor Speed

Reduction equipment and drive shaft
Belt is usually driven by means of electric motor through reduction

gears Driving pulley for the belt is normally arranged at the delivery
end of the conveyor as this arrangement places the
tight side of the
belt on the load carrying side
To obtain maximum driving

efficiency the following methods has to be
considered
The short and medium length conveyors generally allow a

plain open
drive from which sufficient traction will be available
The tension requirements oflonger conveyors may be obtained by the
following
STUDENTS GUmE
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TP 07
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TP 07
1
i
a Increasing the initial or slack side tension

the arc of driving contact
b Using the snub pulley to increase
still further
c Using a tandem drive to increase the arc of contact
d Lagging the drive pulley with the rubber covering
Ioitial TensioD
To obtain maximum belt life it is preferable to run the belt as slack as is
practicable
Snub PuUey Drive
By adding a snub pulley close to the drivepulley the arc ofcontact can
be increased from 1800 to about 2400 thereby increasing belt tension
Tandem Drive
contact to 4200 A
This uses two driving pulleys to increase the arc of
function with one or more electric motors
tandum drive can
2
Recommended belt speeds for various materials are given in table
24 1 3 WRAP LIMITS
5
Limits for the various types of Pulley Drives are given below
WRAP LIMITS
S No TYPE OF PULLEY DRIVE

FROM TO
1800 1800
1 Single no snub
with snub 1800 2400

2 Single
3600 4800
3 Dual
STUDENrS GUIDE
PAGE 1
TP L07 OPERAnON MAINTENANCE OF

2 1 6 BELT IDLERS
4 1 6 1
2
Requirements
To give proper support and protection to belt and also to support the load
being conveyed
The belt in the conveyor has to move

through the cycle of loading
carrying and return Throughout this cycle the belt must be supported
and the idlers are intended fur this purpose
In the loading zone

idlio pfOiect th beit by absorbing the Impact of
loading of material prevent the material spillage and also move the
loaded material away from
loading zone
In the carrying zone idlers are used to convey the load without
spillage
and with minimum
drag on
conveyor power system
When the belt is unloaded and returns the idlers are supporting the belt
to maintain
tracking and prevent damage
Idlers shape the flat belt into a channel to ensure centered loading and
minimize spillage over the edges
2 2
L6 Types of belt conveyor idlen
There are two basic types
i Carrying Type ii Return Type
L CARRYING IDLERS
Carrying idlers support the belt as well as the load and should be
they
placed such that they limit the amount of belt sag under load between
adjacent idlers to a maximum of75 mm
RJOENT GUIDE
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PAGE 20
i
TP 07
1
Various types of carrying idlers are
Idlers
A Trougbing Carrying
than flat belts for the

Troughed belts can carry greater tonnage of load
same belt width and speed
of Troughing Idlers are

Two general types
i In line ii Offset
i In line Trouping Idlers

I
the idler frame WIth
t OI15ists ofthree equal length iuils mounted on
the center lines of the three rolls aligned
Idlers
ii Off set Troughing
center line
The center line of the inclined rolls are in one plane while the
ofthe center roll is in another plane
This type of idler finds application in underground mining because of

low headroom
B Picking Idlers
This is a specialized in line troughing idler with long horizontal roll

rolls This type ofidler provides large belt
area
and two shorter inclined
for material and allows ea3Y inspection of carried material
C Flat Idlers
Flat idlers often

This consists ofahorizontal roll to support the load
are
used on feeders The major problems are material spillage less capacity
etc
STUDENTS GUIDE
PAGE 21
t
D Impact Idlers
These are specially designed Idlers used in the load zone to protect the
belt from impact damage The rollers of standard idlers are replaced
with discs ofrubber or other resilient material These resilient material
flex under the impact to absorb the
energy of impact
E Training Idlers
This Idlers is pivoted on the center ofthe idler frame This allows the
idler to shift positions
slightly as belt runs off the center
This pivoting
actionapplies more pressure to the belt edge which runs offcenter and
guides it back to correct path
The guide rollers are mounted on the outside ofidler controls of the belt
when it is mistracking
F Catenary Idlers
In Idler is of this
design three or more rolls are linked together by
chains pinnedjoints etc and suspended fromconveyor stringer This
idler is more tolerant of mistracking
IL RETURN ROLLERS
Return idlers are usually made of steel They are usually 75 to 150 mm
diameter and spaced at approximately 3 ffi9

I intervals
2 17 CONVEYOR sHAFTS
PULLEYS BACK STOPS AND BRAKES
4 1 7 1
2 REQUIREMENT OF PULLEYS
To convey load from one end to another end the endless belt must be
supported on both ends The pulleys are provided to support the load and
also to transmit the motion from drive unit
rS GUIDE
S11JOEN
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PAGE 22

Module 02 Belt CODveyOrs
2 1 1 1 TYPES OF PULLEYS
They are as follows
1 Lagged welded steel pulley

2 Welded steel pulley with grooved lagging
3 Slide lagged pulley
4 Fabricated wing type of pulley
in wide range ofsizes

The pulleys are usually manufactured a
Most conunonly used is standard steel pulley

It consists of continous I
hubs
rim and two end discs fitted with compression
Other pulleys available are self cleaning wing types which are used at
the tail end takeup or at snub portions
2 1 3 LAGGING OF PULLEYS
7
the belt and pulley

To increase the coefficient ofmction between
fabric or other resilient
are covered with some form of rubber
pulleys
material This is called pulley tagging
effect
Another purpose oflagging is to reduce wear on the pulley and to
self cleaning action
diameters
Lagging thickness varies for different pulley
Common methods of lagging are
1 Bolting
2 Painting
3 Cementing
4 Vulcanizing
STUOENT S GUIDE
23
PAGE
1 P
T 07
Bolted Jagging has the advantage of

being replaceable in the field
Painted and cemented

laggings are limited to lighter service conditions
Vulcanized lagging is preferred for duty

heavy applications
Crowning ofpulley face I
To center the belt the

on
pulley if approach to the pulley is on an
unsupported span the pulley face is crowned
Two types of pulley crowns are
I 1 aper CroWD
The pulley face has a V shape with the rotating axis The diameter
is larger at the center of pulley
Curvr crown I
Crowned
Curve puUeys have a long flat surface in tbe center of puUey
with the ends curved to a small diameter
2 J 2 7 2 SHAFfS
The shaft and puUeys must be treated as acomposite structural assembly

because rigidity of the assembly depends upon both the shaft and
pulley
Shaft material may be
any type ofsteel such as AlSI CI018 steel PuUey
shafts are machined to precise tolerances
Assembly ofpulley and shaft
is usually accomplished by bore and keyway However taperlock bushings
arc also offered
S GUtDE
STUOENT
PAGE 24

4 1 7 4 BACK STOPS
2
A loaded belt conveyor of sufficient slope tends to move backwards

failure
when forward motion is stopped due to power failure or mehanical
in the driving machinery If this is allowed the material would pile up
in serious damage to the belt
at the tail end of the conveyor resulting
To prevent this a
imposing safety hazard and cleaning problems
of
mechanical device called Backstop is used It permits the rotation
the
drive pulley only in forward direction
but automatically prevents
rotation in opposite direction
24 1 5 BRAKES
7 1
restrained from running I

A loaded inclined conveyor when operating is
the power source Any interruption of power or mechanical
away by
of control To
failure of drive will permit the belt and load to out
run
prevent this a properly located brake is required
a controlled
A brake is a friction device for bringing conveyor belt to
surfaces are
stop The brakes operate on the principle that the braking
or by hydraulic
engaged by springs and disengaged either by a magnet
electric motor hydraulic pump combination
pressure induced by an
In some cases abrake is used to regulate the stopping time and distance
TYPES OF BRAKES
i al friction brakes
Mechani
The brakes are interconnected

These brakes are electrically operated
the motor is
off the
electrically with the motor such that when power to
thus allowing spring to
holding coil em tbe brake also is de energised
a
operate the brake
S GUIDE
STUDEHT
PAOE 25

l
MA TERlAL HANDLING EQUIPMENTS
ji Eddy current brakes
In this brake a smooth drum rotates in a magnetic field which is produced
by stationary field coil When the drum rotates eddy currents are
a
produced on the surface ofthe drum The magnetic attraction between

these eddy current and poles of the field produces a braking torque The
braking torque varies directly with the field current and the speed ofthe
drum
An auxiliary fiiction brake is used in combination with eddy current
brake because eddy current brake cannot hold the belt to a standstill
position
J
iii Piugging the Motor
The current is reversed and counter torque is
cage motors are most suitab e for this application

developed Squirrel I
iv Dynamic Braking
This is a system ofelectric braking in which motors are used as

generators
and the kinetic energy of the load is used to exert a
retarding force
2 4 1 8 DEVICES FORACCELERATION DECELERATION AND TORQUE

CONTROL
Smooth starting ofconveyor is important In case of conveyors having

vertical curves or
trippers too rapid a start may cause excessive lifting
of the belt from the idlers
Acceleration can be controlled by several types ofelectrical devices They

are as given below
4 1 8 1 EDDY
2 CURRENT COUPLINGS
These are
composed ofthree basic parts
STUDENT S GUIDE
PAGE 26
T P 07
i Rotor made up of multiple pole pieces Secured to one shaft
2 A hollow iron cylinder or drum which surrounds the rotor secured

to another shaft
3 And a
stationary electro magnetic coil which surrounds both rotor and
drum
A D C power supply energises the coil When either the rotor or the
drum is rotated eddy currents are induced These eddy currents setup
a secondaryfield and thus creates a
torque between the rotor and drum
I J
2 8 2 FLUID COUPLINGS
U f
This
oil
coupling consists ofimpeUer and runner within a housing filled with
The impeller is connected to
to driven shaft
driving shaft and runner is connected
When impeller is rotated oil thrown to periphei
I
impinges on the blades of the runner and makes it to rotate
couplings can produce smooth ac leration of high inertia loads

Fluid
I
24 L8 J VARIABLE SPEED DRIVES
Majority ofthe conveyors require only single speed operation
In some cases two or more speeds necessary such

are as feeders or
conveyors handling several materials ofdifferent weights
Available variable speed devices are
1 Two and fOllr speed squirrel cage motors either constant torque or
constant
hp
2 Constant speed squirrel cage motors connected to mechanical variable
speed transmissions
a V belt drives with varied diameter pulleys

b Belt system or chain devices with variable diameter
c Hydraulic units ith variable displacement pumps
S GUIDE
STUDENT
PAGE 27
TP un OPERATION MAINTENANCE OF
3 D C motors operating with an adjustable voltage system
4 Constant speed squirrel cage motor with electro or fluid

magnetic
type couplings
24 1 8 ELECTRICAL INTERLOCKING FOR CONVEYOR SYSTEMS
Modem high speed high capacity belt conveyor systems reqUIres

electrical interlocking
This interlocking has a provision that a failure or

stoppage of one
conveyor will stop all conveyors feedi e 1 eri c 1 lc has fur liet
provision that before any conveyor is started all subsequent conveyors I

will be running
It should make sure that each unit has attained full rated speed before the
next unit can be started Othenlvise the transfer points wilt be tlooded
with materials
A better f rm ofinterlock is the use of centrifugal switch driven by

idler pulley at the last point on the belt This switch will not startnext
uni until the belt attains ratedthe speed Conversely it can be used to
stop the next belt if speed has decreased below a

given value
2 1 9 BELT TAKEUPS
4
All properly designed belt conveyors require the use ofsome form oftake
up device for the following reasons
1 To ensure the proper amount ofslackside tension T2 at the drive
pulley to prevent belt slippage
2 To proper belt tension at loading and other points along the

ensure
conveyor This to avoid loss oftroughing contour ofthe belt between

idlers
3 To compensate for in belt

changes length
STUDENT S GUIDE
PAGE 28
TP UJ7 OPERATION MAINTENANCE OF

MATERIAL HANDLING EQUlPMENTS 1
4 To allow belt storage for

making replacement splices
5 Take up should ide for

movement pro changes in belt length due
to stretch or shrinkage
There are two types of take up devices namely
Screw take up
In this type oftake up the tail pulley is installed over rails so that it can
be moved by means of screws It is commonly used on conveyors upto
75 meter in length The arrangement is
simple as it requires no extra
bends in tbe bdl The d aJva1llage is that it is not self
adjusting and I
the exact tension applied to the screws cannet be ascertain This is
shown in fig 2 1
y
LEGEND
1 BELT
2 SCREW
J BEARING
1 SLIDING BEARING BLOCA
FIG 2 7 SCREW TAKE UP
S
STUDENT GUIDE
PAGE 29
1
MA TERIAL HANDLING EQUIPMENTS
2 Gravity Take Up
There are two types of gravity take ups
a Vertical b Horizontal
a The vertical type requires more headroom for installation and consists
of a weighted pulley on the return run of the belt Two other
pulleys
I
are required to complete the arrangement and hence it gives the beh
4
b
three extra bends
The
is mounted The
Hori7ont
t1
type con
carriage
sts
agc uil which i ht tail pulley
lc
of l
is forced to retract under the influence

I
J
ofweights attached to it
The advantage ofthe gravity take up is that it is self adjusting and the
tension on the belt can be
accurately controUed by the weights
24 1 10 LOADING AND UNLOADING SYSTEMS
The following points has to be considered before

loading a conveyor
belt
1 The material to be conveyed on the belt should be fed uniformly

in the direction of the belt travel at a close as possible to the
speed as
belt speed
2 The material should be placed in the middle ofthe belt
3 The belt should never have an idler under it at the where the
point
material is loaded in order to decrease the belt wear
4 should be
Spillage prevented by means of skirt boards
S GUIDE
STUOENT
PAGE 30

MATERIAL HANDUNG EQUIPMENTS
Module 02 Belt Con eyors
204 1
10 1 LOADING CHUTES
Chutes are mad ofwood or steel in order to decrease the wear due to
abrasion
Metal chutes are most widely used For abrasive materials the chute
can be lined v jth abrasion resisting material such as ceramic liners For
corrosive the chute is coated with rubber synthetics or fused
materials
glass linings
Chutes may be opened or closed depending on the material to be carried

Closed chutes decrease dust hazard Any chute should be wide enough I
de th thai ii
0 er wc largc3L tWilP would hanciie side ny suJe I
I
A chute should slope in the direction of belt travel at an angle of 350
t0450 1t should be placed such that no material can bejammed between
belt and chute
Outer width ofc hute should not be greater than 2 3 width of receiving
belt for ideal o rating conditions
a for lumpy materials it should be 2 2 to3 times the largest

dimension lump
b For a
mixtureoftumpsand fines itis 2 times the maximum lump size
These proportions are essential to prevent interlocking and jamming

of lumps in the chute
r
VARIOUS TYPES OF LOADING CHUTES
a
Grizzly Screen
In order to reduce the wear of the belt due to abrasive lumps the fines
should be fed to the belt so as to form a cushion This can be achieved
by installing grizzly
a screen at the bottom of the chute or by cutting a
V notch in the bottom of the chute
STUDENT S GUIDE
PAGE 31

b STONE BOX LOADING CtruTE
Where material to be handled is severely abrasive and speed of receiving

is slow this type of chute can bt employed The chute bottom acts as
a box where some material is retained The flow of abrasive material
will be across this box portion Thus wear ofchute bottom is avoided
Illustrated in Fig 2 8
4 110 2 SKIRT BOARDS

2
Skirt Boards are used in

conjunction with chutes They guide the material
centrally on the belt while loading until it has settled down on the belt
They conSist of strips ofwood or metal to which are attached strips of
soft mbber The skirts should n er touch the belt The skirts should
flare slightly upwards and outwards from the chute to prevent material
from wedging J typie a application ofSkirt Board on troughed Belt as
shown fig 2 9
The maximum distance between skirtboards is 23 width of troughed

belt
For freeflowing material it is desirable to have of 1 2 width

a spacing
oftroughed belt
Skirtboard length is a function of difference between loading material
velocity and belt velocity
When this difference is small the be 0 6 for each

length can safely metre
0 50 metres per ond of belt speed
Skirtboards clearance over belt
The metal or wood portion of skirtboard should be atleast 6mm above

to the belt surface This clearance should increase in the
uniformly
direction ofbelt travel to 9mm
S GUIDE
STUDENT
J
PAGE 32

Skirtboard rubber edging
To prevent leakage offines rubber strips are attached to the exterior of

skirtboard by bolting The rubber strip is adjusted to rest
lightly on the belt
surface This should be adjusted frequently as the belt wears
away
chute
Stone box J
FlG 8 STONE BOX LOADING CHUTE
L 07 02 39
Bolted adjustable
Rubber edging
Belt
FIG 2 9 SKIRT BOARD
Jl 2
0 06
STUDENrS GUIDE
I
PAGE 33
P
T L07 OPERATION MAINTENANCE OF
1i
2A 1 10 J DISCHARGING ARRANGEMENT
from the belt Ln

Materials carried by a belt conveyor can be discharged
different ways to effect desired results
but sometimes
Usually unloading is accomplished over the head pulley
intermediate
it is necessary to discharge aconveyor belt at one or more
should be used
points in such cases a fixed or travelling tripper
idlers or by the use of scrapers is not
Unloading by tilting the
recommended
Where material is discharged into chute belt speed determines the

a
it leaves the belt and the chute hoIJ1d b

trajectory of the material as I
piacedaccordmgly There should besufficientclearancebetweenthehelt
between the two
aI d ilie chute so that een the biggo iumps cannot Jam
I
t
Discharge over end pulleystranjectory of material discharged

The
ill fall Dusting
should be investigated to ascertain whether the material
is major problem
with a
Discharge chutes top of the chute can be provided
The
should be far enough
cover Upper edge of the bottom plate orthe lip
even when the belt
under and back ofthe pulley to catch all the material
are contained in the material it
is barelymoving If hard jagged lumps
2 10
provide rubber strips onthe lip Illustrated Fig
in
is good practice to
chutes
Lowering
These are used where dusting and degradation are objectionable
Four common forms of chutes available are
1 Spiral Lowering Chutes
materials
This is used for gently lowering fragile and or dusty bulky
STUDENTS GUIDE
PAGE 34
T p L07 OPERATION MAINTENANCE OF

MA TERIAL
HANDLING EQUIPMENTS
Module 02 Bdt Conveyors
Trajectory
or material
FIG 10
2 SIMPLE
DISCHARGE CHUTE
l 0 02 36
2 Bin
Lowering Chutes
Straight declined inverted channeJ chutes run from the belt

conveyor
discharge point down into the bin and are
secured to the sloping side of
the bin near the bin bottom
Material will slide down these chutes
without dusting until it meets quickly
with the bin side or the surface
ofthe
material in the bin
3 Rock Ladders
These are structural steel or wood tower

having a series of baffles
arranged in such a manner that material
discharged from a conveyor is not
broken crumbling or
degraded
4
Telescopic Chutes
This is used to minimise

dusting when discharging toa The telescopic
sections are
pile
usually cable
onnected
c in such a manner that it lift the
sections to
keep the lower end of chute just clear of top of
storage pile
iP
S
STUDENT GUIDE
PAGE 35

2 4 1 11 Cleaning and Protecting the belt
The belt should be thoroughly cleaned after the discharge point and
face side of
prior to the return run This is most important because the
the belt becomes the pulley side when negotiating snub pulleys a tandem
drive or return idlers Any particles ofmaterial clinging to the face side
wiU be ground into the rubber cover by the action of the pulleys Various
II
types of cleaning systems are shown in fig 2
4 1 11 1
2 Spray system
The spray rod with the 600 hollow circular nozzles which are screwed
unit by
l
i pcsi cn atachcd directly to the outer spindit deflection t
means of special brackets The spray can be directed simply by t 1g
rni
The spray system is made of

the spray rod in its clamping device
rust free material and has fine filter and pressure regulation device
4 1 11 2
2 otating Brushes
These brushes should rotate in the opposite direction to the belt travel
and at asufficient speed to keep the bristles clear of material The brush
diameter should be chosen as per the table given below
of Brush in
Peripheral Speed m
p s
Brush DIameter 10 mm
Condition of
203 254 305
material
I
4 06 41
4 5 08
dry
4 87 5 58 6 09
Damp
Wet 6 09 7 00 7 61
Sticky
STUOENrS GUIDE
PAGE 36

ROTARY RUBBER BLADE CLEANER
I
ROTARY EL T CLEANING BRUSH
SNUB PULLEY WIPER
HEAD PULLEY
SNUB PUllEY
FIG 2 11
BELT CLEANING DEVICES
l 07 02 44i 45
STUDENTS GUIDE
PAGE 37
TP 07
4 I IJ 3
2 Scrapers
Scraper are used to keep the belt clean of any materials
Four methods are

commonly used and combination oftwo or more
methods are required for Sticky in materials
Rapping Roller
This is usually in the form ofan eccentric roller which as it turns exerts
a
rapping effect on the belt shaking the adhering particles free This
is used for loading material and
for effective cleaning
Rubber craptl
I
It is
usually mounted on a counter weight pivot arra1gement to beat
on
the belt
immediately under the discharge pulley This is used for material
such as gravel coal etc A
typical layout and general arrangement of
a belt scraper is shown in
fig no 2 J2 A B
Steel Scraper
It is used for sticky material such as clay Care should be taken while
adopting this method as a
badly fitted or misaligned metal scraper an
cause extensive belt damage
Polyurethene Scraper
These types of are belt cleaners have

polyurethene blades mounted on
a suitable Carrier Assembly with
Elastomount System to facili te
automatic blade adjustment Suitable to be
installed on the
sub frame by means of modular conveyors
support mounts It Cleans the residual
layer present on the inner side of the return belt
Belt Washing Arrangement
In those cases where adhesive material has to

be removed from the belt
it is advisable to instal a
spray system in front of the scraper
STUDENTS GWDE
PAGE 39

By spraying
water on to the belt the removal of
material from the belt
and removal ofmaterial which has
already been scraped offthe belt
are facilitated and the accumulation
of the material on the scraper
structure is
prevented The spray system be
can operated either
continuously or for a limited period
The Spray rod with the 600 hoUow circular nozzles which are screwed
into position is attached directly to the outer
spindle deflection unit by
means of special brackets The
spray can be directed simply by turning
the spray rod in its clamping device The spray system is made ofrust
free material and has fine filter and
pressure service regulation
14 J 12 Deck Plates
Deck Plates areused to prevent

spillage from the carrying belt and
jamming ofmaterial between the beft and
pulley
Types of Decks Round deck Flat deck and Inclined deck
Deck Plates made up of wood

are norrnaUy or steel
WEATHER PROTECTION DEVICES
The material being handled may be affected by rain The moisture on the
pulley side ofthe belt may cause slippage between belt and
pulley Also
lhe life ofrubber cover may be shortened
by the effect ofimense sunlight y
Strong winds can lift conveyor belts offtheir idlers and cause severe belt
aiDing problems and spillage of material
To avoid these ditliculties the

following profection devices can be used
MLF COVERS
f1wers are made oftlat sheets either ofgalvanized iron

or
corrugated or
iuninium They are fastened to the stringers and are situated over the
ldt
STUDENrS GUIDE
r i
PAGE 40
TP L07 OPF RAnON MAINTENANCE OF

Three Quarter Covers These covers are less than complete semi circle
WIND BREAKS
These are
provided by installing suitable reinforced
I
metal sheet on the
windward side ofthe
conveyor stringers
I WIND HOOPS
By providing suitable hoops spaced at regular intervals we can protect

the empty or lightly loaded belt
TPoP RON DEncroRS

o
l
I I
Use of Magnetic pulleys or suspending magnet over the belt are the
I methods of removing iron This is

Seperator
To remove ferrous particles magnet

explained in detail in Magnetic
c
pulleys i e magnets are
suspend
ed over the belt
SELECfION OF COVERS
The selection of cover grades depends primarily on
J ABRASJVE NATURE OF MATERIALS
1l The cover must be able to resist the abrasive action ofmatenal
IS 189 1988 specifies Grade M 24 for sharp and abr ive materials
Grade N 7 for moderately abrasive materials
COVER THICK
aSS
The selection ofcover thickness

depends on the following
I Abrasive nature of material

2 Size of material
3 Loading cycle and arrangements
STUDENTS GUIDE
PAGE 1
l
T P un OPERATION MAINTENANCE OF
MATERIAL HANDLING QUlPMENTS
Module 02 Belt Connyors
2 5 OPERATION
A careful and systematic operation of the Belt Conveyor is very essential

in achie ng longer and trouble free life of the equipment The specific
areas to be taken care during the operation as follows
Inspection and lubrication ofthe equipment
It is essential for the operator to ensure that specified inspection

and lubrication checks are carried out on the Conveyor The respon
sibilities ofensuring it has to bespecifica1ly fixed before commendng
the operation It should be made sure that the walkways platforms
hand rails are all in good condition for easy access
The operator should be fully conversant with the Inspection Doors
Stop switches and the location ofthe rUin Power otf

Shut Switch
Starting and Stopping
For trouble free operation the Conveyor should be empty while

a good practice to empty the Conveyor before
It is also
starting
stopping Care should be taken to avoid starting the Conveyor in
load because this will casue extra strain on the equipment
be thoroughly cleaned before if

Conveyor system should restarting
the material is choked or frozen n the equipment
lfthe Conveyor has to be in load specific care should be taken to see
that no
jamming is taking place any where in the system
Before restarting the Conveyor especially on 10ad makc sure that

the Hold Back system is in order
Make sure that piling ofmaterial either at loading point or di harge

point is eliminated Refer to Trouble Shooting for more details
STUDENTS GUIDE
PAGE 42
l TP 07
1 OPERA nON MAINTENANCE Of
Module 02 Belt
Conveyors
Maximum Lump Size
The maximum size ofthe material

loaded to the Conveyor has to be
kept within the specified range
Wherever Bar Gratings and similar controls are

provided they
should be kept in proper service Never
try to by controls pass
provided for regulating the Lumpsize
entOverLoad5
o
Ah
ays regulate the flow of materials to the Belt Conveyor
I
Regulate the flow to the Centre ofBelt in all circumstances Refer
to Trouble Shooting for Specific Corrections
Load the material at the

specified rate within Belt Conveyor
capacity
Wherever surges in the

loading are likely a Hopper of adequate
capacity should be provided
Flow of the material from the

Hopper to the Conveyor is regulated
by suitable feed
Never over load the Belt

causing spillage either at the loading
points intermediate points or at the
unloading points
Over Load Protection
Before operating the Belt Conveyor make sure that the over load
protection system is in working condition The norow
type of over
load protection is to
incorporate a Shear pin device The Shear Pin
Device should be
regularly checked atleast on
monthly interval
ENrs GUIDE
STUI
PAGE
T P U7 OPERATION MAINTENANCE OF
MA TERIAL HANDLING EQUIPMENTS
Apart from incorporating Limit swithes Sway switches etc a inclusion

ofvibration monitoring at Belt Conveyor Drives and at critical bearing
locations are being practiced to day Ifthe vibration levels at any ofthese
location exceed the set limits a warning alarm shall be initiated If this
alarm is ignored and if the machine is deteriorate further the safety system
wiD give signal to shut off the machine those preventing a major break
down Ofcourse wherever such systems are existing detailed vibration
analysis shall be carried out and the exact defects and inaccuracies shall
be pinpointed The maintenance corrections can be incorporated at the
appropriate time before the equipment reaches unsatisfactory levels of

behaviour
d t
I
Good housekeeping is essential for dependable operation a v cv
maintenance A build up ofmaterial on the deck can brake and eventually

the return
stop idler rollers resulting in damage to belt Spillage on to
belt can also injure it as
lumps are squeezed between belt and pulleys
A build up ofsticky and frozen material on pulleys or idlers can cause belt
and other malfunctions that can damage a belt
misalignment
A carefully planned lubrication programme is very essential to achieve

trouble free operation ofthe Conveyor In aBelt conveyor there are no of
bearings especially in the Idlerrolls and they are to be properly lubricated
Free rotation of the Idler rolls are very essential in maintaining the belt
tension and in achieving minimum power required for the operation ofthe
Conveyor Lubrication of the Motor Bearings the Gear Box Bearnigs
also to
Bearings of the Head Pulley Bearings ofthe ofthe Tail Pulley are
be included in the essential part of the regular maintenance
The various maintenance actions are categorised as Daily Weekly Once

in 3 weeks Once in 5 weeks Once in 13 weeks and once in a year
S GUIDE
STUDENT
43
PAGE
T P 07
To check the function the

pin atthe operator drive This ill
remove
show whether the two sections ofthe shear pin device are free or
whether immediate checking and corrections are required for freeing
the pin sections when required
Never replace a Shear Pin with another pin having a higher rate
within the recommended value for a particular drive
lethe Conveyor is likely to be kept idle for a prolonged period the emptye
equipment should be operated at periodic intervals This will help in
recirculation of the lubrication and maintaining the equipment in good
I fUIU
ing ondition
2 6 MAINTENANCE
2 6 1 INTRODUCTION
Maintenance ofBelt Coveyors is a skilled

activity and have to be very
Periodic and systematic inspection ofBelt Conveyors
carefully planned
to cover
Drive Motor
Couplings
Reduction Gear Box
Head Pulley
Tail Pulley
Idlers
Loading and Unloading arrangements

Conveyor accessories
Take up units etc are very very important
The likely problems of Belt Conveyors are covered in detail in trouble

shooting and an interactive Computer Based Training module also has
been included on these aspects It is recommended to thoroughly learn and
practice the trouble shooting aspects in a systematic manner
STUOENrS GUIDE
PAGE
MATERJAL HANDLING EQUIPMENTS
can be
Non Jly the begining of a major problem in Belt Conveyor
precisely identified during the maintenance inspection but neglecting
such symptoms can lead to major break down
Inspection and Maintenance ofBelts is very important because damage

to belt cal result in totally down time of the Conveyor Therefore apart
from high cost ofthe belts the cost ofdown time has also be considered
in taking maintenance decision
results
Many major break downs and stoppages ofBelt Conveyors
of accidental
were
damage while loading and ingression offoreign materi

l I
such as steel parts spikes and similar materials entrained in the floor It I
is therfore es lJtiaj 10 have an effective coordination between operation
and maintenance to eliminate such possibilities
Before initialoperation ofa Conveyor on production runs there should

be careful and detailed inspection of the conveyor and all of its compo
nents Following such close inspection t runs should be made to allow
careful observation of actual operation before conveying material

During these inspections and test runs the alignment ofall the mechanical
belt on the carrying and
components and the operating alignment of the
return idlers should be checked
materials
Inspection should also establish that there are no construction
tools projecting members that can run tear or cut the belt when it starts
be installed such that they do not touch the
up Chute skirtboards should
belt The rubber edging strips onthe skirts should be adjusted so that they
rest only lightly on the belt surface Belt scrapers should be observed and
a final adjustment made if necessary
Modern electrical control systems an incorporate computers and other

automatic means for measuring performance and controlling such func
and material flow paths Sensors and
tions asweighing mixing blending
other devices for indicating maintenance requirements and unsafe condi
tions may be integral part of an electric control system
STUDENTS GUIDE
PAGE 46
l
T P 07
1 OPERATION
MAlNTENANCE OF
MA TERlAL
HANDUNG EQUlPMENTS
Module 02 BeJt Conveyors
Now the students can be

given various exercises by
length and by giving various tilt Some changing the Pulley
exercises can used to find out
the
angularity ofthe Pulley when the alignment is not
accurate
The same exercise can be given to students

to work out the
correct
alignment between Chain and
Sprockets in case of the Chain
Conveyor
A stuck idler under
high speed belt handling abrasive material will cause
its sheJl wear
presenting a knife edge Well trained
personnel would be
able to detect corresponding failure in such a case and
ma1function before any correct the
damage can OCCllr
I Tne
I
cost of the belt
represents a high proportion of the total
cost The belt is vulnerable conveyor
I
to accidental
Belt operation and maintenance
damage or acceJerated wear
deserve special attention in a
training good
prcgrl1 to
L minimize replacemem and
repair cost
Pneumatic wear or accidental damage may result from

improper grades sizes or volumes of
loading
Also
conveying material on to the belt
foreign materials such as tramp iron spikes timbers and the
like when entrained in
the flow can cause
expensive shut downs and
costly repairs
Before initial operation ofa

Conveyor on production runs there should
be careful and detailed
inspection of the conveyor and all of its
components Following such close
inspection test runs should be made
to allow careful observation of actual
material
operation before conveying
During these inspections and the alignment ofaU the
test runs
mechanical components and the operating
alignment ofthe belt on the
carrying and retum idlers should be checked
STUDENTs GUIDE
PAGE 47
T P un OPERATION MAINTENANCE OF
1
26 2 MAINTENANCE SCHEDULE
DAlL Y
1 Check the belt condition

sway cuts etc
2 Check for any abnormal sound from gear Box
3 Check the head pulley tail pulley and bend pulley
4 Check the Conveyor deck plates
5 Check the Counterweight over sleeve Pulleyfor proper belt tensioning

6 Check the feeding and discharge chutes for any blockages
j
WEEKLY
I
Check for Loose Belts
2 Check Motor condition
3 Clean Motor external
4 VerifY mechanical fixation
level probe
I
5 Check ictanpcae
6 Check Zero speed stnsor
7 Check Main Gear Box Oil Level
8 Pulley shaft and bearing

Check end
9 Check Conveyor belt damage
1 O Check coupling bolt bush
11 Check head pulley shaft and bearing
12 Check Gear Box Noise Temperature and Vibration
13 Check Snub pulley shaft and bearing

14 Check Tail pulley shaft and bearing
15 Check Tak UP pulley shaft and bearing

16 Check Vulcanized belt joint
I7 Look for counter shaft V pulley
IS Look for fluid coupling oil leaks
19 Replaceladjust skirt rubber

20 Checkadjust return idler scrapper
2I Replace damaged idlers
Tighten
22 loose belts
STUOENT S GUIDE
PAGE
OF
MAINTENANCE
TP L07 OPERATION
MATERIAL HANDLING
EQUIPMENTS
1
ONCE IN THREE WEEKS
1 Check Cooling Fan

2 Check Link Switches
3 Check Air Circuit Breaker
4 Check Local Control Station
switch
5 Check Belt driftsway
6 Check Zero speed switch
7 Cbeck Pull rope switch
8 Check Material sevisor
9 Grease Head pulley Bearing
10 Grease Snub pullev Bearing
11 Grease Bend pulley Bearing
12 Grease Tail pulley Bearing
13 Grease Take uP pulley Bearing
ONCE IN 5 WEEKS
1 Check cable glands

2 Check Equipment earthing
or position
3 Check oil circuit breaker
4 verify motor base
ONCE IN 13 WEEKS
1 Check FOB
2 Check Joint boxes
3 Tighten connections
4 Verify overload setting
ONCE IN 23 WEEKS
1 Check main Bus bar

2 Check Bus bars
3 Check Sub switch board
4 Clean Motor lntemals
oil
5 Analyse Gear box
STUDENTS GUIDE
1
PAGE 49
T p L07
OPERATION
MAINTENANCE OF
MATERIAl HANDLING
EQUIPMENTS
1odule 02 Celt Conveyors
ONCE IN 52 WEEKS
Refill grease
2 Chain Main
gear box oil
3 Carry out
maintenance corrections as
identified from condition
monitoring
27 BELT
SPLICING AND ULCANISING
27
1INTRODflCTION
Conveyor Belts are generaJ1y

ofthe spliced with staggered
corresPOnding fabric plies of the two belt endssteps abutment and
ofbelt
splicing VUlcanising are Different methods
1 Hot Vulcanised Splice

2 Cold Vulcanised Splice
3 Metal fastener
4 Wire Hook
type fastener
5 Bolted Plate
type fastener
The different methods

are illustrated in 241
Fig
Hot Vukanised Splice
Hot Vulcanised Splice is preferred

for making Conveyor belt endless
because ofthe
fOllOwing major advantages
I It lasts longer It does not fail
2 It abruptly
maintains a continuous smooth
surface on the belt face 5
and back
forming a smooth endless band It does not let
any material to
through seep
3 It travels well over the idlers
and the pulleys
4 It permits the belt without wear tear
cleaners magnetic
separators ploughs and
scrapers to work
5
smoothly
It prevents
any ingress of moisture or
6 dust through belt
Maintenance and ends
7
cleaning ofthe joints are negligible
Develops nearly the strength of the belt itself
8 Reduced noise as a result ofan almost
9
Economises on maintenance homogeneous surface
and aning
cle
by preventing
through fastener gap spiUage
STUOENrs GUIDe
PAGE 50
107 OPERATION MAINTE ANCE OF

T P
MATERIAL HANDLlNGEQlllPMENTS
Module 02 8elt Conveyors
disadvantages of Hot vulcanising

are
The main
when compared to cold vulcanising

More labour is required
Hot vulcanising
2 It takes more time to complete
Cold Vulcanised Splice

is very
out Cold vulcanising
The process of carrying
procedures and that the application of high
similar to that of Hot vulcanising except solution
time are not involved The
temperature and prolonged curing
from that used in Hot vulcanising and
used in Cold vulcanising is different
Cold vulcanising is preferred today
for most practical purposes
the Cold Vulcanised
Compared to the long life ofHot Vulcanised Splice
Splice will give lesser life
2 7 2 TYPES OF SPLICING
1 Stepped biased type

2 Splice with single bias
3 V shaped Splice
4 W shaped Splice
5 Multi point Splice
In order to achieve
in the entire belt
The Splice is the weakest point
life of the joints stepped biased type splicing
higher strength and longer
is preferred
are two alternatives for carrying out a splicing operation

There
the joint
a Running the splice with
belts or conveying systems with relatively small

For strongly tensioned
laid
pulleys the joints are
in the does not press against the joint

The flexing stress occuring pulley
fabric joint open
and has no point of action at which to press the top
STUDENTS GUIDE
PAGE 51
T P L07
fA TERIAL HANDLING EQUIPMENTS
b Running the splice counter to the joint
Ifthe belt is fitted with

heavy action scrapers it is advisable to run the
splice joint ofthe bottom cover in the
The scraper then slides over
driving direction ofthe belt
the splice without
to meeting a point at which
separate the fabric plies
2 73 EQUIPMENT AND TOOLS
REQUIRED FOR SPLICING BELTS
I Portable Electric
VuJcanising Press
2 Two
moulding irons of sufficient
length
3 Two carpenter
joiningclamps to apply
pressure on the moulding
irons
placed along the edges of belt
4 A chain block or
pull lift and tackle for tensioning the belt
5 Two angle irons or wooden
clamps for lashing the belt
6 Wooden
planks give a firm working area
to
7 Heat resistant leather
gloves to handle the vulcaniser
8 A set of
spanners to tighten the vulcaniser
9 Steel
tape of2 m length
10 Right angle steel
square with atleast 1 5 m long side
II Rubber
cutting knife
12 Ply cutting knife
13 Screw Driver at least 400 mm long
14 Vee Knife
15 Wire Brush
16 Pincer
17 Rubber j
cutting scissors
18 Hand roller
19 Serrated
edge wheel
20 Pricker or
sharp pointed anvil
21 Soft hair brush
22 Paint brushes 50mm wide
23 Emery cloth
24 Naphtha pads
25 Grease proof paper These are placed on the channels ofthe
before curing to prevent the rubber from splice
adhering to the press platens
26 Solvent
Naptha used for cleaning
27 Conveyor Belting Solution
STUDENTS GUIDe
PAGE 52
OF
OPERA nON MAINTENANCE
T P L07
EQUlPMENTS
viATERlAL HANDLING
Belt Conveyors
Module 02
carcass after cleaning

the fabric plies or
This is applied by brush over during the splicing
which is removed
in order to replace the frictioning
belts
or repairing of conveyor
28 Insulation Compound
solution in order to skim coat

This is applied over the conveyor belting
their adhesion
the plies and increase
29 Cover Compound
and is used to build up the
This is requiredreplace rubber cover
to
covers
in splices and for replacing damaged
face and back cover channels
FOR BELT SPLICING

1 PRELlM
2 7
ARY PREPARATION
the horizontal portion ofthe conveyor

1 Select a suitable location on
where it is covered
is at its minimum position
2 Ensure that the take up for overlap
has sufficient length available
3 Ascertain that the belt
be on the top
Canying side should in the selected location and
fit
atleast six sets of idlers
4 Remove
the area to be spliced
clamps on the belt beyond and pull the
one clamp to the structure
5 Tension the belt by anchoring
in order to reduce the stretch
block or pull lift
other clamp with achain
has been completed
in the belt after the splice C
thermostat is set at 1440
6 Ensure that the vulcaniser the ends are
that the belt is not wet and
i of a used belt ensure
7 n case
fit for splicing
BELT SPLICING
5 PROCEDURE OF
line of the belt of
2 7
and mark the true centre
1 Cut the belt end square line for all other
will be used as a datum
about 3 m length This
Belt edges should not
is shown in Fig 2 15
measurements This
be used for reference denote the
mark a base line
to
the belt centre line
2 At right angles to
splice
25mm The method to calculate
limit of the splice length plus
Table 4
length is given in
GUIDE
STUOENrS
Ii
PAGE 53
Tp L07
OPERATION
MAINTENANCE OF
MATERIAL HANDLING
EQVCPMENTS
PlM
TOTAL SPlICE LENGTH
1
8IAS Ca
i
I
i
oJ
5 s s
Note
Based Upon an angle 9 of 26 12 Bias 8 Q SWg can
1fied to correspond be
with the platten angle of
ronmboidaf shaped presses
SECTION OF A STEPPED
BACK END
OlRECTIOH OF BELT TRAVEL
FIG 2 13
STEPPED BIAS SPLICE
MUlTIPlY EXAMPlE
STUDENTs GUIDE
PAGE 54
MAINTENANCE OF
T P un OPERATION
Table 4 Cakulation of Splice length
S Insulation
Belt Rating TotalSplice Step Length
mm Compound
Length rom
150 0 7
0 5W 325
3 5 3
175 0 7
400 3 5W
O 375
200 0 7
0 5W 425
3
500
250 0 7
630 3 5W
O 525
200 0 7
630 4 5W
O 625
n V I
800 4 O 5W 775 oJ
300 1 05
5W
O 925
I 100014
5W
0 1165 380 1 05
1250 4
300 1 05
1250 5 0 5W 1225
380 1 05
1400 5 O 5W 1545
450 40
1
600 5 5W
0 1825
450 40
1
1800 6 0 5W 2275
W Width of belt in mm
from the formula

The splice length L may also be obtained
L W 2 N l S
Where L Splice length rnm

W Width of belt mm
N Number of plies
S 150 rom for fabric 28
and
CN 45
Fabric 32 eN 40
200 mm for fabric 36 CN 50
250 for fabric 42 eN 60
rom
300 mm for fabric 48 eN 75

350 rom for fabric CN 00
STUDeNTS GUfDE
PAGE 56
TP 07
1
MATERIAL HANDLING
EQUlPMENTS
3 The base line should be

marked on the face COver
for the
and
on the back cover
for the leading end
4 Mark a bias trailing end
length along the belt edge from one
edge of the base line
Bias length LA 0 3 x Belt width
5 Join this marked

point to the other end of the base line
for the splice line to provide
6 Mark aline parallel to this
for a width of25mm inward
the and
cover rubber in this
25mm width
strip off
7 Remark the
spJiCe Jinf on the outer ply nd
wide emove 1cthci
l
strip ofcover rubber 25ii
outward the
8 Cut splice line
through the first ply along the splice line
cutting knife using the single ply
9 Adequate care should be taken
destroy
the fabric which is to r main
10 Remove the first
as
not
to cut
deeper than required and
part of the splice
ply and rubber cover rubber
outwards of the splice
I
line preferably in thin
J 1 Mark bias and strips
length step length along the belt
line and draw the edge from the base
step line
12 Now cut the
second ply Care should be
taken not to cut
13 Mark the other
steps from the base line in the same deeper
14 Cut way
through the last ply and COver rubber at the eod
of the splice to
make the last
step 12mrn longer than the nonnal
15 Remove rubber step length
COver for a
strip of38 mm width on the reverse
side ofthe belt
16 Repeat the
stripping down operation for the reverse
end side on the other
commencing from marking the bias length
from the base line along the belt edge
17 The steps for splice should always be prepared from the base line
across the belt
18 The
edge of each step must be measured from
the base line and not
from the edge of the
previous step
19 Clean the surface of
the ply steps without
using coarse emery cloth and damaging the fabric
20 Care should be
light wire brush
taken to not let the rubber
plies to come off impregnation within the
STUDENTs GUIDE
PAGE 66
MAINTENANCE OF
T P un OPERATION
Belt Conveyors
Module 02
to the splice to ensure satisfactory

21 Buff the cover rubber adjacent
bonding at both
ends are clean and dry paint steps
22 After ensuring that the step
of conveyor belting solution
ends of the belt with three coats
with the next coat
before proceeding
23 Allow the first coat to dry on the
over the exposed steps
24 Lay a layer pfinsulation compound
face side leaving a channel
taking care to avoidany
crease
with a roller
25 Roll this down in position
overlap and trapped air
insulation compound
26 Finish by edge wheeling the
end to it
the prepared belt end and fit the other
27 Layout
matchmg the two ends leave the alkathene in
protective I
28 Whiie
so that the surfaces do not adhere
place and the fabric steps
are
29 Make sure that the splice is properly aligned

not overlapped
stepsfabric
30 Do not leave gaps between and remove
matched turn back one half
31 When the splice is perfectly before
down the other half of the splice
the alkathene Then roll
and mating the two halves
removing the alkathene last ply on the face
in and trim off the overlapping end of the
32 Dig
and back to make a close fitting joint
the channel in covers
the edges oftbe rubber along
33 Apply solutions to in the requisite
mm insulation compound
34 Insert a strip of 0 35
width along the channel of requisite
and fill with cover compound
35 Apply a coat ofsolution
gauge
36 Roll thorol ghly and prick the whole splice area
knife
trim the joints with the trimming
37 Finally edge wheel and
area with hand roUer
38 Roll dawn the whole splice the
from the conveyor and position
39 Remove the working surfaces
vulcanising press
THE SPLICE
2 7 6 VULCANtSlNG
taken
than one charge care should be
if the belt is to be cured in more
channels are vu1canised in one single cure

to see that the
S GU1DE
STUOENT
CI
PAGE 57
TP L07
MATERIAL HANDLING
EQUlPMENTS
Ensuf that first and last

charge at the ends of the
mm inside the platens of the splice are atJeast 75
vulcaniser and an
mm exists
between two consecutive adequate overlap of75
carried out in the charges The Vulcanising ofsplice is
sequence given below
1 Place
moulding irons along the
edges ofthe belt and
against the belt press them
sufficiently to make contact with
the belt
of a joiners by means
clamp and tighten these clamps
2 Position the top section of the press and
ensuring even carefully tighten the press
pressure
3 Th minimum curing pressure on the belt surface should be 7

kgcm2
4 After
curing one charge open the at
the recommended
and position the next temperature
charge providing 25 mm
previous one overlap on the
5 Repeat for further charges
6 Once
splicing has been cured examine for
for excess defects and trim the
spew edges
7 Re instaIJ the idlers and release the belt

after one hour
28 7
PRECAUTIONS TO BE TAKEN
WHILE SPLICING
1 Take care while using ply cutting knife not to cut
intended deeper than
2
Thebutnng operation should be done
and the rubber carefully so that the fabric
impregnation between the plies are not ply
else it would reduce damaged or
the strength of thl
splice considerably
STUDENrs GUIDE
pAGI A
MAINTENA CE OF
TP L07 OPERA nON
1 MA TERlAL HANDLING
EQUlPMENTS
Module 02 Belt CODveyOrs
for the conveyor

fonned due to insufficient time
3 Blisters are
belting solution to dry and moisture

examined to
and the area carefully
4 Blisters should be cut open be cleaned
blisters Then the area should
determine the cause of two coats of
and after it dries up apply
thoroughly with Naptha after the
solution Apply the Second coat only
conveyor belting
first has dried completely
be
blistered then only the cover part should
S If only the cover is
It should be replaced by cover compound by building
removed
required thickness
up the
the area should be cut open longitudinally

6 If theblister is in the carcass cloth and
the surface will emery
and dried thoroughly Rough up
coats of conveyor belting
so utio aUoVving each coat to
apply two
and cure at recommended
dry thoroughly Then close the opening
temperature and pressure
not fitted tightly or if

the pressure
7 When the moulding irons are the splice
the edges of the belt along
is insufficient during curing and
has to be removed carefully
porosity
becomes porous This
replaced with new compound
must be
found to be porous the channel rubber
8 If the channel is
for repairs
r rnoved and treated
FOR BELT REPAlRING

2 1 8 PROCEDURE
fabric will
are damaged in ser ce the exposed
When conveyor belts
deteriorate if left unattended
should be repaired
obtain maximum belt
life damaged covers
To
immediately
belt
should be followed to make
on the spot conveyor
The following steps
cover rep31rs
GUIDE
sTlJDENTS
PAGE 69
T p L07 OPERA TION

MA TERlAL
MAINTENANCE OF
HANDLING
EQUIPMENTS
ModuJe 02 BeJt Conveyors
I Cut around the area to be repaired with rubber

remove all
dirty loose cover cutting knife to
2 Take care nat to

cut into outer ply of
3 carcass
The cut should be circular or ova in
4 Take care to see that two shape
cuts never meet
ata point
and form
split in the cover
a they do not cross
5
Using pincers remove the
defective portion of the rubber COver
This must be done
without loosening the rubber
area to be cover outside the
stripped
6 When large areas are
to be
removed divide the strips
and remove the
strips one at a time longitudnally
7 Clean the exposed surface
with solvent
Roughen the exposed carcass surface andnaphtha
8
level cut
emery cloth or wire brush edges with No 2
9 See that the carcass
is free from
moisture otherwise
surface under a expose the
spot vuJcaniser for about
10 Cool half an hour
and apply twcoats of conveyor
each coat to belting solution allowing
dry for atJeast 5 minutes
I Cut a
patch ofCOver to correct
the underside with shape Bevel the edges and
one paint
coat of
12 When solution on conveyor belting solution
carcass and
of patch to belt and patch is dry fit solutioned
roU down well surface
13 with hand roller
Build up the COver
to the required
and prick it thickness edge wheel each
layer
14 Trim offany excesses at the joints with hand
knife and prick
thoroughly patch
15 Cure in press for
specified time
a Cover repairs
upto and including 6 0mm thick 40
b Over 6 Omm
thick 55 minutes minutes
STUDeNrs GUIDe
PAGE 60
OF
OPERATION MAINTENANCE
T P L07
odule 02 Belt Conveyors
2 8 SAFETY
to avoid accidents while

Some of tbeImportant Safety procedures
are given below
working with belt conveyors
above its conveying
1 Should not load the material on the conveyor
capacity
which
the material on the belt conveyor for
2 It is good to convey
it is designed and also at specified speed
by trained personnel one who has I

3 Conveyor shouid be operated only
knowledge on safety points
4 All the operators of conveyor

instruments and how to operate
must
them
know about the safety and alarm I
boxes must be
alarm instruments and First aid
5 Safety equipments the place must
known to all persons And
located in places which are
at the time of emergency
be easily accessableto all persons
fluid couplings and balancing

6 While lubricating puUeys idlers bearings
should be stopped
the belts the conveyors
the above
be provided while carrying out
7 Caution boards should
works
whether above
or walk across the conveyor
8 It is dangerous to travel covers
to use cross
it is running It will be better
or below it while
for this purose
ladders
and provided
in Belt conveyor
of Belts conveyor
9 While walking along the sides hands legs
always ensure that your
Gallery for Inspection purpose and idlers No
are not in touch with the moving belts
head and hair
work
loose Garments to be worn during
STUOENTS GUIDE
PAGE S1
T p to7
OPERA nON
MAINTENANCE OF
MATERIAL HANDLING
EQUIPMENTS
Module 02 Belt
Conveyors
IO In both the walls and

stair cases of
the
Protrusions of iron rods conveyor gallery small
should be
be kept clean eliminated The floors
by removing shoUld
spillages such as clinker
limestone etc
II The
dismantled acceSSOries such as
safety guards etc should couplings motor gears
be replaced pulleys
places after repair work properly in their respcctive
After
conveyor should be started ensuring the above things
again only the bell
12 The
feeding points should be
and personnels provided with
proper caution boards
working there should be
safety equipments given helmets and other
13 The Belt
conveyor gaUery should be well
burning lamps should be illuminated The non
replaced with new ones
14 It is
immediately
advisable to provide caution boards for
danger zones etc operarion lures
proce
15 The
safety and cautions
equipments should be
I
everyday and the damaged ones inspected properly
should be rectified
16 The
immediately
idlers of tbe belt
conveyor shouid be lubricated
lubricating material according to the supplier s proper
ith the
it may lead to faster specifications Else
Wearing of idlers and cause
accidents
17 The
moving machineries should
be covered with
safety guards j
18 The
pull cord switch can be
used in case
and it should not be of
used emergency sitUation
unnecessarily
19 While cleaning idlers
and
instead of using cotton pulleys specified cleaners can be used
Wastes
20 We should avoid running on

I I is stair cases of
advisable to conslruct bell conveyor
hand rails on both sides ofbell gaileI
conveyor
STUDENrs GU10E
ir
PAGE 62
T P 07
1 OPERA TION MAINTENANCE OF
21 While carrying out the maintenance work the tools used should not
be sent through the moving conveyor it can leads to greater accidents
22 While loading on belt conveyor feeding chute care should be taken

to avoid tools such as hammer crowbar etc from getting carried
with the material Otherwise it may cause severe damage either to
human life or equipment
24 Skirt board rubber be used

can as a
cushioning material at feeding
points instead of using steel plates
25 The safety equipmenb h

su Anti run mechanism and Ratchet and
I Pawl mechanism should be checked properly for le

their in good
operating condition before running the conveyor
26 While doingwelding or gas cutting on belt conveyor steel structure

one should be very careful as the belt material is
easily inflanunable
While doing maintenance work standing below the verticcl gravity
tensioning unit we have to be very careful It should be kept in mind
that the units like pulleys and weight boxes are movable up and down
while the conveyor is running
27 The switches like limit switch belt sway switch starting and
stopping
switch and mechanicalelectrical interlocking switches should be
checked periodically to know whether they are in good operating
condition
t
28 It 111 be safe to switch offall the conveyors even if one

conveyor
is because of break down in a system
stopped
29 Working with loose dresses or uncombed hair is dangerous in these

it hazard
conveyors as can cause a safety
S GUIDE
STJDENT
PAGE 63

MATERIAL HANDLING
EQUIPMENTS
2 9 AUXILIARY EQUIPMENTS
2 9 1 MAGNETIC SEPARATOR
This consists ofa simple collector ring assembly connected to the axles
ofa rotating pulley Direct current is supplied to the magnetic coils in
the pulley This
produces electro magnetic current and attracts any iron
or steel
particles moving on the conveyor belt and thus prevents any
damage to the belt A typical electro magnetic pulley is shown in fig 2 14
2 15
Points to be con dered while selecting a

magnetic separator are
I of material
Type
2 Size of material I size
lump
3 Condition of material to be handled
4 Type ofconveyor belt
5 Size of conveyor belt
6 Type of tramp
7 Available current
supply
2 9 2 ROTARY TABLE CONVEYOR
This consists of rotary table driven

by an electric motOt The chute of
the hopper is kept just above the table but they can be varied
by changing
the distance between the table and the bottom
edge of the chute by
telescopic arragements The feed rate can be varied by the changing speed
of the table or
by changing the
scraper position The capacity of the
feeder can be estimated from the height ofthe chute above
the table the
angle of repose and the speed of the table A rotary Conveyor is
Illustrated in Fig 2 6
STUDENT S GUIDe
PAGE 6
T P un OPl RATION MAI Tl NAN

l 0
MAn RlAL HANDLING EQUIPl
1ENTS
lodule 02 Belt Conveyors
ex
0
a
w
V1
1 j 0
41 1
r
I
W
I I
e
1
Z
Q
e
Cot
4
s
o a 1
t
l 1
0
I I
71 i
t f
I
4
1 I
4 N
I C
u
1
TRAINER S TEXT BOOK

PAGE 65
Tp L07
MA TERtU
HANDLING EQUlPMENTS
Module 02 Belt ConVt ors
co
o
co
N
o
Cl
oct
I e
0
en
C
W
z
0
w
J
LU
0
I
0 I
I C
0 z
W
J
W 0
0 W
0
3
l
C
z LO
f
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J
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w
lr tL
RS
I
STUDENTS GUIDE
PAGE 66
OF
OPERATION MAINTENANCE
TP L07
f I
FIG 16
2 Rotary Table Feeder
L 07 02 85
STUDENTS GUIDE
I
PAGE 67
Tp 07
1
OPERAnON
MA1NTEN CE OF
MATERIAL HANDLING
EQUlPMENTS
MOdule 02 Belt
Conveyors
2 9 3
VIBRATORY FEEDER
The typicaJ
Operating characteristics ofthe
Vibratory feeder are
1 Low amplitude
I to 34
mm
2 High frequency upto 3000 per
minute
The
Vibratory feeder is driven
by
a Crank and
rotating rod
b Electro
magnet A
Tht rough is
I
suspended on drive and
supported by string bar
I
The
Vibratory fueders are used to feed
materials
etc A mall lumps
typical vibratory feeder is minimum lumpy
shown in fig 2
q
The
advantages of the Vibratory
Feeder are
1
Arching tendencies are reduced
2
EconomicaJ
3 Flow rate can be controlled
effiCiently
2 9 4
OSCILLA TINe FEEDER
The
operating principle ofan
Ihal of an Oscillating Feeder is sligbtly differeD
Oscillating
conveyor When Ihe table from
materiaJ is carried moves forward the
aJong by friction Certain
hopper fills the free amOunt of
material from the
space below the table
shown in fig 2 IB A typical
oscillating feeder is
There are two

types of
Oscillating feeder
J
Horizontal
2
Slightly declined table
STUDENT S GUIDE
PAGE 68
T P 07
MATERIAL HANDLING fJIPMENTS
e I
L
t
I
J I
t
I
0
I t
t
It
1
J
FIG 2 17
VIBRATORY FEEDER
L 07 02 06
I I
i
I
I
It
I
r t
J
t
I
1
I t
1 t t 1
I L 1
1
1
I
1
1 4
t
J
e I
1 1 1 J 1 I
I
I
1
I I
11 I
1
I
FIG 218
Oscillatory Feeder
L 07 Z 07
O
STUDf NT S GUIDE
I
PAGE 69
TP 07
1
OPERATION MAIN
MA TERlAL rENANCE OF
HANDLING
EQUlPMENTS
The table is
usually started by standing rollers
rods or
ay be
on
suspended
The advantages of Oscillating feeders are
I Simple in construction and Operation

2
Relatively Inexpensive
These feeders are

not used for
feeding abrasive and
as coal
lumpy materials such
2 9 5
BELTWEIGHER
29 5
1INTRODUcnON 1
The conveyor scaJes
are mstaJled on a
of a belt rectanguJar Or
incJined section
conveyor
The feeder scales
consist ofthe
fOHowing
J
Platform with
two
2
weighing roUers
Bearing one side on a knife
edge the other on the rod
weighing mechanism suspended
3
Weighing and Recording mechanism in a
4 enclosed
Supporting column case
5 Drive Unit
The belt
weigher is used to weigh any bulk
This is a rugged materials thai can
system and suitable ith be conveyed
A typical belt continuous weil
weigher is hing operations
illustrated in fig 19
2
29 5 2
PRINCIPLE OF OPERATION
The belt
weigher works on the principle that
rectified ifthe live
by the speed at that instant it weight on it is
at that gives the rate ill tonnes
instant This is per hour
tonnes ofthe material
continuously added to obtain the
total
passing over the conveyor Const weight in
important factors to be considered are quently the most
STtJDENTS GUIDE
GE 70
TP L07 OPERAnON MAINTENANCE 01

MATERIAL HANDLING EQUIPME rs
I
I
I
I
I
I
w
en
en
STUDENrS GUlt E
PAGE 71
TP 07
1
Instantaneous weight on the weigh bridge
2
Pulley speed
2 9 53
MAINTENANCE OF BELT WEIGHER
WEEKL Y
Clean the weigh bridge weekly

More frequently if the weigh bridge is located in a dusty area
Build up ofmaterial on the
conveyor strings close to the suspended
idlers may cause weighing errors
by preventing free movement of
the weigh bridge This build
up must be removed regularly
Check the bent pulley for
any material build up
MONTHLY
Check the weigh bridge alignment

Check cable assemblies
Burge and refill the bent pulley with coarse bearings
HALF YEARLY
Inspect major parts pivotareas cable assemblies bent

pulleys etc
tacho generator
on
anticipating potential problem prior to failure
Take corrective action
2 10 CONCLUSION
The belt conveyor

being one of the very important material
handling
equipments in a cement plant All relevant aspects have been covered in
this module
The component parts and accessories

of belt conveyors are to be
familiarised buy the operators and maintenance
staff
Higher levels of knowledge

including conclusion of belt tensioning has
been included so than in
an
depth understanding of the equipment is
feasible
STUDENTS GUIDe
PAGE 72
T P L07 OPERATION MAINTENANCE Of

are given significant

The operation and maintenance of belt conveyors
that a through learning and practising the
importance and it is expected
skills are required after completing this module
ofbelt conveyor is very

The specific do s and don ts and trouble shooting
sufficient length ofthe module has been devoted
very important and hence
for this part
A specific skill on belt splicing and ulcanising should be an integral part

therefore the
of any maintenance programme of belt conveyors and
coverage of this skill has been done very carefully
STUDENrS GUIDE

M 02 - Belt Conveyors

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PAGE 1

T P L07 OPERA nON MAINTENANCE OF

Module 02 Belt Conveyors

Course Name OPERA nON MAINTENANCE

Course Number L07

Module Title BeltConveyors including Magnetic

Objective Participants will be able to

Identify different components ofBelt

Learn the operating principles

Learn maintenance aspects of belt

conveyors with respect to

Troubleshooting of Belt Conveyors

Belt splicing and vuleanising Video

Safety aspects Video

Understand the operation and

OPERA TlON MAINTENANCE OF 1

Module 02 Belt Conveyors

Duration 125 days Ten sessions of45 Min each

including video and CBT

Module 02 Belt Conveyon

27 BELT SPLICING VULCANISING 49

Module 02 Belt Conveyors

In this session we shall cover theoperation and maintenance of Belt

b Various parts ofBelt Conveyor

I e Belt Splicing and V ulcalising

CBT dealing with of trouble shooting of belt conveyor system

Belt Conveyors have attained a

materials due to economy safety of operation reliability versatility and

Belt Conveyor is an endless moving belt for transporting materials

inclination either up down

T P L07 OPERA nON MAINTENANCE OF

Module 02 Belt CODveyon

In a process Industry like Cement Plants

22 1 Advantages of Bdt Conveyors

Bdt Conveyor has the advantages of simplicity of constuction high

a Coaveying ofvariety ofMaterbls

b Wide range of Capacities

Belt Conveyors of handling

t Adaptability to path of Travel

The Belt Conveyor system provides the means of conveying materials

Module 02 BeJt Conveyon

T P L07 OPERATION MAINTENANCE OF

Module 02 Belt Conveyors

The Belt Conveyors are capable of transporting material generaJly

Angle of Repose It is the angle of the sloping surface of material

Angle of Surcharge The angle of surcharge of a material is the

Very free Free flowing Average flowing Sluggish

50Angle of 100 Angle of 200 Angle of 250 Angle of 300 Angle of

00 190 Angle 200 290 3 0 340 350 390

T P L07 OPERATION MAINTENANCE OF

Module 02 Belt Conveyors

the Material Institutions the ability

to flow from the Bett or in the chute easily

the material is classified

2 3 1 SELECTION OF BELT CONVEYOR

while choosing belt

Spillage of material both at feeding point and discharging point have

design of chutes lead to poor performance of belt conveyor

to carrying side ofbelt and

damage to return idlers

Module 02 Belt Conveyors

24 1 BELT CONVEYOR COMPONENTS AND