Methods (India) Private Limited

Methods for Better Material Handling Methods

 OPERATION AND MAINTENANCE
MANUAL FOR

COAL HANDLING SYSTEM

(VOLUME I OF II)

METHODS (INDIA) PRIVATE LIMITED,

BANGALORE.

PROJECT : COAL HANDLING SYSTEM FOR 1x30 MW CPP, DAHEJ.

CLIENT : M/s. FILATEX INDIA LIMITED.

P.O No. : MIPL / FIL / Q-19082 REV-0 DATED 24.12.19

 CONTENTS

SECTION DESCRIPTION

Section-1 Scope of Supply

Section-2 Technical Specification

Section-3 Drawings

Section-4 Trouble Shooting & Maintenance

Section-5 Preventive Maintenance

Section-6 Lubrication Schedule

 SECTION 1

SCOPE OF SUPPLY
.1 SCOPE OF SUPPLY:

- 1 No. 800mm wide Belt conveyor BC-1 having profile length of 54.64 meters including Drive,
Belt, all type of pulleys, all type of idlers, bearing assembly, discharge chutes, take-up assembly,
support frames, scrappers, stringers, short supports, head end, tail end, Drive Base, safety
switches etc.

- 1 No. 800mm wide Belt conveyor BC-2 having profile length of 63.36 meters including Drive,
Belt, all type of pulleys, all type of idlers, bearing assembly, discharge chutes, take-up assembly,
support frames, scrappers, stringers, short supports, head end, tail end, Drive Base, safety
switches etc.

- 1 No. 800mm wide Belt conveyor BC-3 having profile length of 71.27 meters including Drive,
Belt, all type of pulleys, all type of idlers, bearing assembly, discharge chutes, take-up assembly,
support frames, scrappers, stringers, short supports, head end, tail end, Drive Base, safety
switches etc.

- 1 No. 800mm wide Belt conveyor BC-4 having profile length of 93.03 meters including Drive,
Belt, all type of pulleys, all type of idlers, bearing assembly, discharge chutes, take-up assembly,
support frames, scrappers, stringers, short supports, head end, tail end, Drive Base, safety
switches etc.

- 1 No. 800mm wide Belt conveyor BC-5 having profile length of 17.20 meters including Drive,
Belt, all type of pulleys, all type of idlers, bearing assembly, discharge chutes, take-up assembly,
support frames, scrappers, stringers, short supports, head end, tail end, Drive Base, safety
switches etc.

- 1 No. 800mm wide Belt conveyor RBC-1 having profile length of 54.86 meters including Drive,
Belt, all type of pulleys, all type of idlers, bearing assembly, discharge chutes, take-up assembly,
support frames, scrappers, stringers, short supports, head end, tail end, Drive Base, safety
switches etc.
 SECTION 2
TECHNICAL SPECIFICATION
GENERAL:
The length of the conveyors indicated in the specification are drive pulley center to discharge
pulley center (c-c) distance. The length and lift of the conveyors are based on the design
parameters and also by considering the dimension and arrangement of equipments.
The belt and equipments are designed by considering maximum conveyor capacity to be
conveyed. The maximum angle of inclination of conveyor belt is 17o to horizontal. The belt
conveyors and accessories are suitable for continuous operation under severe dusty working
condition.

BELT:
The belt is of Nylon-Nylon type (800 B.W) with suitable top and bottom rubber cover. The
number of plies and thickness of cover are suitably selected depending upon the load and
belt troughing. Belt joints should be Vulcanized at site. The rating of the belt is such that the
maximum tension induced in the belt does not exceed 80% of the maximum recommended
belt tension. The rating and duty conditions have been decided on the maximum tension
anticipated in the belt. The safety factor considered is 10.

IDLERS:
The idler assemblies for belt conveyors are Base angle type. Rollers are made of ERW ‘B’
Class heavy duty pipes. The idler rollers are fitted with deep groove ball bearings, which are
seize- resistant and life long lubricated. The shafts are of EN-8.
 CARRYING IDLERS:
Carrying side of the belt is supported by carrying idlers. This idler is of three roll
construction. The two outer rolls are inclined upwards and the center roll is horizontal.

 RETURN IDLERS:
Return side of belt is supported by return idlers. This idler is of single roll
construction.

● IMPACT IDLERS:
This idler is provided with closed spacing at loading points. This is nothing but a
carrying idler provided with rubber rings to take care of the impact due to loading.
PULLEYS:
The conveyor pulleys are of welded steel construction with closed ends. The pulley
diameters are designed for maximum belt life and confirm to IS 1891(Part I) & IS 8531
specification. The pulleys have self aligning double row spherical roller bearings / double row
ball bearing with adaptor sleeve and provision for grease lubrication through grease nipples.
The entire assemblies of the pulleys are balanced. 12mm thick Diamond groove rubber
lagging is provided for head pulleys and for 10mm thick diamond grooved rubber lagging is
provided for tail / take-up / snub / bend pulleys.
 HEAD PULLEY:
The pulley at discharge end of the conveyor is called as head pulley. This also acts
as drive pulley. Invariably this pulley is rubber lagged for better traction.
 TAIL PULLEY:
The pulley at the loading end of the conveyor is called as tail pulley.
 SNUB PULLEY:
This pulley placed near head pulley is called snub pulley. It keeps the wrap angle
between belt and head pulley high.

SCREW TAKE UP / VERTICAL GRAVITY TAKE UP (VGTU):

Take up is provided to ensure the proper amount of slack side tension at the drive pulley and
to insure proper belt tension at loading and other points along the conveyor. The required
amount of belt tension can be maintained by adjusting screw in case of screw take-up or by
adding weights in case of VGTU.

SKIRT BOARD:
Skirt boards are provided to retain the material on the belt after it leaves the chute and until it
reaches belt speed. It also avoids the spillage of the material at feed point. Side and rear
plates made of 6mm thick MS plate with 10 mm thick single ply rubber & 3.15mm thick top
cover plates.

DECK PLATE:
3.15mm thick M.S deck plate provided at conveyor feeding point only to avoid spillage of
material.
BEARINGS:
All bearings are of antifriction type and self aligning in nature. The bearings have effective
labyrinth and dust cover. The bearings are selected for a minimum working life of 40000
hours.

PLUMMER BLOCKS:
Plummer Blocks are made of cast iron to IS 210/low carbon steel to IS1030.The housings
are machined to micron tolerances and hence needs careful handling while fitting/removing
the bearings.

BELT CLEANERS:
 EXTERNAL SCRAPER:
The Primary Scrapers are of segmented type with multiple scraping blades to cover the
effective width of conveyor belt. Each blade to have individual sprung back action provided
by a rubber elastomount to achieve superior cleaning effect and to safeguard the belt. The
metallic blades are of high grade tool steel material. Deflector plate of SS material is
provided on both sided of the rubber elastomount to shield the same from dust as well as
guide the scraped material to the discharge chute. The design of the assembly is modular for
individual replacement of Blade tips, Deflector plates, Rubber Elastomount etc. with ease
during maintenance.

 INTERNAL SCRAPER:
This is used to clean the return side of the belt. It is ‘V’ type and placed near Tail
pulley.

HOLD BACK:
The inclined conveyors may tend to move down due to the weight of the material on the
conveyor belt. To avoid this Internal Hold Back are provided in the Gear box. The Hold back
will allow the shaft to rotate only in one direction.
SECTION 3

DRAWINGS
 SECTION 4

TROUBLE SHOOTING & MAINTENANCE

 Trouble Shooting & Maintenance of Belt Conveyor :
COMPLAINT PROBABLE CAUSE
1. Belt runs off at a. Low tension.
tail pulley
b. Idlers on return side
near tail pulley out of
square with centerline of
the conveyor.
c. Improper loading.
d. Frozen idlers
e. Material build up on tail
pulley
2. Belt runs off at a. Idlers on carrying side
head pulley near head pulley and /or
head pulley out of
square with centerline of
the conveyor.
b. Head pulley lagging
worn out
c. Material build up on
head pulley
3. Entire belt runs a. Side loading and /or
off at all points of improper loading
the line.
b. Idlers /pulleys, out of
square with centre line
of the conveyor.
c. Material builds up on
idlers and pulleys.
REMEDY
Increase tension by adjusting take- up.
Re –align.
Load properly.
Feed should be in the direction of belt
travel, centered on the belt. Ensure
uniform continuous loading.
Free the idlers by hitting the shaft
axially in either direction lightly.
Lubricate & improve maintenance.
Remove accumulation and adjust
scrapper for effective scraping.
Re – align
Replace worn lagging.
Remove accumulations and adjust
scrappers.
Load centrally in the direction of belt
travel. Ensure control loading.
Re – align
Remove accumulations and adjust
scrapper for effective scraping.
 COMPLAINT PROBABLE CAUSE REMEDY

4. One belt section a. Belt improperly spliced. Re - splice correctly.

runs off at all
points of the line b. Belt edge worn out or Repair belt edge. Remove badly worn
broken. or out of square section & splice in a
new piece.

5. Belt runs to one a. Idlers out of square with Re – align.

side through out centre line of conveyor.
the entire length
at specific idlers b. Material builds up on Remove accumulations and adjust
idlers. scrapper for effective scraping.

6. Belt shift a. Conveyor has Level out the conveyor.

alternatively to transverse slope.
left and right.
b. Excessive belt tension. Adjust tension.
c. Insufficient belt tension.

7. Belt sags badly a. Insufficient belt tension If the take up is screw type, adjust it.
between carrying If further adjustment is not possible cut
idlers. out some length of the belt and re-
splice.

If the take up is gravity type, check

adequacy of counter weight. Add
weight if required. If take up travel is
not adequate, increase it. Otherwise
cut some length of belt and re-splice.

8. Belt slip a. Head pulley lagging Replace worn out lagging of drive
worn out. pulley.

b. Low belt tension. Increase belt tension.

Remove accumulations and adjust

c. Material builds up. scrappers.

d. Frozen idlers. Free the idlers by hitting the shaft

axially in either direction lightly.
Lubricate & improve maintenance
 COMPLAINT PROBABLE CAUSE REMEDY

9. Excessive belt a. Over tension of belt. Reduce take up tension.

stretch
b. Material between belt Remove accumulations and adjust
and pulleys. scrappers.

10. Vulcanized splice a. Belt improperly spliced. Make new splicing correctly.
separation.
b. Excessive tension. Reduce belt tension.

c. Material between belt Remove accumulations and adjust

and pulleys. scrappers

11. Excessive wear a. Frozen idlers. Free idlers.

including rips,
gauges, ruptures b. Excessive impact of Avoid shock loading.
and tears on the material on belt.
top surface of the
belt. c. Improper loading. Load properly in the direction of belt
travel, centred on the belt

d. Flood loading. Avoid flood loading.

Control feed rate.

e. Relative loading velocity Adjust chute or correct belt speed.

too high.

f. Excessive pressure of Scrapers and skirt boards should

scrapers and skirt touch the belt gently.
boards on the belt.

g. Pieces of material Remove wedged material and close

caught between belt and the gap between belt and skirt board.
skirt boards.

12. Excessive a. Frozen Idlers. Free idlers and lubricate.

bottom cover
wear. b. Material between belt Remove accumulations and adjust
and pulleys. scrappers
 COMPLAINT PROBABLE CAUSE REMEDY

13. Longitudinal a. Excessive impact of Avoid Shock loading.

grooving or material on belt.
cracking of belt Free idlers and lubricate.
conveyors. b. Frozen Idlers.
c. Material build up. Remove accumulations and adjust
scrappers.

d. Skirts / Scrapers Install skirt boards / Scrapers correctly

improperly fixed. so that they do not rub against belt

14. Belt edges a. Belt edges rubbing Train belt.

damaged. against stationary parts
owing to belt out of train.

b. Frozen guide rollers.

Free rollers.
c. Side loading and
improper loading. Avoid side loading.
Load centrally in the direction of belt
travel.

15. Belt Swells in a. Belt damages by Control loading.

spots / streaks or abrasives, chemicals, For abrasive materials working in to
belt hardens or oils and heat. cuts and between plies, make spot
becomes brittle. repairs with cold patch.

Use correct grade of belt.

Enclose belt line for protection against

sun and rain.

16. Heavy spillage of a. Improper loading. Load properly. Feed in the direction of
material at belt travel centered on the belt.
loading point
b. Flood loading. Avoid flood loading.
Ensure controlled loading.

c. Rubber strip at the Replace rubber strips and ensure they

bottom of skirt board touch the belt so that there are no
worn out / missing. gaps.
 COMPLAINT PROBABLE CAUSE REMEDY

17. Abnormal a. Lack of lubrication. Lubricate with grease.

heating of pulley
bearings or b. Use of wrong grease. Use correct type of grease.
seizure of pulley
bearings. c. Grease and / or Remove grease, Flush bearings with
bearings contaminated. kerosene and refill with fresh grease.

d. Worn out bearings. Replace bearings.

e. Faulty assembly. Check fitment / alignment and correct.

Do not locate bearing at one end of
pulley.
 SECTION 5

PREVENTIVE MAINTENANCE
 INSTRUCTION FOR OPERATION

Before starting the conveyor, the following should be checked:

1. The material loaded is according to the specification given. For example, the
maximum lump size, % of moisture content, capacity, etc., should be according to the
designed specification.
2. All the fasteners in the structure, equipments etc. are tightened properly.
3. All the moving parts are lubricated properly (Refer the section titled ‘Lubrication
Schedule’).
4. All the parts which are touching the belt, (say skirt plates, scrapers, etc.) are touching
the belt only lightly.
5. Weather any material is sticking on the return side of the belt. It may cause damage to
the belt when moving.
6. All the guards are fixed with out damage.
7. The oil level in the gear box is up to the mark. If not, top–up the oil level.
8. If the screw take-up arrangement is adjusted suitably, so that correct belt tension is
maintained.
After checking all the above, start conveyor with out material for test run. During the test
run, the following should be checked.
1. That the speed of the conveyor does not exceed the specified limit.
2. That the belt is moving straightly.
3. That no unusual noise is coming from the drive.
4. The motor current rating is with in 80 % of full load current.
Only after satisfactory test run, the conveyor should be run with material.

NB: it is very important that you refer back to METHODS when in doubt with regard to the
above instructions.

Methods shall not be held responsible if, due incorrect understanding of the above
instructions, trouble shooting tasks are carried out wrongly resulting in breakdowns and / or
damages to conveyors.
 SECTION 6

LUBRICATION SCHEDULE
Sl Description Lubricant Duration
No.
1 Bearing Lithium base grease AP-3 or For every month of operation
equivalent

2 Gear Box As per gear box Max. level should always be

manufacturer’s maintained. Oil shall preferably be
recommendations changed once in 6 months.