B1 0 Pipe Conveyor en 2

22135_B1_0_Pipe conveyor_EN_2
Page 1 of 246 Original version
TISUR
Islay Bay
Assembly, Operating & Maintenance

Instructions
- PART B1 -
Pipe conveyors
- Mechanical -
Client: TISUR
Islay province, Arequipa, Peru
E-807, 450 N-8, 117,700 (UTM)
Engineer: ODEBRECHT
Contract No.: 2.2135 / 6074M
Supplier: FLSmidth Wadgassen GmbH

Karl-Koch-Str. 1 - 66787 Wadgassen - Germany
P.O. Box 160 - D-66781 Wadgassen - Germany
Phone: ++ 49 (0)68 34 – 470 0
Fax: ++ 49 (0)68 34 – 470 210
E-mail: wadgassen@flsmidth.com
4
3
2
1 Updated edition BRLE-DE 05.11.2014 MIFU-DE 19.12.2014
0 First edition MIFU-DE 03.04.2014
Rev. REVISION NOTE DESIGNED DATE CHECKED DATE
The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not
be duplicated, disclosed or utilized without written consent from FLSmidth.
Assembly, Operating &

Maintenance Instructions
Plant: Islay Bay
Location: Islay province, Arequipa,

Peru
E-807, 450 N-8, 117,700
(UTM)
Client No.: 6074M
Contract No.: 2.2135
Design Year: 2014
FLSmidth Equipment: Materials handling equipment

Pipe conveyors
All sentences or words highlighted in yellow must be

checked and adapted with supplier data, terms of contract,
etc. (to be deleted after completion).
Table of Contents
1 Foreword................................................................................10
1.1 Safety...................................................................................... 10
1.2 Definitions and abbreviations ...................................................... 10
1.3 Safety legend ........................................................................... 11
2 Equipment according to material flow / Flow Sheet...............12
3 Introduction ...........................................................................13
4 Technical Parameters .............................................................14

4.1 Environmental conditions ........................................................... 14
4.2 Electrical parameters ................................................................. 15
4.3 Material characteristics .............................................................. 15
4.4 Plant data ................................................................................ 15
4.5 Scope of Supply for Pipe Conveyor .............................................. 16
5 Instructions for Transport......................................................19

5.1 Scope ...................................................................................... 19
5.2 Definitions................................................................................ 19
5.3 General.................................................................................... 19
5.4 Environmental considerations ..................................................... 20
5.5 Instructions for Equipment Transport........................................... 20
6 Instructions for the Storage of the Delivery ...........................22

6.1 General remarks ....................................................................... 22
6.2 Storage and preservation requirements for mechanical equipment .. 22
6.2.1 Preservation on Storage ............................................................. 22
6.2.2 Preservation measures............................................................... 23
6.3 Storage and preservation requirements for switch cabinets and other
electrical equipment .................................................................. 25
7 Description of Equipment .......................................................26

7.1 Scope ...................................................................................... 26
7.2 Design ..................................................................................... 26
7.3 Normative references ................................................................ 26
7.4 General description of the process flow ........................................ 27
7.5 Pipe conveyors.......................................................................... 28
7.6 Pipe conveyor´s principle ........................................................... 29
7.7 Pipe Conveyor components......................................................... 31

7.8 Drive station............................................................................. 32
7.9 Drive units ............................................................................... 33
7.10 Pulleys ..................................................................................... 34
7.11 Rubber belt .............................................................................. 35
7.12 Belt scraper .............................................................................. 36
7.13 Idler stations including belt forming idlers .................................... 38
7.13.1 Adjustable idler stations ............................................................. 39
7.13.2 Panels with 12 carrying idlers ..................................................... 40
7.13.3 Belt forming idlers ..................................................................... 41
7.13.4 Safety panels............................................................................ 42
7.13.5 Return idler stations .................................................................. 43
7.13.6 Return guiding wheel ................................................................. 43
7.14 Return station........................................................................... 44
7.15 Vertical gravity take-up.............................................................. 45
7.16 Steel construction ..................................................................... 46
7.16.1 Standard belt frames ................................................................. 46
7.16.2 Walkway bottom covering .......................................................... 46
7.16.3 Support, trestle......................................................................... 46
7.16.4 Standard belt frames at feeding and discharging area.................... 47
7.16.5 Material guidance ...................................................................... 47
7.16.6 Discharge chute ........................................................................ 48
7.16.7 Dust sealing equipment.............................................................. 48
7.17 Electrical components ................................................................ 49
7.17.1 Emergency pull cord switch ........................................................ 50
7.17.2 Belt misalignment switch............................................................ 51
7.17.3 Speed Monitoring ...................................................................... 52
7.17.4 Clogged chute sensor ................................................................ 53
7.17.5 Take-up limit switch and sensor .................................................. 54
7.17.6 Over filling switch...................................................................... 55
7.17.7 Twist switch ............................................................................. 55
7.17.8 Belt rip detection....................................................................... 56
7.17.9 Safety panel switch ................................................................... 57
7.18 Description of attached equipments with pipe conveyor ................. 57
8 Scope of works by the construction company ........................58

8.1 Responsibility of the construction company................................... 58
8.2 Quality of work ......................................................................... 60
8.2.1 Scope and documents................................................................ 60
8.2.2 General quality requirements...................................................... 60
8.3 Welding ................................................................................... 60
8.4 Surface treatment inspection ...................................................... 61
8.5 Machinery installations............................................................... 61
8.6 Fastening of bolts...................................................................... 61

8.7 Project plan .............................................................................. 62
8.7.1 General.................................................................................... 62
8.7.2 Project plan .............................................................................. 62
8.7.3 Follow-up of the project plan ...................................................... 63
8.7.4 Mounting works ........................................................................ 63
8.7.5 Common requirements mounting alternatives ............................... 64
8.8 Components to be delivered by FLSmidth..................................... 64
8.8.1 Design ..................................................................................... 64
8.8.2 Components and structures ........................................................ 64
8.8.3 Arrival of components and structures........................................... 64
8.9 Preassembly works.................................................................... 65
8.10 Mounting works ........................................................................ 65
8.10.1 Mounting equipment .................................................................. 65
8.10.2 Mounting works ........................................................................ 66
8.11 Testing .................................................................................... 66
8.11.1 Supervision by FLSmidth ............................................................ 66
9 assembly and disassembly Instructions .................................67

9.1 Instructions for the installation and mechanical completion ............ 67
9.1.1 General Safety Instructions ........................................................ 67
9.1.2 Using the machine documentation ............................................... 70
9.2 Introduction ............................................................................. 71
9.3 Preparatory work ...................................................................... 73
9.3.1 Important mounting equipment and tools..................................... 74
9.3.2 Drawings and documents ........................................................... 74
9.3.3 Reference axes and levels .......................................................... 75
9.3.4 Tightening torque and tensile force.............................................. 76
9.4 Sequence of the mounting of the conveyor ................................... 78
9.4.1 Pre-assembly............................................................................ 78
9.4.2 Materialization of the conveyor centreline..................................... 83
9.4.3 Installing the frame of the drive pulley......................................... 83
9.4.4 Installing the substructure.......................................................... 83
9.4.5 Installing the return frame ......................................................... 84
9.4.6 Installing the counterweight ....................................................... 84
9.4.7 Installing the idler supports ........................................................ 85
9.4.8 Adjustable carrying idler station .................................................. 85
9.4.9 Belt forming idler ...................................................................... 86
9.4.10 Safety panel ............................................................................. 86
9.4.11 Carrying idlers – Panel ............................................................... 86
9.4.12 Installation of the belt................................................................ 87
9.4.13 Installing the drive unit .............................................................. 91
9.4.14 Installing the steel plate items and various fittings ........................ 91
9.4.15 Skirt board ............................................................................... 92
9.4.16 Installing the electrical components............................................. 92
9.4.17 Adjusting the belt tension and providing various settings ............... 93
9.4.18 Preparing the tests .................................................................... 94

9.4.19 Allowable tolerances .................................................................. 95
9.5 Settings ................................................................................. 101
9.5.1 Materialization of the axes of reference ...................................... 101
9.5.2 Pulleys ................................................................................... 102
9.5.3 Substructure........................................................................... 104
9.5.4 Idler supports ......................................................................... 106
9.5.5 Guides of the counterweight box ............................................... 109
9.5.6 Counterweight variations.......................................................... 111
9.5.7 General description on works in case of belt misalignment ........... 111
9.5.8 Conveyor belt ......................................................................... 112
9.5.9 Conveyor pulleys..................................................................... 112
9.5.10 Take-up stations ..................................................................... 112
9.5.11 Idler stations .......................................................................... 112
9.5.12 Transfer chutes ....................................................................... 113
9.5.13 Belt cleaning equipment........................................................... 114
9.5.14 Conveyor structure.................................................................. 115
9.5.15 General belt misalignment........................................................ 115
9.5.16 General inspection of the pipe conveyor prior to aligning the belt
without material...................................................................... 115
9.5.17 Inspection of the take-up station............................................... 116
9.6 Interferences, faults and repair ................................................. 117
9.6.1 Correct fixing of belt forming idler ............................................. 117
9.6.2 Belt twist ............................................................................... 118
9.6.3 Overlapping of the belt ............................................................ 119
9.6.4 Belt correction at twisted belt ................................................... 120
9.6.5 Correction of belt running......................................................... 121
9.6.6 Belt tension ............................................................................ 122
9.7 Installing the attached equipents with conveyor .......................... 123
9.8 Installation of cable trays and cables ......................................... 124
9.9 Final assembly ........................................................................ 126
9.10 Pre-operational verification....................................................... 127
9.11 Test on mechanical completion ................................................. 127
9.12 Commissioning ....................................................................... 127
9.13 General conclusion .................................................................. 127
10 Start-up / Commissioning / Operating Instructions.............128

10.1 Check list ............................................................................... 128
10.2 General remarks ..................................................................... 131
10.3 Procedure............................................................................... 131
10.4 Positioning of personnel ........................................................... 131
10.5 Preparation ............................................................................ 132
10.6 Activation............................................................................... 132
10.7 1st Test run............................................................................ 133

10.8 2nd Test run........................................................................... 133
10.9 3rd Test run ........................................................................... 133
10.10 Run-in ................................................................................... 134
10.11 Operation ............................................................................... 134
10.12 Pre-operational check .............................................................. 134
10.13 Trial-run with application of material ......................................... 135
10.14 Start...................................................................................... 135
10.15 Shutdown procedures .............................................................. 135
10.16 Operation modes..................................................................... 136
10.17 Emergency shutdown............................................................... 137
10.18 Local control stations ............................................................... 137
11 General Maintenance Instructions........................................138

11.1 Introduction ........................................................................... 138
11.2 Regulations for maintenance works ........................................... 138
11.3 General inspection and maintenance routine instructions.............. 139
11.4 Maintenance & assembly instructions for standard equipment ....... 140
11.5 General maintenance instructions for pipe conveyors................... 140
11.5.1 Cleaning................................................................................. 142
11.5.2 Steel structure ........................................................................ 142
11.5.3 Bolts...................................................................................... 142
11.5.4 Gear, gear motor .................................................................... 142
11.5.5 Motor..................................................................................... 142
11.5.6 Brake .................................................................................... 143
11.5.7 Fluid coupling ......................................................................... 143
11.5.8 Flexible coupling ..................................................................... 143
11.5.9 Shrink disk ............................................................................. 143
11.5.10 Bush at torque arm ............................................................. 143
11.5.11 Roller bearings.................................................................... 143
11.5.12 Sealing ring ........................................................................ 144
11.5.13 Pulleys ............................................................................... 144
11.5.14 Idler stations ...................................................................... 144
11.5.15 Rubber belt ........................................................................ 145
11.5.16 Status check of roller bearings .............................................. 148
11.5.17 Functional test .................................................................... 148
11.5.18 Electrical equipment ............................................................ 149
11.5.19 Maintenance and modification works on and around pipe conveyors
and its secondary structures ..................................................... 150
11.5.20 Commissioning after maintenance and modification works........ 150
11.5.21 General description on maintenance works in case of belt
misalignment.......................................................................... 151
11.5.22 General description on maintenance works in case of fault ....... 151
11.6 Dismantling and disposal.......................................................... 152

11.6.1 Dismantling work .................................................................... 152
11.6.2 Disposal ................................................................................. 153
12 Instructions for the Lubrication of the Equipment................154

12.1 General safety instructions ....................................................... 154
12.1.1 Personal safety - Health and safety instructions .......................... 155
12.1.2 Personal protective equipment .................................................. 155
12.1.3 Regulations for the prevention of accidents ................................ 155
12.2 Storage of lubricants ............................................................... 156
12.3 Cleaning of machines............................................................... 156
12.4 Disposal of waste lubricants...................................................... 157
12.5 Types of lubricants .................................................................. 157
12.5.1 General application of oil and grease ......................................... 157
12.5.2 Methods of lubrication.............................................................. 157
12.5.3 Oil ......................................................................................... 158
12.5.4 Grease................................................................................... 158
12.5.5 Synthetic lubricants ................................................................. 158
12.6 Lubrication plans ..................................................................... 159
12.6.1 Use of lubrication plans ............................................................ 160
12.6.2 Factory filling.......................................................................... 160
12.6.3 General lubrication instructions ................................................. 161
13 Specific Instructions and Information ..................................162

13.1 Assembly drawing list .............................................................. 162
13.2 Technical data ........................................................................ 163
13.3 Spare parts ............................................................................ 169
13.3.1 Spare parts catalog for Pipe conveyor 0720-PC-1021................... 170
13.3.2 Spare parts catalog for Pipe conveyor 0320-PC-1012................... 186
13.4 Lubrication plan ...................................................................... 203
13.4.1 Lubrication plan for Pipe conveyor 0720-PC-1021........................ 205
13.4.2 Lubrication plan for Pipe conveyor 0320-PC-1012........................ 212
13.4.3 SEW Lubricant ........................................................................ 221
SEW Lubricant .................................................................................. 223
SEW Lubricant .................................................................................. 223
13.5 Inspection & maintenance schedule guideline ............................. 225
13.6 Troubleshooting chart .............................................................. 232
13.6.1 General.................................................................................. 233
13.6.2 Gear unit................................................................................ 234
13.6.3 Motor..................................................................................... 235
13.6.4 Fluid coupling ......................................................................... 236
13.6.5 Disc brake .............................................................................. 237
13.6.6 Thruster at disc brake.............................................................. 238
13.6.7 Elastic coupling ....................................................................... 238
13.6.8 Shrink disc ............................................................................. 239
13.6.9 Silent block ............................................................................ 239

13.6.10 Pulley ................................................................................ 240
13.6.11 Belt ................................................................................... 241
13.6.12 Belt cleaner ........................................................................ 242
13.6.13 Idler .................................................................................. 243
13.6.14 Belt forming idler ................................................................ 243
13.6.15 Tension guidance with take-up station ................................... 244
13.6.16 Skirt board ......................................................................... 244
13.6.17 Dust sealing equipment ....................................................... 245
13.6.18 Discharge hood and chute .................................................... 245
13.6.19 Belt scale ........................................................................... 246
13.6.20 Additional equipments (belt scale, maintenance hoist, etc.) ...... 246
1 FOREWORD
The present instructions are concerned with the situations which, according
to the experience of FLSmidth, are the most likely to occur during
manufacture, installation, operation and maintenance of the equipment. An
exhaustive enumeration of all conceivable situations, which may occur,
cannot be provided.
Consequently, if a situation should arise, the occurrence of which is not

foreseen in the instructions, and which the operator is/or feels unable to
handle, it is recommended that FLSmidth is contacted without undue delay
for advice on appropriate action.
All references to relevant safety standards are given at the EC declaration of

conformity if required.
Reference by seller to any international or national standard does not incur

an obligation on seller to provide any recipient, reader or user of the
documentation with samples or copies of the said standard(s).
Hence, any recipient, reader or user of the documentation is expected – at

his own cost – to obtain necessary knowledge of the contents of any of the
standards referred to.
1.1 Safety
Potential safety risks, and correct mode of conduct subject to such risks, are
continuously described in the text in relation to specific actions.
See Part A “General safety instructions” and the separate equipment-specific

safety instructions for a complete list of all unforeseen risks in connection
with the installation, operation and maintenance of the equipment.
1.2 Definitions and abbreviations
Authorized person A person who is qualified and who, by the

responsible manager, is entrusted with certain tasks.
Skilled person A person who, after an education as a craftsman, is
capable of doing skilled work.
SDS Safety Data Sheet (in US known as MSDS)
MSDS Material Safety Data Sheet
OM Operation and Maintenance
1.3 Safety legend
In this instruction manual dangerous situations are indicated by the

following safety warnings, following the harmonization of the ISO 3864 and
ANSI Z535.6 standards.
Notice
Indicates a property damage situation only.
Caution
Indicates a hazardous situation which, if not avoided, may result
in minor or moderate personal injury.
Warning
Indicates a hazardous situation which, if not avoided, could result
in serious personal injury or death.
Danger
Indicates a hazardous situation which, if not avoided, will result in
serious personal injury or death.
Structure of safety warnings

All safety warnings are structured as follows:
Signal word panel

Hazard type.
Consequences of not avoiding the hazard.
Describe how to avoid the hazard, or redirect the reader to such
information for example a specific procedure.
Additional safety signs

Additional safety signs may be used in the safety warnings and placed to the
left of the warning box. All safety signs follow the definitions and graphical
design according to the ISO 7010 standard.
2 EQUIPMENT ACCORDING TO MATERIAL FLOW / FLOW SHEET
Equipment: Pipe conveyors

Item / KKS No. Description Remark
0320-PC-1012 Pipe Conveyor
0720-PC-1021 Pipe Conveyor
Type plate
E.G.: 2.2135 - 0320-PC-1012
The complete factory serial number must be stated when making technical
enquiries or ordering spare parts.
The present operating manual is valid for pipe conveyors.
3 INTRODUCTION
This assembly, operating and maintenance manual will help you to

understand the function and the operation of the equipment. All information
contained in this manual is important for a safe and reliable operation of the
equipment.
Only persons who are fully familiar with the content of this manual are
authorized to operate and to maintain the equipment.
This manual forms part of the entire assembly, operation and maintenance
instructions for the equipment supplied under the Contract Order 2.2135
scope. It has to be read in conjunction with all other Parts of the operation
and maintenance instructions including sub-suppliers’ documentation.
For further information or spare parts inquiry please contact us on the

following address:
FLSmidth Wadgassen GmbH

Karl-Koch-Straße 1 - 66787 Wadgassen - Germany
P.O. Box 160 - D-66781 Wadgassen - Germany
Phone: + 49 - 68 34 – 470 - 0
Fax: + 49 - 68 34 – 470 - 339
E-mail: wadgassen@flsmidth.com
4 TECHNICAL PARAMETERS
4.1 Environmental conditions
Site .......................................................Arequipa, Peru

............................................................E-807, 450 N-8, 117,700 (UTM)
Temperature ..........................................max. + 27 °C
............................................................min. + 8 °C
Relative Humidity of air ..........................55 - 82 %
Wind speed: ...........................................21 m/s
Annual rainfall (average)..........................<32 mm
Seismological design:
According to ...........................................Zone 3
Elevation above sea level .........................+ 6 - + 54 m
Aggressive environmental conditions .......Saline & humid
4.2 Electrical parameters
3 phase voltage MV:................................10 000 VAC 60Hz

Motor voltage LV:....................................440 VAC 60 Hz
Low voltage (lighting, etc.): .....................220 VAC 60 Hz
Control voltage (I/O, valves, etc.):............120 VAC / 24 VCC
4.3 Material characteristics
Material .................................................Copper concentrate

Bulk density ...........................................1,8 t/m3
Material size ...........................................> 50 mesh mm
Angle of repose.......................................22 °
Temperature of material ..........................Ambient °C
Moisture ................................................9 - 11 %
4.4 Plant data
Operating conditions ..............................24 hrs per day, 7 days per week
4.5 Scope of Supply for Pipe Conveyor

Update schemes if necessary (to be deleted after completion).
Construction
Pipe Conveyor
Drive station
14 15-16
13
9
16
1
10
16
5
21
Take-up station
16 16
8
Return station
16
19 6-18
23
4
9 14
6-18
21
Skirt boards & safety panels
26 11
10 11
25
Cross section, skirt boards
26 20
25 10
6-18
14
12-18
PIPE CONVEYOR
Denomination
Engineered by FLSmidth (mean not supplied by FLS)
1. Framework for drive station

2. Framework for take-up station
3. Framework for return station
4. Belt supporting structure
5. Discharge chute with impact plate
6. Idler supports
7. Covers (if necessary)
8. Counterweight and its box
9. Safety covers and guards
10. Feeding chute with skirt boards
11. Safety panels
12. Idler panels
13. Grating
14. Supports for electrical equipment (brackets)
15. Drive unit
16. All pulleys, i.e. drive, snub, bend, take-up and tail, with bearings
17. Self-aligning idler set
18. Idlers
19. Rubber belt
20. Rubber strips
21. Belt cleaners
22. Actuator and base plate
23. Electrical equipment (safety devices)
24. Idler panels
25. Adjustable idler station
26. Belt forming idler
5 INSTRUCTIONS FOR TRANSPORT
5.1 Scope
The procedure for transporting personnel and equipment establishes

guidelines for the safe transportation of personnel and equipment on the
jobsite.
5.2 Definitions
Qualified Inspector
An experienced alliance of specialty subcontractor, craftsperson or engineer,
acceptable to client, has demonstrated his or her ability or competency to
inspect equipment.
Qualified Operator
An experienced alliance of specialty subcontractor, craftsperson experienced
and has demonstrated competency to operate a specific piece of equipment.
5.3 General
Equipment inspection
A qualified inspector must inspect all equipment used for the jobsite
transportation of personnel and equipment prior to their use on site and at
least yearly thereafter. Records of all inspection and maintenance works shall
be completed and maintained for review by client.
Equipment operators must inspect all controls and safety devices each day
before beginning work. If any of the controls do not operate properly, they
must be repaired before the equipment is operated.
Operator qualifications
All operators must meet the following minimum requirements:
 They must pass an annual medical examination.

 Only experienced employees, authorized by subcontractor
management may operate equipment.
 They must demonstrate satisfactory operating skills.
 Supervisors are not allowed to operate any piece of mobile equipment
except cars and pickups.
Equipment requirements
All equipment must be provided with at least the following:
 An automatic audible reverse signal alarm. Such alarms must have a

sound pressure level of 112 dBA +/ - 4 dBA.
 A class BC fire extinguisher (of a minimum size of 5 pounds, 2.3
kilograms) must be kept in the equipment's cab.
5.4 Environmental considerations
Hydraulic unit and gearboxes must be maintained to prevent leakage. If a

leak or spill occurs in such a system, the spill must be cleaned up
immediately in accordance with governmental regulations.
5.5 Instructions for Equipment Transport
Notice
Immediately on receipt of the machine parts, check that all items
are complete and in good condition. FLSmidth must be advised of
any transport damage immediately. If this is not done any claim
under the guarantee lapses.
To avoid any damage to persons and plant appropriate caution should be

observed when transporting the machine parts. In addition to the pointers in
this chapter, the general and local safety and accident prevention rules (such
as German UW) are to be observed.
If the equipment is packaged, the symbols indicating transport and storage

guidelines are to be observed:
Warning
Only use ropes, fasteners and lifting tackle of sufficient carrying
capacity. Always observe the weight of the machine parts (see
Parts lists) or packages (see packing lists).
Danger to life or serious injury through tipping or falling loads.
When lifting the equipment, you must observe that nobody is in

the danger area of the suspended loads.
Warning
For in-plant transport, storage and retrieval, use the transport
aids provided for this purpose (e.g. eyes), and follow appropriate
sub-supplier instructions.
Before transport of any sub-supplier product (e.g. drive units)

read the sub-supplier instructions for transport and assembly!
6 INSTRUCTIONS FOR THE STORAGE OF THE DELIVERY
These instructions are to be understood only as supporting documentation to

the suppliers documentation in Part C1.
6.1 General remarks
FLSmidth guarantees that all parts of the FLSmidth delivery portions are
provided with an adequate protection of a total storage period of minimum 6
months.
Damaged packages will be opened by the client and checked as to

completeness and / or damages.
If parts or the whole of FLSmidth’s delivery will be stored, an inspection of all

containers or packages has to be carried out during unpacking in the
presence of a representative of the company FLSmidth on basis of the
packing list.
Seller's and buyer's representatives have to put down on record any missing
parts as well as any noted damages as compared with the packing lists by
stating the reasons thereof and provide it with their signatures directly after
receipt of the goods. In absence of the seller, the buyer has to check the
correctness and the condition of the delivered parts and containers. Later
complaints are excluded.
The costs incurred with such journeys and stays will be borne by the buyer.
6.2 Storage and preservation requirements for mechanical

equipment
Special preservation measures are required for storage of components on the

job site over a longer period than 6 months.
6.2.1 Preservation on Storage
Six months after delivery of the plant parts at the latest, the packages have
to be opened at site or in the intermediate storage and the protective plastic
foil have to be removed. A completeness check has to be carried out.
6.2.2 Preservation measures
The preservation measures to be taken in detail are described below. In

addition, the sub-suppliers’ recommendations have to be followed.
Rubber belts of conveyors

The rubber belts have to be tension released. For preservation, the belts will
be treated with glycerin. The rubber belts will then be stored in a cool and
dry place and protected against light. Ozone influence (in the tropics,
especially near the sea) proved to be very harmful for the rubber belts. In
such cases, the rubber belts have to be dismantled, foil welded, and stored
in a dark surrounding.
Other rubber parts

Other rubber parts on the equipment such as collars, cleaning strips and
packing are to be treated like rubber belts as far as preservation and storage
are concerned.
Idlers
Idlers have to be turned manually from time to time (e. g. every six months)
to prevent segregation and gumming of the lubricant. The protective coating
of the carrying idlers has to be checked and touched up if necessary.
Anti-friction bearings
Anti-friction bearings should be stored in a dry and dark surrounding. No
special preservation measures are required for storage.
Shaft seals with stuffing box packing

They should be stored in a dry and dark surrounding. No special preservation
measures are required.
Blank parts
Protective coatings of blank parts have to be checked and retouched and / or
reapplied if necessary, e.g. TECTYL 506.
Gearboxes
Gearboxes will usually be delivered without oil filling, but provided with a
preservation medium. If storage periods of more than 6 months after
delivery are to be expected, i.e. the time expected for transport plus storage,
the gearboxes have to be rinsed and then re-protected again. In case of
longer storage periods, a special preservation medium has to be applied.
This procedure must be repeated and documented every 6 months until
start-up.
Follow the respective instructions of the sub suppliers.
The outer blank parts of the gearbox have to be provided with an appropriate
protection.
Motors and gear motors

Electric motors will generally be dismantled, and checked or retouched as far
as their outside preservation (blank parts) are concerned and then stored
together with the electrical equipment. Gearboxes are to be treated as
described above.
Frequency speed indicators

They are to be treated like electric motors.
Electro-mechanical parts
They are to be treated like electric motors.
Storage
The complete mechanical equipment, except for those components to be
stored with the electrical equipment and the rubber belts for conveyors, has
to be repacked after carrying out the aforementioned preservation
procedures and then stored in this packing. The cover of the packing (case)
should not be firmly closed but has to be provided with distance pieces to
allow for air circulation in the case. The cases are to be stored in a closed
hall or at least in a covered stockyard.
It has to be pointed out once again that storage of motors and frequency
speed indicators must always be carried out on the same conditions and by
strictly observing the same requirements as described for storage of the
electrical equipment.
Structural steel parts can be stored in the open air up to a period of 6

months. The ground, however, has to be kept free from contamination and
water collections. The cases, packages etc. have to be stored on square
timbers. Coatings have to be checked and retouched if necessary.
6.3 Storage and preservation requirements for switch cabinets

and other electrical equipment
During storage, the electrical equipment has to be reliably protected against

moisture penetration by rain, dripping and condensation water, because
preservation measures are not possible for certain elements. This especially
refers to such parts that, due to the requirements they must fulfil, have a
bright surface. In addition, capacitors, resistors and integrated circuits are
also endangered by moisture penetration.
To prevent moisture penetration into the electrical equipment, these parts

have to be stored in a closed room equipped with an air-conditioner, which
avoids the precipitation of condensation on the parts.
The kind of packing selected by us for the switch cabinets provides protection
against all influences normally occur during transport, for a period of 6
months. If these parts should remain packed over the above period of time,
it is necessary to inspect the condition of packing inside the foil. For this
purpose, inspection flaps have to be provided on the switch cabinet packing
so that the moisture indication, which shows the amount of moisture
penetration, can be easily checked for efficiency. Inspection of these
indicators should be carried out in an interval of three months after storage.
If it is detected that these indicators are moisture-saturated, i.e. not
effective any longer, the packing will have to be opened. If these parts
cannot be stored in a closed room with air-conditioner afterwards so that
moisture precipitation on the electrical equipment is avoided, a new packing
according to the type used in our works is absolutely required.
If the switch cabinets are unpacked after arrival at site and stored in a room
without air-condition, moisture precipitation in the switch cabinets could be
avoided by heating equipment. For this purpose, all those switch cabinets,
which will finally be connected with cabinets next to them, must be
additionally furnished with a sidewall and with a heating element inside. Of
course, even in this case the parts have to be stored in a closed room that,
in addition, has to be clean and dry ("switch room quality").
The drive motors and speedometers fitted to the different parts of the
equipment are provided with standard insulation. In this case, penetration of
dirt has to be avoided, and the appropriate permissible grain sizes and other
requirements can be taken from the type of protection.
Please note that both the packing and the unpacked aggregates have to be
protected against vermin.
7 DESCRIPTION OF EQUIPMENT
The complete factory serial number must be stated when making technical
enquiries or ordering spare parts.
7.1 Scope
The present instruction manual is concerned with the operation and

maintenance of pipe conveyors.
7.2 Design
Pipe conveyors are only suitable for conveying and handling of inflammable
and non-explosive materials. It has not to be installed in processes in which
explosion risks require the machine to comply with the ATEX Directive or
other similar regulations.
The pipe conveyors under review must under no circumstances be changed

or modified relative to the original design or the original application without
prior approval from FLSmidth.
7.3 Normative references
The pipe conveyors are prepared to be included into a a terminal for loading
copper concentrate.
All references to design standards are given at the EC declaration of
conformity. Local regulations take precedence over instruction manuals. For
dated references to any publication, subsequent amendments to or revisions
of any of these publications apply to this instruction only when incorporated
in it by amendment or revision. For undated references, the latest edition of
the publication referred to applies.
See also Part A “General safety instructions”.
7.4 General description of the process flow
TISUR Company SA builds a terminal for loading copper concentrate in Islay

Bay.
The terminal will handle bulk carrier vessels of 20.000 to 55.000 DWT (Dead
Weight Tonnage). The annual export volume estimated for the terminal is 2
million tons. The material to be loaded on ships is coming from the
Antapaccay and Las Bambas mines.
The maritime facilities include the construction of a deep water site
composed of a loading dock and mooring Dolphins.
The dock should be suitable for the operation of the design vessels
mentioned and travel loader that caters to them.
The conveyor system, through which is performed the transporting the
material from the collection areas to the loader will operate on dock, it is
installed on a structure designed for this purpose. This structure links the
terminal onshore works with the loading dock located offshore.
In the dock is installed a loader traveler type (traveler shiploader) that
travels along the front of the berth, on rails suitable for such equipment,
covering all the warehouses, preventing shifting maneuvers for load
transfer.
Terminal maritime facilities are located to the south of the existing Matarani
port offshore, offsite coat of such port.
For more information, also refer to the “Functional Description” of the pipe
conveyors in the "Electrical Instructions".
7.5 Pipe conveyors
The Pipe Conveyor 0720-PC-1021 transports copper concentrate. It runs

over approx. 372 m horizontal length and 4,24 m way down.
Pipe conveyor 0720-PC-1021 feeds gallery conveyor 0730-CB-1022 in the

transfer tower TT06.

over approx. 223 m horizontal length and 5 m way up.
Pipe conveyor 0320-PC-1015 is feeding conveyor 0410-CB-1016 via the

transfer tower TT02 and is feeded from conveyor 0320-CB-1014.

over approx. 115 m horizontal length and 14 m way up.
Pipe conveyor 0320-PC-1012 is feeding conveyor 0410-CB-1013 via the

transfer tower TT02 and is feeded from conveyor 0320-CB-1011.
0320-PC-1015
0320-PC-1012
0320-PC-1015
0320-PC-1012
7.6 Pipe conveyor´s principle
Tubular shape
material feeding closed pipe
return belt also

forms closed pipe
Material unloading
Frame
Handling material
Idlers
Belt
Belt overlapping to avoid

material leakage
Material feeding area: Belt closing section:

The belt is troughed and fed The belt is closed and forced
like a conventional conveyor. into its tubular shape by special
devices.
During transport: During transport:

The belt forms a sealed The return belt forms a
pipe, which protects the sealed pipe as well and
material to be transported such contamination by
from outside influences spillage is avoided.
such as wind and rain.
During transport: Material discharge area:

The flexible belt pipe design Belt opens automatically
allows for directional changes at the discharge area.
without requiring transfer After material discharge
stations. It enhances cost- the belt is closed again to
effectiveness and operating exclude the possibility of
reliability. contamination of the conveyor
line.
The advantages of pipe conveyors are:
 extreme adaptability including horizontal, vertical and 3D curves

 steep inclination
 long distance transport
 dust-free conveying
 no spillage on return sector of conveyor
 simultaneous conveying in upper and lower conveyor run
 dustless transfer
7.7 Pipe Conveyor components
 Drive station
 Drive unit
 Pulleys (drive pulley and non-driven pulley)
 Rubber belt
 Belt scraper (primary, secondary, V-type)
 Idlers & belt forming idlers
 Safety panels (at tail station)
 Return station
 Take-up station
 Steel construction
 Electrical components (pull wire switch, misalignment switch, speed
monitor, local devices…)
7.8 Drive station
5 2 1
4 3
The drive station consists of:
1. Drive frame for pulley is made of solid steel sheet and profiled steel
construction, including necessary support plates and fixation screws.
2. Drive pulley with friction lining.
3. Snub pulley.
4. Belt scrapers arranged at drive pulley.
5. Discharging hood, divided and removable with inspection doors.
6. Baffle plate.
7. Drive unit directly coupled to and mounted on the drive pulley shaft.
8. Protection meshes where needed.
7.9 Drive units
The following drive units are installed at the Pipe Conveyor's drive / head
station:
 Pipe conveyor 0320-PC-1012 55 kW drive unit

 Pipe conveyor 0720-PC-1021 200 kW drive unit
Update schemes (to be deleted after completion).
4
1 2 3
The drive unit consists of:
9. Three phase current standard motor

10. Fluid coupling
11. Disc brake with elastic coupling (Not on all drives)
12. Shaft-mounted bevel helical gear with internal backstop
13. Drive unit support and torque arm with silent block
The drive units are arranged at the discharge end of the pipe conveyor.
For details, refer to Part C1, supplier’s documentation “ON HOLD”.
Moreover the pipe conveyor 0720-PC-1021 is equipped with 2 disc brakes

at the tail/return pulley.
Insert schemes (to be deleted after completion).
For details on the brakes, refer to Part C1, supplier’s documentation “ON
HOLD”.
7.10 Pulleys
Pulleys mainly consist of three parts:
 The shell in rolled steel with variable thickness depending on diameter

and loads.
 The pulley-end flanges in plate welded on shell and hub.
 The two hubs.
The drum is welded and machined. This work includes boring and execution
of lock form (groove for locking ring).
After that the drum is fitted on shaft. The shafts are made of carbon steel.
The pillow block bearings are SKF brand, type SNL. The housings are
provided with bosses, so that grease nipples can be fitted.
All pulleys are statically balanced. All bearing housings are adjustably bolted
onto support plates.
Pulleys are provided with the following lagging:
 Drive/Discharge pulley 20 mm rubber lagging

 Return/Tail Pulley 13 mm rubber lagging
 Bend Pulley 13 mm rubber lagging
 Take-up pulley 13 mm rubber lagging
 Snub pulley 13 mm rubber lagging
All pulleys are designed with cylindrical / tapered shape.
For details, refer to Part C1, supplier’s documentation “LORBRAND”.
7.11 Rubber belt
The rubber belts are of EP qualities thus ensuring both a high carrying
capacity and a good resistance against moisture, acids and lye. The top
layers on the carrying side are made of abrasion-resistant rubber. The
temperature resistance and resistance against chemical matter are as
specified in the technical data.
Based on conveyor track with curves, the pipe conveyor belt is fabricated
with an especially developed type of carcass.
The belt quality for each pipe conveyor is as follows:
 Pipe conveyor 0320-PC-1012 1000 EP500/3 – 6+3

 Pipe conveyor 0720-PC-1021 1600 EP 1600/5 – 6+3
7.12 Belt scraper
Each discharge pulley will be furnished with a cleaning system comprising:

 one primary cleaner (Martin QC™#1 XHD scraper)
 one secondary cleaner (Martin SQC2 scraper)
At the tail / return end, a V-plough belt scraper is provided.
Scrapers on the discharge pulleys
The primary belt cleaner consists of a plastic blade installed in the lower
quarter of the discharge pulley, in order to clean the belt with a minimum of
pressure on the pulley. The operating pressure can be adjusted by the spring
tensioner, in order to compensate the blade wear.
The secondary belt cleaner consist of a tungsten carbide blade located after
the discharge pulley, immediately following the primary cleaner to remove
staying material after first cleaner. The operating pressure can be adjusted
by the spring tensioner, in order to compensate the blade wear.
A scraper mainly consists of:
 Plastic blade for the primary cleaner and tungsten carbide blade for
the secondary.
 The main frame support holder.
 Two tensioners (spring) allowing a self-adjustment of the scraper on
to the belt in order to compensate the wearing of the blades.
Primary Cleaner - QC™#1 XHD
Secondary Cleaner - SQC2™
For details (primary & secondary scrapers), refer to Part C1, supplier’s
documentation .
Scraper on the belt return strand
V scraper on conveyor with one running direction
At the tail / return end, a V scraper (30 ° angle) is mounted on the upper
side of the return strand of the belt immediately before the tail / return
pulley to prevent product entering between the belt and the pulley. This unit
rests on the belt, but is also equipped with an adjustable screw stop to
prevent the metal parts coming into contact with the belt in case of wear of
the blade.
7.13 Idler stations including belt forming idlers
The carrying part and return part of the belt are supported by idlers.
The ordinary plain idlers consist of a cylindrical tube (D) with a stationary
shaft (E), roller end caps (A), ball bearings (C) and labyrinth seals (B).
Typical idler
The idler stations consist of:
 Adjustable idler stations in the belt closing and opening areas.

 Panels with 12 carrying idlers each in the area of closed belt.
 Belt forming idlers in the belt closing areas.
 Safety panel after the feading area.
 Return idler stations in the belt return strand.
 Return guiding wheel in the belt return strand (only on pipe Ø400)
All carrying idlers are lifetime greased, provided with multiple labyrinth
sealing and powder coating.
7.13.1 Adjustable idler stations
Adjustable idler stations allow to set progressively the troughing angle in the
belt closing and opening areas from 0° to 80°.
Typical idler station 0° to 35°
7.13.2 Panels with 12 carrying idlers
Typical panel with 12 carrying idlers
Typical half panel, carrying side
Typical half panel, return side
Over the conveyor track, the belt is carried by 6 pieces of carrying idlers
each in the upper and lower chord. The holding devices of carrying idlers are
fixed on a special steel sheet construction (panels) which is welded to the
standard frames. In curve area, panel distances are reduced compared to
straight line panel distances.
7.13.3 Belt forming idlers
For pipe forming, idler stations are provided each with 2 pieces of adjustable
belt forming idlers running one side bearings.
Typical belt forming idler
7.13.4 Safety panels
Apart from standard safety devices for belt conveyors, the pipe conveyor is
monitored in respect of possible material overload in the area immediately
after the feeding point. For this purpose, the first panels after the belt
forming area are designed swivelling in order to minimize belt damage in
case of blockage by excess lump size material.
Safety panel:
(lifting upwards)
Safety panel: (lifting

downwards)
In case of blockage, these panels open and activate a proximity switch. As a

consequence, the pipe conveyor is immediately stopped.
Safety meshes in this area protect the staff against injury.
The safety panel number for each pipe conveyor is as follows:
 Pipe conveyor 0320-PC-1012 4 safety panels

7.13.5 Return idler stations
Typical return idler stations
7.13.6 Return guiding wheel
Typical return guiding wheel
7.14 Return station
3 1 2 4
It consists of:
1. Return frame for pulley is made of solid steel sheet and profiled steel
construction, incl. necessary support plates and fixation screws.
2. A return pulley provided with friction lining.
3. V plough scraper (2), in order to keep the inner belt side and the
pulley lagging clean.
4. Protection meshes where needed.
7.15 Vertical gravity take-up
The counterweight box made of steel plate and profiles in welded

construction is filled with steel plate and/or concrete on site. The tensioning
weight is guided in a rail which is integrated either in a steel construction or
in a tower.
This includes the take-up pulley, the bend pulleys as well as the protective
grating and other protective equipment.
The take up stations are equipped with a low limit switch and a low sensor.
The proximity sensor is activated in case of excessive elongation of the belt.
The low limit switch is activated in case of excessive elongation or break of
the belt and shut down the conveyor.
Deflection of the return strand of the belt is done by the bend pulleys (1).
The take-up pulley (2) is mounted vertically movable to a frame which is
connected to the counterweight (3).
Vertical gravity take-Up
7.16 Steel construction
7.16.1 Standard belt frames
Standard belt frames consist of:
 Self-supporting profiled steel construction with welded-on panels for

the take-up of carrying idlers.
 Walkway on both sides along the conveyor.
 Galleries from the latest trestle to the discharge area.
All walkways, platforms or stairs are secured by handrail.
7.16.2 Walkway bottom covering
Walkways bottom covering and under conveyor covering consist of:
 Necessary checkered plates welded on the platforms.
7.16.3 Support, trestle
Support are design as single supports "A" form.
7.16.4 Standard belt frames at feeding and discharging area
Standard belt frames at feeding and discharging area (pipe forming area)
consist of:
 Steel construction
 Material guidance
 Screwed-on carrying adjustable idler stations
 Adjustable belt forming idlers
The pipe forming area is divided into standard joints, the upper carrying
idlers are supported by U-steel profiles.
7.16.5 Material guidance
Material guidance incl. adjustable rubber sealing rail, side angular steel
supports and protection guards arranged on both sides of the loading points.
The material guidance is made of rigid steel plate construction (mostly

welded constructions). The plate thickness is selected according to the
specific conveyor dimensions.
7.16.6 Discharge chute
The discharge chute consists of:
 Solid steel sheet construction with necessary reinforcement, with wear

plates as well as connections and joint flanges.
 The inspection doors (if necessary).
 The chutes are designed removable.
7.16.7 Dust sealing equipment
All hoods and material guidance are effectively sealed by means of rubber
skirts or seal lips. In case of conveyor plants with special dedusting
equipment, the required connections are provided at the discharge hoods.
7.17 Electrical components
Pipe conveyors have the following standard monitoring devices:
 Emergency pull cord switches are provided over the entire length of
the pipe conveyor.
 Belt misalignment switch provided on both sides of the belt at the
pipe conveyor head and/or tail end.
 A speed monitoring is provided on a non-driven pulley of the pipe
conveyor (usually the return pulley).
 Warning horns and flashing lights are arranged along the pipe
conveyor.
 The pipe conveyor has an emergency stop button close to each drive
unit.
 Clogged chute sensor.
 Limit switch which detect the counterweight lower position and 2
proximity sensors which detect the counterweight lower and upper
positions.
 Overfill sensor which detect if the conveyor is overfilled.
 Twist switch which detect if the belt twists.
 Rip switch which detect if the belt is damaged after the loading area
(skirt boards).
 Proximity sensor on safety panels which detect if the belt is overfilled.
For more details refer to "Electrical documentation".
7.17.1 Emergency pull cord switch
The emergency stop consists of a steel wire (1) which is stretched out along
the conveyor and connected to the arm of an electric switch (2) in the
middle. Thus the conveyor may be stopped by pulling the wire in an
emergency situation.
If not supported by holes in the frame, the steel wire rests in eye-bolts (3)
which are mounted in compliance with the dimensions specified in the
drawing. The maximum distance between two eye-bolts (supporting hole) is
2,5 m.
The Emergency stop switch is bolted on panel frame.
Mount the switch as illustrated on the relevant drawing! The maximum

distance between tension spring and switch is 50 m.
1 2 3
Typical emergency stop pull rope switch.
7.17.2 Belt misalignment switch
The belt misalignment switches (A) are mounted on both sides of the pipe
conveyor near the return and discharge pulley. The switch is mounted on a
support (C) which is fastened on the stringer (D).
The function of the belt misalignment switches is to emit a signal in case belt
misalignment on idlers is ascertained.
The belt misalignment switch (A) is equipped with an idler (B) and is
activated by the rubber belt in the event of off centre belt training on the
idlers.
Typical belt misalignment switch
7.17.3 Speed Monitoring
Conveyors are typically equipped with one (1) speed monitor fixed at a non-
driven pulley (usually the return pulley).
Monitoring the speed ensures that the pipe conveyor runs properly and
without difficulties, e. g. To detect any belt slipping or circuit-breaker failure,
this could cause an overloading of the conveyor.
The speed monitor consists of one proximity switch (inductive sensor) with
integrated the pulse sensing and processing electronics. The proximity switch
is fixed at the conveyor to detect activation flags on a rotating non-driven
pulley.
Typical speed monitor
7.17.4 Clogged chute sensor
A tilt switch is installed inside the chute to detect the chute jam.
Typical tilt switch
7.17.5 Take-up limit switch and sensor
A limit switch is provided at the bottom position of the counterweight box to

stop the conveyor in case of belt elongation or break.
An inductive proximity sensor is provided at the lower and upper positions of
the counterweight box to send a warning in case of activation.
Typical take-up limit switch and sensor
7.17.6 Over filling switch
A proximity switch is installed after the feeding area to detect the overfilling
of material.
Typical over filling switch
7.17.7 Twist switch
A roller arm switch is installed above of the belt, just before the belt forming
idlers, to detect the belt twisting.
Typical twist switch
7.17.8 Belt rip detection
As belts are subjects to wear and tear during operation, a belt rip detection
could be installed under the upper strand of the belt to detect the following
damages:
 Parts of the belt have come off in shreds.
 Steel or textile ropes stand off from the belt.
 Belt edges are torn
 Facings of a repair point have come off
 Splices are defective
 An external object goes through the belt
A belt rip switch is installed under the belt, after the feeding area, to detect if
the belt is damaged.
It consists of a pull cable under the belt connected to one proximity switch. If
an object is hanging below the belt, it sweeps away the cable. This
deactivates the switch.
Typical belt rip switch
7.17.9 Safety panel switch
An inductive sensor is mounted on each safety panel to detect oversize or

overfilling material.
Typical safety panel switch
7.18 Description of attached equipments with pipe conveyor
To be done if any other equipment (belt scale, maintenance hoist,

etc.)
8 SCOPE OF WORKS BY THE CONSTRUCTION COMPANY
Preamble
As the assembly of the Pipe Conveyor is not in the FLSmidth scope of supply,
the folowing indication, information are just recommendation for the
Construction Company.
This scope of works by the Construction Company is covering the mechanical

machinery installations and mechanical mounting of the EQUIPMENT as
specified on the cover page. Construction Company shall also carry out the
tests and inspections related to his scope of supply.
Construction Company shall provide all the necessary tools, labour,

equipment and materials to carry out the works.
Definitions
FLS EQUIPMENT: means the pipe conveyors, steel construction, to be
erected as specified on the following pages.
Works: means all the scope of supply and duties specified to be completed
by the Construction Company
8.1 Responsibility of the construction company
Construction Company is fully responsible to follow all the local safety

regulations and other rules established by local government and/or
requirements and working practices by the FLSmidth and end client. This
responsibility is to include, but is not limited to, all scaffoldings, walkways,
lifting operations, electrical installations, appliances and tools used,
personnel safety devices, fire extinguishers etc.
The safety measures are to cover the risks to the Construction Company's
own personnel but also any hazards towards employees by FLSmidth, end
cient, other mounting companies or any other person who may be on the
site. Similarly, the measures are to cover any risk towards the FLS
EQUIPMENT itself, any equipment and material which may be on the site.
Construction Company shall keep the mounting site and the FLS EQUIPMENT
always clean and arranged in a manner preventing any accidents to happen
due to the falling items, blocked walkways or drive ways etc.
Construction Company shall be responsible to arrange detailed training for its

personnel on the general safety of works, and also to familiarize its
personnel to the specific features of the works, its surroundings and local
safety practices above. Construction Company shall provide FLSmidth and/
or the client with safety training certificates of his employees.
Construction Company is to provide its personnel with hard hats, safety

boots, hearing protection, safety glasses, overalls, gloves, safety belts and
other safety devices as may needed case by case.
In case FLSmidth observes any employee of Construction Company to

neglect the safety rules or use of personal safety devices or otherwise violate
the safety of the works, FLSmidth has a right to immediately expel the
person from the mounting site.
Construction Company shall also arrange weekly safety meeting where he

and his site personnel analyse the safety risks of the mounting site, a report
on the meeting will be handed over to the FLSmidth supervisor as well as
mailed to FLSmidth head office.
Any safety risks observed by Construction Company, his employees, either

during the works or in the safety meetings, must be immediately handled or
overcome, prior the progress of the works in the particular zone.
Construction Company is responsible to use its own auxiliary supports and

scaffolding as needed for the execution of a safe mounting work.
8.2 Quality of work
8.2.1 Scope and documents
Construction Company is responsible to carry out all the tests and

inspections specified in the contract documents and belonging to the scope of
Construction Company. Construction Company shall also provide FLSmidth
with all the QC documentation. The QC documents must be handed over to
FLSmidth prior the final acceptance of the FLS EQUIPMENT. The QC
documents must also be presented to supervisor by FLSmidth at the site
whenever so required.
Construction Company is also responsible to supply FLSmidth with possible

non-conformance reports and as-built modifications as may case be.
8.2.2 General quality requirements
The responsibilities by Construction Company shall include, but shall not be

limited to following:
 The quality of material, equipment and workmanship by Construction

Company shall comply with the requirements of the specifications and
drawings according to the subcontract.
 Construction Company is to carry out tests of his parts as specified in
the quality documents.
In the event that re-test and re-inspection is required due to defective work
or material by Construction Company, the cost of the re-test and re-
inspection shall be at the Construction Company’s expense.
8.3 Welding
Only certified welders are allowed to weld any structural joints. Construction
Company shall present the Welding Procedure Specification (WPS), Welding
Procedure Approval record (WPAR) and welder's certificates for FLSmidth
approval.
Construction Company shall provide suitable welding machines and filler

materials, according to technical requirements specified in the drawings.
8.4 Surface treatment inspection
Construction Company shall repair any paint damages due to:
 Removal of transport supports.

 Touch-up painting for damages during the seal land transport &
welds.
 Installation and/or removal of mounting supports and lifting lugs or
other installations by Construction Company.
 Other damages and wear during mounting procedure.
The painting after the completion of the works must be inspected and touch-
up painting applied if painting does not meet the quality requirements.
Construction Company must arrange possibility for shot blast cleaning for
paint repairs. Construction Company shall also provide other tools needed for
painting.
Construction Company shall do following inspections and reports for surface

treatment:
 External conditions, i.e. temperature, humidity and dew point to fulfil

requirements specified by paint supplier/FLSmidth during cleaning,
shot blasting, painting and drying processes.
 Inspection of pre-treatment, cleaning and shot blasting, to fulfil the
requirements.
 Inspection of coats, visual and dry film thickness measurements to
fulfil requirements.
8.5 Machinery installations
Construction Company shall carry out all the measurements and reporting on
machinery installations on his scope of supply. The measurements shall
include alignment, torque of bolts and other measurements as first filling of
gear boxes, fixing, fastening or welding of supports for electrical devices and
the devices as well.
8.6 Fastening of bolts
Construction Company shall install the structural and other bolts with specific
torque requirements as shown in the individual drawings.
The bolts with torque requirements shall be closed only by using calibrated
torque wrench. Construction Company shall provide signed measurement
reports on the bolt torque.
8.7 Project plan
8.7.1 General
Construction Company is aware of the fact that there will be other mounting
companies as well as other activities of FLSmidth progressing at the same
time of his works. Such activities may include electrical installations,
hydraulic installations, air conditioning units, etc. All the mounting companies
must take into considerations in their project plans and works the other
activities underway. The mounting companies and FLSmidth shall jointly
make a plan allowing the other parties to proceed in their works in order to
maximize the total efficiency of all works.
This will have an influence on certain mounting sequences where one of the
parties must wait for the other Construction Company to be able to finish its
works on the area. This type of co-operation is already considered in the
overall costs and no separate compensation is paid to any of the mounting
companies.
8.7.2 Project plan
Construction Company shall provide for inspection and comments of

FLSmidth a project plan. The plan shall include the following:
 Detailed, daily implementation schedule.

 Manning plan for each group of specialists.
 Plan for the lifting equipment to be provided and used.
 Detailed plan for the mounting phases and lifting operations.
FLSmidth has a right to approve or reject the project plan or any details of it,
in case it does not meet the obligations of Construction Company.
Construction Company shall also present the qualifications of the intended

personnel for FLSmidth approval.
Construction Company has to nominate a site manager full time present at

the site with good command of English / Spanish.
If Construction Company wishes to use sub-suppliers, he has to propose any

possible sub-supplier, for FLSmidth approval prior any commitment.
FLSmidth has a right to approve or reject the sub-suppliers.
8.7.3 Follow-up of the project plan
During the mounting works the Construction Company shall arrange weekly
meetings together with FLSmidth supervisor to discuss the progress of the
works, activities completed and activities for the coming weeks. Moreover,
Construction Company shall inform FLSmidth supervisor on all day to day
activities.
Construction Company shall also prepare a weekly report to FLSmidth head

office on the progress of the works.
8.7.4 Mounting works
The allowed loads in the building area have to be checked with the end user
locally. In case the loads from the mobile cranes used by Construction
Company exceed the allowed loads, then distributing the loads to wider area,
using e.g. gravel, steel plates or wooden blocks, and all related costs,
transport, rent, removal etc., has to be arranged and covered by
Construction Company.
The Construction Company has to arrange sufficient area for the mounting
works. The area and all related services proposed by Construction Company
are to be sent for FLSmidth approval.
The loads from the FLS EQUIPMENT and from the mobile cranes used during
the mounting works have to be taken into consideration. The preliminary
loads of the FLS EQUIPMENT are enclosed. Construction Company is also to
check the loads from sufficient size mobile cranes and crawlers for handling
the FLS EQUIPMENT parts. Construction Company is responsible for
distribution of loads by FLS EQUIPMENT and mobile cranes during the
mounting works and moving parts of the FLS EQUIPMENT to the final
position.
8.7.5 Common requirements mounting alternatives
Construction Company has to provide movable shelters as may be needed.

Such shelters may be needed for welding, painting, touch-up painting, or any
installation work of sensitive equipment.
But in principal the FLS EQUIPMENT should be erected out of the roof
protected storage area.
Construction Company shall arrange fence or other approved method

separating the mounting area from its surrounding as well as warning signs
for unauthorized persons preventing them to enter the area.
8.8 Components to be delivered by FLSmidth
8.8.1 Design
The mounting and lifting methods will be reviewed by Construction Company.

Thereafter, any further lifting lugs Construction Company may need, is in the
scope of Construction Company.
8.8.2 Components and structures
The weights of the components and structures are specified in the bill of
materials, see separate documents.
The components and structures shall arrive in one or more shipments and/or
road transport, to be defined by FLSmidth.
8.8.3 Arrival of components and structures
Construction Company shall remove all transport supports and packing

materials of the goods, which may be needed during the transport.
Construction Company shall wash with high-pressure machines the goods

from salt spray, dust and dirt as case may be. Construction Company shall
arrange the washing equipment.
Construction Company shall store the goods needing weather protection or

with risk of theft into proper heated, ventilated and secured storage
depending of the case.
8.9 Preassembly works
Construction Company shall prepare the structures and components on the

ground level as far as possible ready prior their lifting to other structures.
Construction Company shall apply touch-up paint on those points where the
painting has been damaged due to removal of transport supports, unloading
or transports.
Construction Company shall install those outfitting parts which have been
removed due to the transport or coming from different sources, such as
structural parts, walkways, platforms, heavy electrical components and
machineries.
8.10 Mounting works
8.10.1 Mounting equipment
Construction Company shall provide with all the necessary lifting equipment,
such as:
 all necessary mobile cranes, lifting slings, forklifts and all other
means and equipment of handling and lifting of the FLS EQUIPMENT
parts
 man baskets and lifting platforms which may be needed
 any temporary scaffolding which may be needed during the mounting
Works
Construction Company shall also arrange all necessary tools for completing
the installations and mounting Works in their scope of supply.
The weights of the structures are specified in the Bill of materials, these
weights are binding. The preliminary mounting method as well as the
weights defines the required capacities for the main lifts. The adequate
capacities of the mobile cranes and other equipment are the responsibility of
the Construction Company.
8.10.2 Mounting works
The mounting method and lifting of the structural components are specified
in the chapters "Assembly instructions" and in the "Assembly drawings". Any
possible deviation to this method has to be agreed upon in advance in
writing.
All the labour needed for the mechanical mounting Works shall be supplied
by Construction Company.
Construction Company shall fully mount the FLS EQUIPMENT mechanically

and perform the tests as specified. The mechanical mounting shall also
include fitting of the parts together.
8.11 Testing
Construction Company shall ensure that the FLS EQUIPMENT is mechanically

fully completed prior the start of the commissioning and testing.
Construction Company shall provide assistance during commissioning and

final tests of the FLS EQUIPMENT.
The electric power for testing shall be either from local network or by diesel
generator set.
8.11.1 Supervision by FLSmidth
FLSmidth will follow up the Construction Company's works during its

progress. FLSmidth will solely judge the amount of necessary supervision.
The role of supervision is to advise and assist Construction Company in his

works and to approve or reject the works carried out. The presence of
FLSmidth supervisor does not relief Construction Company from his
responsibilities or to fulfil his obligations.
Construction Company shall provide an office space on the mounting site for
FLSmidth supervisors.
9 ASSEMBLY AND DISASSEMBLY INSTRUCTIONS
9.1 Instructions for the installation and mechanical completion
Foreword
These instructions are written to allow a safe mounting and dismounting of

pipe conveyors. To dismantle them, follow these instructions from the last
step to the first. The same caution applies in each case.
9.1.1 General Safety Instructions
Warning
Read all safety instructions in this manual carefully and observe
them during the work. Please also refer to Part A "General safety
instructions".
Before starting the installation work, it is mandatory that you

disconnect the plant from the main power supply!
During installation works, observe the regulations which apply to

the country where the plant will be installed.
Personnel Qualifications
Deploy only qualified personnel to perform the mounting/installation.

They shall:
 Be familiar with works related to the installation of the product.

 Be qualified by reading and understanding the complete manual of
the equipment or by instruction and training.
 Know the local hazard prevention regulations.
 Have passed first aid training.
Warning
Personal protective equipment
As a minimum, all persons working on or anywhere near the
machines have to wear personal protective equipment in strict
compliance with the signs posted at site (plant) and also in
compliance with local requirements. Additional safety equipment
may be required for specific jobs.
There is may be a risk of inhaling dust which may be detrimental

to health, depending on the type of material.
Etc.
Caution
Respiratory equipment and ear protection
In case of substantial dust loads, personnel working at site must
use respiratory protection equipment. Depending on the material
being handled and the local regulations, it will be necessary to
decide at site in each individual case whether the requirement to
use respiratory protection shall apply in general and which
protection class shall apply.
Ear protectors have to be provided by the employer when noise
level (sound pressure) is above 80 dBA and have to be used by
the employee when noise level (sound pressure) is above 85 dBA.
Caution
Chemical products
Due to the risk of personal injury through breathing, skin contact,
eye contact or input of chemical products, relevant data sheets
containing safety information must be available during mounting
works involving chemical products such as paint, anti-corrosion
agents, lubricants, cleansing agents, etc. The data sheets must be
studied carefully by the personnel involved prior to
commencement of work.
Warning
Cleaning of equipment
Mechanical equipment, steel structures and surfaces of
components must be kept clean from dust, scrap and dirt.
In particular all kinds of combustible material constitute a risk of
fire or dust explosion.
Warning
Completion of mounting procedures
Before any operation or test activity commences, a qualified
person must declare that mounting or maintenance have been
completed and that the equipment has been released for
operation or test.
9.1.2 Using the machine documentation
To ensure the assembly of a safely operating machine and to prevent

accidents during mounting, it is not sufficient to read the assembly
instructions in this Chapter 9. It is very important to pay attention to the
following points:
 Study all the safety instructions given in this chapter! Please also
refer to Part A General safety instructions.
 Study the descriptions of equipment!
 Study all the drawings and follow all the given assembly instructions
(e.g. screw fixing torques, etc.)
 Take the weights out of the parts lists to choose the right
transportation tool!
 Check all the parts for damage! Do not assemble damaged parts!
 Follow the instructions given by the supervisor from FLSmidth!
 Do not deviate from the original design without approval of the
supervisor!
 Follow the assembling steps and all instructions given in the assembly
instructions in this Chapter 9!
 Follow the supplier instructions for transport and installing of supplier
products!
 For electrical installation study and follow the electrical instructions!
 Before starting electrical installation work, it is mandatory that you
disconnect the plant from the main power supply! During installation
works, observe the regulations which apply to the country where the
plant will be installed!
9.2 Introduction
These assembly instructions are intended as a guide to perform the

mounting works in a proper and economical manner.
The sequence of this description does not mean that the assembly activities
will follow this sequence. The assembly sequence must be defined by the
assembly contractor taking into consideration:
 Supply of the structures and components from the fabricator to the

installation site
 Availability and size of a storage area at the installation site
 Availability of lifting equipment and other equipment required for
assembly activities
 Availability of work force to work simultaneously at different locations.
Taking into consideration the shipping instructions, the machine is delivered

in largest possible parts and according to the documents approved by the
customer.
Complex components have undergone a trial assembly in the workshop. The

joining elements have been marked. These markings are intended to prevent
confusion of parts that appear similar and to ensure that they are positioned
in the same way as during the trial assembly.
It is recommended to start the mounting works with the assembly of the

large components which have been shipped in sections.
The following mounting procedures are composed to provide for a smooth

sequence of operations between preliminary assembly and final mounting.
They cover the main steps of mounting works.
Some preassembly/installation of subassemblies can be performed in

parallel.
This also applies to the electrical installation and the completion of the final
coating.
The time schedule for the electrical installation of electrical equipment must
ensure that these are available for the commissioning of the relevant
assemblies.
Any damage to the painting caused by mounting works, such as welding,

must be removed in accordance to coating specification.
The mounting is considered completed with the achievement of the
"Mechanical Completion".
All "punch list" items arising out of the "Pre-operational verification" are
rectified and the mechanical installation services were performed as per
specifications and in conformance with good engineering practice.
Notice
All documents and drawings supplied for the mounting of this
machine shall be used for this purpose only. They shall not be
used for any other purpose nor be disclosed to any third party!
The mounting and assembly of the machine is to be performed in

accordance with these instructions. The sequence of mounting the
components, component parts and accessories is described in
Chapter 9.4 "Sequence of the mounting". The information is given
on the basis of the general arrangement drawings and detailed
drawings of the machine.
It is imperative that all the data given on the general and detailed
drawings are observed.
In order to assure an effective and trouble-free execution of the

mounting works, it is strongly recommended to carry out the
mounting under supervision by FLSmidth.
Warning
Take specific safety precautions concerning mounting works.
Any mounting-related, operational activities must be carried out

by qualified or authorized persons and are subject to the
supervision of a qualified person.
The mounting contractor is expected to have a site safety plan of

his own to ensure the safety of workforce.
Before any lifting operation commences, all equipment to be used

is to be checked for its suitability, safe working load and current
test certificates. Crane studies have to be executed.
Prior to performing any welding on the machine, always ensure

that ground connections are directly affixed to the part on which
the welding operation is actually to be performed.
9.3 Preparatory work
Storing of components
Assure even storage area with solid subsoil for the operations of crane and
transport vehicles.
Assure adequate accessibility for cranes and transport vehicles.
Provide sufficient space and facilities for preassembly of components and for
field welding.
Structural parts shipped loose must be stored on temporary supports such as

track sleepers or square-end timber. To prevent damage, store the individual
bundles side by side.
Components supplied in cases should also be set on timber.
If steel cables are used as slings, protect the coating against damages
caused by the sling.
Store damageable equipment according to manufacturer's specification.
Verification of supply
Unload shipped components at the job site according the shipping documents
and store generally in accordance with the installation sequence as described
in the mounting procedure.
Remove packing materials and unload containers. Check the received parts
and verify against shipping documents. Inspect components for shipping
damage and notify FLSmidth representative of damages and missing items
immediately.
Check all the parts for damage! Do not use damaged parts!
Selection and preparation of the mounting site
Assure even stockyard area with solid subsoil for the operations of crane and
transport vehicles.
Provide sufficient space and facilities for pre-assembling of components and

for field welding.
Assure adequate accessibility for cranes and transport vehicles.
9.3.1 Important mounting equipment and tools
Among the common tools and hoisting devices for mounting and installation
the following equipment will be required:
 Personal protective equipment (safety footwear, helmet, gloves, ear

protection, eye protection, safety harness with lanyard).
 High accuracy machine water level.
 Surveying instruments.
 Hydraulic cranes (To be defined dependent from site conditions).
 Temporary supports.
 Scaffolding.
 Lifting beams.
 Chain and rope hoists.
 Hydraulic jacks with pressure gauge and locking ring.
 Welding equipment.
 Dynamometric key.
9.3.2 Drawings and documents
To ensure the mounting of a safely operating machine and to prevent

accidents during mounting, it is not sufficient to read the Assembly
Instructions in this chapter only. It is very important to pay attention to the
following notes:
 Study the Descriptions of Equipment!

 Study all the drawings and follow all the given Assembly Instructions
(e.g. screw fixing torques, etc.)!
 Use weights stated in parts lists or shipping documents to choose the
right transportation tool!
 Follow the instructions given by the Supervisor from FLSmidth!
 Do not deviate from the original design without approval of FLSmidth!
 Follow the mounting sequence and all instructions given in the
Assembly Instructions!
 Follow the manufacturer instructions for transport, storage and
mounting!
 For electrical installation study and follow the Electrical Installation
Instructions!
For the available drawing see: chapter 13.1 “Assembly drawing list”
The mounting of the pipe conveyors has to be carried out based on the
appropriate drawings, parts lists and technical instructions.
9.3.3 Reference axes and levels
Prior to start of the assembly the concrete foundations have to be checked

and the results have to be documented. Besides evenness and surface
condition special care has to be taken that reference axis and elevations are
in accordance with the requirements of the drawings.
Materialize with the geometer the reference points on fixed elements at the
drive and the return end of the conveyor.
Provide reference marks for levels on walls, steelwork posts, bedded stakes,
etc.
Provide reference marks for longitudinal and transverse axes on frames,

walls, floor, etc.
For long distance conveyors, it is necessary to take additional intermediate

marks between drive and return end.
9.3.4 Tightening torque and tensile force
HV bolts (not reusable)

For HV bolts (according to DIN 6914, DIN 6915, DIN 6916 and DIN EN
14399-4/6) the tightening torque must be reported by means of a torque
wrench. The bolts have to be tightened at torques indicated on the drawings
or on contract specifications. If there are no indications, refer to table 1
below.
Schrauben Regel-Vorspannkraft Drehmoment / Torque (Nm)
Bolt Required preload force Verzinkt + MoS2 Schwarz + leicht geölt
10.9 kN Galvanized + MoS2 Black + lightly oiled
M12 50 100 120
M16 100 250 350
M20 160 450 600
M22 190 650 900
M24 220 800 1100
M27 290 1250 1650
M30 350 1650 2200
M36 510 2800 3800
Source: PEINER (07-2011)
1: Manufacturer name
10.9 Bolt grade
HV preloaded bolt
Reusable bolts
Reusable bolts have a bolt grade according to ISO 898-1.
The following torques are valid for hexagonal head screws, hexagon socket
head cap screws but not for countersunk screws, locknuts and HV bolts. They
are also valid when using plain washers and not using lock washers.
Locknuts and lock washers increase the friction coefficient.
Torque values in table 2 are given for 85% of yield strength, with friction
coefficient μ = 0,15 (tightening torques for new galvanized bolts fitted dry).
During installation works, use tightening torque 75% of the yield strength.
This tightening torque is calculated as: Tt=Tx75/85.
If bolts are lubricated, the tightening torque should be reduced of about 20%
of the values in table 2.
Table 2
T: Tightening torque (Nm)
F: Tensile force (N)
d p Grade Grade Grade Grade Grade
5.6 6.8 8.8 10.9 12.9
mm mm T F T F T F T F T F
1,6 0,35 0,075 234 0,12 374 0,16 499 0,235 732 0,275 857
2 0,4 0,159 388 0,254 621 0,339 829 0,498 1217 0,582 1424
2,5 0,45 0,33 648 0,529 1036 0,705 1382 1,04 2030 1,21 2375
3 0,5 0,57 972 0,91 1556 1,21 2075 1,79 3048 2,09 3567
4 0,7 1,3 1685 2,09 2696 2,78 3594 4,09 5279 4,79 6178
5 0,8 2,59 2759 4,14 4414 5,5 5886 8,1 8645 9,5 10116
6 1 4,49 3891 7,1 6226 9,5 8302 14 12194 16,4 14269
8 1,25 10,9 7145 17,4 11432 23 15242 34 22388 40 26198
10 1,5 21 11379 34 18206 46 24275 67 35655 79 41724
12 1,75 37 16594 59 26550 79 35401 116 51995 136 60845
14 2 59 22789 95 36463 127 48618 187 71408 219 83563
16 2 93 31385 148 50216 198 66955 291 98340 341 115079
18 2,5 128 38123 205 60998 283 83746 402 119454 471 139787
20 2,5 182 49039 291 78463 402 107941 570 153657 667 179811
22 2,5 250 61326 400 98123 552 134806 783 192157 917 224865
24 3 313 70616 500 112986 691 155489 981 221266 1148 258928
27 3 463 93042 741 148868 1022 204577 1452 291534 1700 341157
30 3,5 628 113045 1005 180872 1387 248811 1969 354209 2305 414500
33 3,5 854 141009 1366 225614 1884 310343 2676 441828 3132 517033
36 4 1096 165409 1754 264655 2418 363974 3435 518282 4020 606501
39 4 1424 198910 2279 318257 3139 437669 4463 623253 5223 729339
42 4,5 1760 227588 2816 364141 3872 500694 5515 713110 6453 834491
45 4,5 2203 266613 3525 426580 4847 586548 6903 835386 8079 977579
48 5 2659 299530 4254 479248 5849 658966 8330 938528 9748 1098277
52 5 3425 359684 5480 575495 7335 791306 10731 1127011 12558 1318843
56 5,5 4270 415172 6832 664275 9394 913378 13379 1300871 15656 1522296
60 5,5 5306 485416 8490 776666 11673 1067916 16625 1520971 19455 1779860
64 6 6382 548969 10212 878350 14041 1207731 19998 1720102 23402 2012885
Source: FACOM (07-2011)
Notice
These torque values are for guidance only! Always check with the
equipment/bolt manufacturer. Use these values only if there is no
other value on drawings or contract specifications.
9.4 Sequence of the mounting of the conveyor
9.4.1 Pre-assembly
All plant components should be pre-assembled as much as possible. This

means that all components should be assembled so that the plant
components only need to be placed in their final position and no additional
work needs to be done.
Pre-assembly might be restricted due to the maximum admissible transport

load or lifting equipment.
Before pre-assembly can start the site manager must have a clear
perspective about the order of final assembly.
The site manager must schedule the pre-assembly by means of drawings and
weight specification lists in order not to exceed the maximum admissible
loads of lifting tackle in use.
Furthermore he must plan in a way that no deformation of the construction
elements through lifting after assembly or overloading of the fasteners might
occur.
Pre-assembly must take place as close as possible to the location of final

assembly. Special care must be taken as to the crane outreach (considering
the load).
For a smooth pre-assembly the following measurements must be taken:
 The area of pre-assembly must be prepared for placing the

construction elements for final assembly.
 No deformation of any steel member or bracing must occur during
pre-assembly.
 Detailed drawings for the construction elements must be at hand.
 The various components must be prepared.
 The necessary fasteners must be prepared.
 Built-in parts must be prepared.
 All necessary lifting tackle (cranes, forklifts, winders, etc.) must be
prepared.
 The measurements of the construction elements must be checked,
especially the fitting dimensions.
Adjustments may only be carried out during pre-assembly. Therefore all

malfunctions must be solved during pre-assembly.
Columns
Depending of the size of the columns, the columns could be supplied as

bolted structures. Prior to placing of the columns to the foundation, they
must be bolted on the ground. After the columns have been placed, the
columns must be aligned and levelled by means of shims. Depending on the
column height, the columns must be secured by means of temporary
supports.
It is highly recommended to start any assembly sequence with fixed

columns, otherwise, pendulum columns have to be secured properly.
The following instructions must be respected:
 Only slings with proper length must be used. The rope angle must
exceed 30°.
 The supports must be put up in an upright position. Hereby the
support must not be deformed or damaged.
 The crane must move in such a way that the support is never pulled
along the ground.
 For lifting, the suspension points must carefully be selected. They are
different at different columns depending on design or geometry.
 Before the support leaves the ground, the safety ropes must be fixed
to the support.
 Assembly personnel must be provided to protect the support during
lifting (e.g. against twisting).
 The crane boom must not be moved hastily.
 In case of strong wind or storm warning, lifting must be stopped. The
support must be laid down again.
 Before fitting the support to the foundation it must be lined with
appropriate profiles. Only part of the bearing surface may be covered
(grouting).
 The support must be brought to the foundation in a way that all
screws can easily be inserted in the boreholes without damaging the
threads.
 During mounting no personnel is allowed under the load.
 The supports must be erected in an upright position.
 The anchor bolts must be tightened hand-tightly.
 The crane must secure the support until it has been anchored.
 Grouting must be carried out.
 After the grout has been dried the anchor bolts must be tightened
and countered.
Standard conveyor bridges
The conveyor bridges will be supplied as a welded structure consisting of the

conveyor panels including the cross beams designed as cantilever. The
length of the bridges corresponds to the maximum allowable transport
length. That means the bridges could have a bolted joint.
The splices to form the joint (bolted connection) have been marked in the
workshop and it is necessary to use the splices according to the marking.
That means each joint has a pre-defined splice. It is no specific splice
preparation required on site.
Some of the standard conveyor frames are identical and can be installed at
different location.
The assembly has to be performed in connection with the parts list, where
reference drawings are mentioned.
Gantries and galleries with cambers according the workshop drawings have
to be assembled on the ground by using of adequate locally supports to
create the curve of the camber before the bolts will be tightened.
The supporting bar for the walkway is designed as a cantilever. The

connection between two parts is achieved by means of a bolted joint.
For pre-assembling of the standard conveyor frames the assembly contractor

should provide a levelled working area where the two frame elements can be
aligned and bolted. Afterwards the railing should be installed.
The installation should be done in the following sequence:
 Both the first and the last railing post must not yet be tightened in
order to simplify the assembly of the connection from one steel
structure to the next.
 In case of partitioned railings their mobility must be guaranteed.
 Railing tubes must be checked for any kind of malfunctions which
might lead to injury (welding spatter, cutting ridges at the ends...).
After pre-assembly of the railings all system measurements and fitting

dimensions must be checked again and laid down in writing.
Walkway flooring
Usually, the walkway flooring has been designed as galvanized grating. The
fixing of the grating will be done by means of bolted clamps. The fixing of the
each grating must be done immediately after installation to avoid
moving/slipping of the grating which could lead to work accidents.
After installation of all gratings on the walkway the fastening of each grating
must be again checked carefully.
Each grating must be fixed with four clamps to avoid moving.
When installing the gratings it must be ensured that there are no steps or
edges between the single panels which could cause somebody to stumble.
Lifting of the standard conveyor bridges
Depending on the availability of the lifting equipment, the assembled

standard conveyor frames including railing, walkway flooring and idlers can
be lifted to the final position in one lift.
The assembly sequence will start at a fixed point of the frames. It is possible
to start at different fixed points and to work simultaneously in both
directions.
The assembly contractor has to check the weights of the standard conveyor
frames based on the part lists considering as well the outreach and the lifting
height of the lifting equipment.
The following instructions must be respected:
 For lifting of steel structures the lifting points must be selected

carefully (e.g. upper chord near to the panel).
 Lifting is only permissible by the strong main girders of the structure
(by no means by the diagonal struts).
 For easier assembly the steel structure should be lifted with the
inclination it will be finally assembled. In case of curved steel
structure the displaced gravity caused by the curve outer radius must
be considered.
 When lifting a curved steel structure, consideration must be given to
its remaining in a stable (horizontal) position, both in longitudinal and
transverse directions. If necessary, corrections must be made.
 In case of long steel structures the lifting points must selected neither
too close nor too far away from the steel structure ends in order to
prevent deflections or overhanging.
 Only lifting sling gear with proper length must be used. The rope
angle must exceed 30°.
 During lifting no personnel is allowed under the load.
9.4.2 Materialization of the conveyor centreline
Tighten a piano wire, which is ballasted at both ends, between the reference
marks.
See scheme 1 in chapter 9.5.1.
It is also possible to use a theodolite for the longitudinal setting.
9.4.3 Installing the frame of the drive pulley
Lay out the drive frame by means of the reference axes and the indications
of the drawings.
Mount the drive frame.

After setting according to the reference axes, fasten the frame by bolting or
welding on the floor steelwork. Verify the level of the pillow-block seating
vertically and horizontally.
Mount the part of the discharge chute which is included in the drive frame.
Mount the drive pulley and the snub pulley.
9.4.4 Installing the substructure
Assembly by bolting the posts and the substructure beams. Proceed from the
drive to the tail end.
Mount the frame of the bend pulleys, at the take-up station.

Set the substructure and the frame of the bend pulleys, according to the
reference axes and the indications of drawings.
Fasten on the steelwork.
Verify the level of the pillow-block seating vertically and horizontally.
Mount the bend pulleys.
See schemes 2 and 3 in chapters 9.5.2 & 9.5.3.
9.4.5 Installing the return frame
Lay out the return frame by means of the reference axes and the indications
of the drawings.
Mount the return frame.

Set the frame according to the reference axes and the indications of
drawings.
Verify the level of the pillow-block seating vertically and horizontally.
Bolt the frame.

Install the tail pulley and the snub pulley.
9.4.6 Installing the counterweight
Mount the guides of the counterweight box.

Mount the counterweight box and the take-up frame (with pulley) in the
guides.
Set the guides with the box and the take-up frame in the conveyor centerline
and fasten by bolting, welding and/or grouting.
In particular, ensure accurate perpendicularity of the guides.
9.4.7 Installing the idler supports
Mount the return idler supports on the beams by using the holes provided for
this.
Respect the perpendicularity of the supports to the beams.
Fasten the supports, the oblong holes pushed as much as possible backwards
(i.e. in direction of the return tail frame).
Mount the upper idler supports.

Begin at the return station with the impact idler supports which are bolted.
Fasten the supports, the oblong holes pushed as much as possible
frontwards (i.e. in direction of the drive frame).
Set the supports in the conveyor centerline, with the spacing shown in the
drawings.
See schemes 4/1 and 4/2 in chapter 9.5.4.
Mount the idlers on the upper and lower supports.
9.4.8 Adjustable carrying idler station
Pre-assembly of the adjustable carrying idler stations demands the following

steps to be taken:
 According to the general arrangement drawing the positions of the

adjustable carrying idler stations must be determined.
 The adjustable carrying idler stations must be fixed perpendicular to
the transporting direction.
 After the idlers have been fitted into the adjustable carrying idler
stations the carrying idler stations must be completely open.
 This position must be fixed.
 From the top edge of the reverse pulley and/or drive pulley a string
must be tightened to the lowest idler of the first panel.
 The carrying idler station must be fixed in such a way that the middle
(lower) idler of the carrying idler station is exactly brought into line
with the string.
9.4.9 Belt forming idler
Pre-assembling the belt forming idlers plus holders demands the following
steps to be taken:
 According to the general arrangement drawings the positions of the

belt forming idler holders must be determined.
 When installing the belt forming idlers the overlapping of the belt
must be considered in order to fix the belt forming idlers to the
correct side. FLSmidth defines the overlapping.
 The belt forming idlers are installed provisionally and are fixed for the
lifting of the stations.
9.4.10 Safety panel
Pre-assembly of the safety panels demands the following steps to be taken:
 The carrying idlers must be parallel to the panel (for double-sided

positioning of the idlers this applies to both sides).
 The pitch between the idlers must be checked.
 Noise created by touching idlers, faulty bearings or too big idler
mountings must be avoided.
 After the idlers have been fixed to the panel and appropriately
adjusted, the fitting and/or aperture resistance of the resistance
elements must be adjusted.
 The rotation behaviour of each idler must be checked.
 The protection against falling out must be checked on each idler.
 In case of double-sided positioning of idlers the alignment of the idlers
to each other must be checked.
9.4.11 Carrying idlers – Panel
When pre-assembling the carrying idlers to the panels the following items
must be considered:
 The carrying idlers must be parallel to the panel.

 Fix the carrying idlers with the holders to the panel.
 Noise created by touching idlers, faulty bearings or too big idler
mountings must be avoided.
 All bolts must be tightened appropriately.
 The rotation behaviour of each idler must be checked.
 The protection against falling must be checked on each idler.
After pre-assembly of the carrying idlers in the panels the idlers must be
checked for completeness.
9.4.12 Installation of the belt
Preparations
Before installing the belt the following preparations must be made:
 In case of lower boom covering the appropriate coverings must be

installed before installation of the belt.
 The site manager decides in co-operation with the management and
the vulcanizer where the belt reel is placed.
 The site manager and the vulcanizer decide about the order (where
will the power press be installed, beginning on top or at the bottom).
 All necessary devices must be prepared (belt tensioning
equipment...).
 The towing devices (traction cable, cable winch, reverse pulleys...)
must be checked, prepared and adjusted for the maximum loading
capacities.
 In order to guarantee communication among the assembly personnel
hand radio sets must be prepared.
 The space for the belt reels must be prepared.
 The expiry date of the splicing kits must be checked.
 The site manager must instruct the personnel as to the safety
connections.
Installation of belt
Special care should be taken when transporting the belt to the unit to ensure
that the cover or the edges of the belt are not damages by ropes etc. Pointed
or sharp objects, which could damage the belt, must be removed before
placing the belt on the ground.
The idlers and pulleys should be checked for easy running before installation
of the belt; any dirt or oil has to be removed. The rollers in the upper and
lower frame must be aligned at right angles to the conveyor axis. The
tensioning devices and brakes must be completely released.
Special care must be taken when fitting the belt to ensure that the edges are
not squeezed, bent or folded over. Moreover, it has to be ensured that the
belt passes freely over all points. To avoid any incisions or indentations
during installation of the belt, wood or rubber pieces should be placed under
hand devices, tensioning brackets, clamps etc. The belt must be positioned in
a straight line onto the unit and aligned before tensioning, as far as this is
possible without using force.
Pay attention to right installation of the belt side, i.e. the top or running
surface of the belt must be on the top (not upside down!). See also the
manufacture’s instructions.
The end of the first belt will be connected to the pulling rope by using a
“bullet”. To connected the belt end the rubber has to be cut off that the inner
textile cords can be fixed to the pulling rope by means of rope clamps. The
first 10 m of the belt have to be wrapped to a round shape with tape.
Alternatively, the round shaped belt end can be fixed with bolts onto a steel
cone. The cone is fixed to the pulling rope.
Tapering the belt

For tapering the belt the following steps are necessary:
 The towing devices must be fitted to the construction and the cable
tightened to the belt with an assembly sling.
 The appropriate overlapping must be considered.
 Should winders be used, they must not act on the steel structure, but
only on especially set up girders.
 These girders must be fixed in a way that they are only supported by
strong main girders (like end frames). Stringers must never be used
as such supports.
 The girders must be secured mechanically (e.g. by clamping) against
sliding.
 If the winder must be reset the belt must be secured at that time.
Example of installation at the return end
Intermediate vulcanization
As the entire belt very often does not fit on one reel intermediate
vulcanization must be carried out.
 The belt may only be run in so far that its end lies where the power
press is situated.
 The reel is then changed and the belt from the new reel is pulled to
the power press.
 The power press is installed, the belt ends are prepared and
vulcanization is carried out.
 This may only be done by an especially qualified belt vulcanizer
following the belt producer’s instructions. The vulcanizer has the sole
authority for this procedure.
 The power press is removed and the running in of the belt may be
continued.
Infinite vulcanization
After the belt has been run in, both in the upper and the lower strands,
infinite vulcanization may begin:
 One end of the belt is clamped and secured. The clamping device
(recommended are, according to the plant, channel- or W-shapes).
The clamping device may only act on the appropriately strong main
girders of the steel structure.
 The belt slack is removed by pulling the belt, the take-up pulley is
held at its higher position.
 The other belt end is clamped and secured. The clamping device may
only act on the appropriately strong main girders of the steel
structure.
 The power press is installed, the belt ends are prepared and
vulcanization is carried out.
 This may only be done by an especially qualified belt vulcanizer
following the belt producer’s instructions. The vulcanizer has the sole
authority for this procedure.
 The infinite vulcanization could be done at head or tail end, before the
pipe forming area.
 Power press and clamps are removed.
A report must be made about each vulcanization process, stating the

important data (date, atmospheric temperature, press temperature,
duration, executing firm…) and transmitted to FLSmidth.
Commissioning
Before tensioning of the belt, check the unit carefully (as to the correct
amount of idlers, tightness of the bolts; moreover, remove all tools etc.).
Then tension the belt at a standstill. The initial tension should not be greater
than that required for slip-free transmission of forces. Start the tensioned
belt for a no-load test run. Observe the running of the belt. Stop the system
after several revolutions of the belt for inspection purposes. Re-tension if
necessary and correct the straight run of the belt by shifting the return
pulley, bend pulley or carrying idlers.
Rule: The belt runs to the non-tension side. Reduce the tension at the
opposite side!
Allow the system to run in no-load condition until the belt runs correctly. If
the belt drifts when under full load, then the system must be inspected for
possible faults (charging, alignment etc.).
Repeat no-load test run.
Small corrections may still be required in order to achieve correct running of

the belt. It may be necessary to re-tension the belt after the first few days or
weeks of operation since the belt must be run-in under operational loads.
9.4.13 Installing the drive unit
Pre-assembly of the drive unit must be decided by the site manager on the
spot. Special care must be taken of:
 Centre of gravity movement by the weight of drive.

 Assembly possibilities.
 Maximum load of lifting tackle and sling gear.
Pre-assembling the drive unit demands the consideration of the following

items:
 At first all fitting dimensions must be checked.

 Each producer’s regulations must be complied with throughout
assembly.
 When connecting the gear unit with the transmission shaft the latter
must not be overloaded.
 Bracing and bending of the transmission shaft must be prevented.
 The drive unit must be protected during assembly. The safety devices
may only be removed after the stable and safe connection of the
torque arm with the steel construction.
When the installation of the drive unit is finished, the alignment of motor,
coupling and gearbox has to be accurately checked again.
Even if the site manager decides not to pre-assemble the drive unit, all
fitting dimensions and fittings must be checked. If necessary, the drive unit
must be lifted to its prospective position in order to decide about the
assembling possibilities and corrections of the measurements.
Adjustments may only be carried out on ground.
9.4.14 Installing the steel plate items and various fittings
Mount the skirt boards, the safety scraper, and the prospective guards at the
tail station.
Mount the lower part of the discharge chute, the hood on the chute, the
cleaning scraper and the whole protective guards.
9.4.15 Skirt board
Pre-assembling the skirt board demands the following steps to be taken:
The drawings of the skirt board and the construction elements must be
prepared.
Each construction element is installed in the station.
The adjustability of each construction element must be checked.
The rubber skirts must be trimmed / tailored.
There must be enough reserve for exact adjustment during the final
assembly.
The lateral guides must be adjusted so that they do not touch the belt.
In order to guarantee consistent alignment gauges of 1 to 2 cm (6/16 to
13/16”) should be used.
Afterwards all parts of the skirt board which might obstruct the installation of
the belt must be removed. The decision over the parts remaining lies in the
judgement of the site manager.
9.4.16 Installing the electrical components
Mount the emergency stop switches with their supports and pull ropes.
Mount the belt misalignment switches with their supports.
Mount the clogging detector with its support.
Mount the speed controller with its support.
Mount the take-up limit switches with their supports.
Mount the over filling switches with their supports.
Mount the warning horns and flashing lights with their supports.
Mount the belt rip detections with their supports.
Mount the over flow switches with their supports.
Mount the belt twist switches with their supports.
Mount the safety panel switches with their supports.
The setting of all these fittings must be done during the no load tests and
tests under load.
9.4.17 Adjusting the belt tension and providing various settings
Fill the counterweight box with the theoretical quantity of counterweight

blocks specified in the drawing (to be readjusted during the tests if
necessary). Release the box to get the belt tension.
Set the blades of the cleaning scrapers.

Set the tension of the scraper springs.
Set the rubber skirts of the skirt boards.

The skirts must be tangential to the belt without pressing the belt.
Skirts which press the belt cause a heating-up of the rubber during operation
and the union of the skirts and the belt when stopping.
Set the safety scraper over the counterweight box.
Set the rubber scraper after the snub pulley in the drive station.
For more details, see the following chapter 9.5 "Settings".
9.4.18 Preparing the tests
Before performing the tests, it is necessary to check the whole plant and to
remove all foreign objects from the carrying belt and the return belt.
Furthermore, check the following points:
 Presence of oil and grease in the reducers, pillow blocks, fluid

couplings and various fittings.
 Adjusting the belt tension.
 The winches, if any, over the counterweight boxes must be
disconnected and fixed to the steelwork.
 Securing of all bolts.
 Correct welding of the frames and the posts to the steelwork if
necessary.
 Correct sealings in civil works.
 Presence of protective guards around rotating parts and under the
counterweight.
 Presence and connection of all safety devices (they must be tested
before starting the conveyor).
 Connection of the couplings where applicable (because of the
disconnection is required for verifying the running direction of the
motor).
 Presence of a safety system under the counterweight in case of fall
due to a belt rupture (wood, sand, old tires, to protect the box and
the floors).
Warning
Any work near or on the conveyor is strictly forbidden during the
tests.
All persons not directly involved in the tests should not move or
stay near the conveyor. A correct signalization must inform
people of possible danger.
9.4.19 Allowable tolerances
Notice
These tolerances are usual tolerances and for guidance only!
Always check on the drawings. Use these values only if there is no
other value on drawings or contract specifications.
9.4.19.1Conveyor stringer alignment
These tolerances are guidelines for design/manufacture to facilitate proper

alignment in accordance with the Idler Alignment section of this standard.
The overriding issue is idler and belt alignment as opposed to structural
alignment.
Conveyor frame / stringers must be installed parallel, straight, square, and

level to allow proper belt training. During installation, dimensional checks
shall be made to insure that the following tolerances in the idler carrying
chords are not exceeded.
Parallel
A maximum tolerance of ± 3 mm (1/8 inch) shall be allowed for the back to
back dimension in channel frame or angle stringers. Similarly, ±3 mm (1/8
inch) shall be allowed between webs of I-beams, wide flange beams, or tees
when used as truss chords.
Straightness
The maximum allowable lateral offset in conveyor stringers shall be 3 mm
(1/8 inch) in 12 m (40' feet) of length
Squareness
A check on squareness can be made by comparing diagonal measurements
between idlers, as shown
Lines A and B must be within 3mm (1/8 inch) to assure conveyor frame
squareness. Return idlers should, likewise, be installed level and parallel to
the head and tail pulleys.
Level
The two idler support members shall be level within 6 mm (1/8 inch)
regardless of belt width. In addition, the elevation of stringer above support
structure shall be within ±3 mm (1/4 inch).
9.4.19.2Pulley and shaft alignment
Except for special purpose applications, all belt conveyor pulleys should be
set level, and the shaft centerline should be perpendicular to the centerline
of the belt. Significant departure in alignment will result in unnecessary
thrust load on bearings, accelerated and uneven pulley lagging wear, and
belt training problems. It is most convenient to field align pulleys after
supporting steel is secured and before belting is installed.
After alignment, it is good practice to match mark bearing housing and

supporting steel to enable realignment if disturbed for any reason.
Intentional misalignment should not be used as a means to counteract other
misalignment forces for training the belt.
By use of adjustable bearing stops and full bearing surface shim packs, the
following alignment tolerances can be reasonably achieved. Using a level and
checking both sides of the pulley, shaft elevations at the bearings should be
set within 0.8 mm (1/32 inch).
Measuring from a line constructed perpendicular to the conveyor centerline;

the shaft centerline should not deviate greater than ± 0.8 mm (1/32 inch) at
the bearings. Because of pulley locations and access thereto, it is common
practice to utilize offset lines and plumb bobs to make these measurements.
When pulleys are mounted on shafts by the equipment supplier, they shall
be secured to the shaft in accordance with the recommended practice of the
locking element manufacturer. When supplied separately, they should be
located on the shaft ± 3 mm (1/8 inch) of the position shown on the
drawings.
If pulleys and shafts are field assembled or repositioned, pulley

manufacturer recommendations must be followed to avoid dishing of end
discs and residual end disc pre-stress.
With some locking elements, it may be necessary to check and tighten

clamping bolts several times to insure security of hub and shaft assembly.
Manufacturers’ recommendations should be followed with regard to checks
and bolt torques. Pulleys, shafts, bearings, and supporting steel may be
shipped in various degrees of preassembly.
Due to manufacturing and mounting tolerances, final bearing setting should

be done in the field after supporting steel has been secured. Procedures and
tolerances for bearing settings should be obtained from the bearing
manufacturer's catalogs. Improper setting of both fixed and expansion type
bearings may result in thrust pre-load, causing premature bearing failure.
9.4.19.3Idler alignment
Idlers shall be set from a previously squared and levelled terminal pulley
(preferably the discharge pulley, although this is not essential). The
suggested method is to use laser alignment techniques to establish a datum
line. Alternately, use a tight wire on the conveyor centerline or offset to it,
stretched to form a true centerline reference. This line should be at least 30
m (100 feet) long and referenced to the squared starting pulley.
Idlers shall be placed at design spacing and square to the line. After a span
of about 15 m (50 feet) has been filled with idlers, the 30 m (100 feet) line
shall be relocated so that there is a 15 m (50 feet) overlap on the first
position. Repositioning of the laser or tight wire should continue until the
entire conveyor length is filled with idlers.
Belt training is usually minimized if:
 Conveyor has been installed straight and level with tolerances stated
herein.
 All pulleys and idlers are square with the conveyor centerline.
 Belt splices are correct and square.
 There are no defects in the conveyor belting.
 All idler rolls turn freely.
However, all these conditions are rarely present concurrently, and some
training of the belt is usually required.
Notice
Belt training should be supervised by one person to insure
consistency in adjustments.
Training the belt is a process of adjusting idlers and the method of loading in
a manner that will correct any tendency of the belt to run off to one side or
the other.
When the belt continues to run off consistently over a fixed length of
conveyor, the cause is probably in the alignment or levelling of the conveyor
structures, idlers or pulleys in that area.
If one or more segments of the belt run off at all points along the conveyor,
the cause is more likely the belt itself, a splice, or the method of loading.
When a belt is loaded off center, the lightly loaded edge will rise on the
inclined idler roll that it contacts.
All pulleys should be level and at 90 degrees to the centerline of the

conveyor. They should be maintained this way and never shifted to train the
belt.
Training the belt with the troughing idlers is accomplished by shifting the
idler axis with respect to the path of the belt, commonly known as knocking
idlers. This method is effective when the entire belt runs to one side along a
fixed length of the conveyor. The belt can be centred by knocking ahead (in
the direction of belt travel) the end of the idler to which the belt runs.
9.5 Settings
9.5.1 Materialization of the axes of reference
SCHEME 1
9.5.2 Pulleys
General
The following pulleys are concerned:
 drive pulley
 tail pulley
 snub pulleys (at drive and/or tail end)
 bend pulleys
A correct installation of the steelworks, frames and support elements is a

sure advantage for a quick setting of the pulleys.
See scheme 2 in - This scheme illustrates the mode of operation.
Mode of operation
Before positioning the pulleys, verify the levels of the various drive and tail
frames.
Mark the symmetry axis of the pulley.
Straighten the pillow blocks of the pulley, by partial insertion of fine shims
under the left side or right side of the pillow-block, to set it horizontally.
To the wire which materializes the conveyor centerline, hang a plumb line
over the upper generating line of the pulley.
Shift the pulley in order to align its axis of symmetry with the end of the
plumb line.
Hang a plumb line to the wire on both sides of the pulley.
Verify perpendicularity of the pulley with the conveyor centerline as follows:
 on the front generating line, mark the position of the plumb line at the
tangential point with the sleeve of the pulley
 swing round this point by a rotation of 180° of the pulley
 verify on the back horizontal generating line that this mark exactly
coincides with the back plumb line at tangential point with the sleeve
of the pulley
If it coincides, the pulley is perpendicular with the conveyor centerline.

If it doesn’t coincide, shift the pulley and start again as described until the
pulley is perpendicular.
Notice
The setting of the level and the perpendicularity of the pulleys is
an operation which requires a lot of precision and care, because it
is an essential element for a good working of the belt.
The pillow blocks seating must be definitively welded on the
steelwork after setting and no load tests.
Take-up pulley
For a vertical gravity take-up, only center the pulley on the frame of the
counterweight box in accordance with the drawing, and straighten the pillow
blocks.
SCHEME 2
9.5.3 Substructure
Steelwork
General
The drive frame, which is set up with precision in accordance with the
reference bases, is used as starting point for the installation of the conveyor
substructure.
See scheme 3 in - This scheme illustrates the mode of operation.
Mode of Operation
Substructure at ground level or on civil work
a) Posts
a1) Level
Transversely level the posts by means of an air level, by adjusting the
oblong holes of the sealing angle-irons or adding shims as required.
a2) Symmetry
Align the axis of the post with the conveyor centerline by means of a plumb
line which is hanged to the wire and a rule.
b) Beams
Verify the length of the diagonals and the perpendicularity of the joints with
the conveyor centerline.
Substructure in galleries
a) Posts
a1) Level
The transverse level of the posts is the one of the gallery, because they are
welded or bolted on 2 longitudinal sections provided for supporting them.
a2) Symmetry
Align the axis of the post with the conveyor centerline by means of a plumb
line which is hanged to the wire and a rule.
b) Beams
Verify the length of the diagonals and the perpendicularity of the joints with
the conveyor centerline.
SCHEME 3
9.5.4 Idler supports
General
The supports must be mounted when the substructure is set and fixed.
The loading area at the tail station, with fixed idler supports, is used as the
starting point for the installation of the idler supports.
The support types and the spacing are specified in the drawings.
See schemes 4/1 and 4/2 in - They illustrate the mode of operation.
Lower idler supports

Push the supports to the end of the oblong hole on the beams (in direction of
the return station) and bolt them.
Put a square on the upper side of the beam and correct the perpendicularity
before locking the bolts.
Upper idler supports
Spacing
After the last impact idler support, set the first standard upper support and
mark its position on the left and right beam.
For marking the spacing, use a rule or a previously made gauge of the exact
length.
Perpendicularity
It is checked using a large square which must be put on the inner or outer
side of the beam.
Symmetry
After installing the support with a correct spacing and perpendicularity with
the axis, mark the axis of symmetry of the support and align it with the
plumb line hanged to the wire of the conveyor centerline.
Verification
In order to avoid too big divergences, it is necessary to:
 verify the equality of the diagonals every 10 or 20 supports

 verify the perpendicularity from time to time by the method of the
isosceles triangle.
SCHEME 4/1
SCHEME 4/2
9.5.5 Guides of the counterweight box
General
The setting of the guides of the counterweight must be done with much care,
because it is important for the position and the function of the take-up
system.
See scheme 5 in - This scheme illustrates the mode of operation
Mode of operation
To set up correctly the guides, define their longitudinal and transverse axes.
Center the guides with regard to the bend pulleys:
 The axis of the guiding sections must be in the axis of symmetry of

the bend pulleys (after setting of the pulleys).
 Materialize this axis by marking on the frame of the pulleys or the
substructure.
 By means of a plumb line, mark this axis on the various levels where
the guides are fixed.
 Center the guides with regard to the conveyor centerline:
 By means of a plumb line hanged to the wire of the conveyor
centerline, mark this centerline on the various levels where the guides
are fixed.
Verify, before sealing or welding, the verticality of the guides in both

directions, by means of a plumb line (an air level is too short).
SCHEME 5
Beam
X
Bend pulley
Z
Take up pulley
Counterweight box
Guides
X
Z
Plumb line
The total weight of the counterweight + box + pulley & frame must be equal
to the tension force divided by the gravity (P= F/9,81), see chapter 13.2
"Technical data", but must be adjusted and recorded if required.
9.5.6 Counterweight variations
Generally the counterweight of take-up stations or the tension force has to

be adapted for commissioning. The required tension weight / force can vary
from the calculated nominal weight / force, caused by different belt
properties.
It is also necessary to check the tension weight / force in regular intervals (6

months). The belt behaviour can require a weight / force variation to a later
date.
Notice
Whatever the take-up system (gravity or screw), the conveyor
belt with textile rope must not be tensioned more than 2%. The
belt tension must be limited at the minimum required for non-
slipping under load. At the first commissioning, the belt tension
should be limited to 80% of the value given in the technical data
in chapter 13.2"Technical data".
9.5.7 General description on works in case of belt misalignment
The following description is to give an overview of necessary adjustment

works in case of belt misalignment and shall serve as a guideline for the
staff.
The most important basic elements of a conveyor belt are described below.
All these elements contribute to the straight running of conveyor belts:
 Conveyor belts.
 Conveyor pulleys of any kind.
 Take-up stations.
 Idler stations.
 Transfer chutes.
 Belt cleaning equipment.
 Conveyor structures.
The listed basic elements shall be inspected continuously.
Also refer to chapter 11.5.15 “Rubber belt”.
9.5.8 Conveyor belt
The conveyor belt has to be kept clean. For this, it is essential that the belt
cleaning equipment is correctly adjusted.
9.5.9 Conveyor pulleys
No material caking shall occur at the conveyor pulleys. Rubber-lagged

pulleys shall be checked on damages of the rubber lagging. The functioning
of the V-scrapers provided at the lower strand shall be checked. It is
absolutely important that the V-scrapers scrape off any material from the
belt before the tail pulley is reached.
9.5.10 Take-up stations
Take-up stations have to be checked on sufficient belt tension. The belt

tension can be checked by controlling the belt sag in the returning, lower
strand of the conveyor belt shortly before the take-up station is reached. By
pressing down with the hand, the sufficient tension can be roughly
estimated.
9.5.11 Idler stations
Many types of idler stations are available. In the upper strand, they are
designed as adjustable troughing idlers.
Below the transfer chutes, the idler rolls are mostly designed as rubber-disc
rollers. In the returning, lower strand there are different types of idler
stations.
9.5.12 Transfer chutes
Transfer chutes shall transfer the conveyed material centrally onto the next
downstream conveyor belt. The material flow is routed centrally to the next
conveyor belt by means of baffle plates. Transfer chutes shall be kept free of
material caking so that the adjusted flow of material to the next conveyor
belt does not change.
SKETCH Chute with Impact plate

Baffle plate Discharge pulley
Conveyor belt with

material
Belt scraper
Center oft he belt
9.5.13 Belt cleaning equipment
Scrapers are used to clean the conveyor belt. In the returning lower strand
V-scrapers are provided in order to protect the pulleys and the conveyor
belt. The scrapers shall avoid that material or parts get between the pulley
and the belt since this may lead to material caking at the outer pulley shell
which, in turn, may damage the conveyor belt or may cause belt
misalignment.
SKETCH V scraper Conveyor belt
Belt travel direction
Pulley
V scraper
Belt travel direction
Scrapers
Pre-assembly of the scrapers must be done before the final assembly of the
stations. In this case it serves to:
 Determine the fitting dimensions.

 Find out whether simple access to the scrapers is possible.
 The scrapers can be serviced.
As guard hoods or coverings might also obstruct access to the scrapers they
must also be pre-assembled in the course of this action, if necessary.
Should access to or simple maintenance of the scrapers not be possible

adjustments (only during pre-assembly) must be carried out.
For pre-assembly of the scrapers the following items apply:
 Fitting dimensions must be checked.

 The producer’s regulations must be considered.
 The feasibility of maintenance must be checked.
 For lifting of the stations the scrapers must be protected.
 For installing the belt the scrapers must be fixed sufficiently far away.
If necessary, they must be removed.
9.5.14 Conveyor structure
The conveyor structure with the construction components such as drive unit,
take-up station and steel structure of the conveyor belt are already aligned
during the assembly. These components only have to be checked again if
any structural changes or displacements have occurred.
9.5.15 General belt misalignment
There are two kinds of belt conveyor operation: no-load operation without
any material and the operation with load, i.e. with material. First of all, all
basic elements of the belt conveyor shall work perfectly in no-load operation.
It is therefore important, that the checking of the no-load operation forms
part of the maintenance works, so that a misalignment of the belt can be
detected and remedied immediately.
9.5.16 General inspection of the pipe conveyor prior to aligning the

belt without material
First, the take-up station has to be checked on sufficient tension at the take-
up pulley. If there is sufficient tension, the position of the take-up pulley in
connection with the lower idler rollers in the return belt shall be checked. It
is a prerequisite that all conveyor pulleys, idlers and the belt are clean.
9.5.17 Inspection of the take-up station
The take-up station is provided in the lower strand of the conveyor.
The counterweight shall also be positioned perpendicular and shall be

centrally guided to the center of the belt. The take-up pulley shall be
positioned horizontally. The tail pulley is adjusted as described in chapter
9.6.5.
SKETCH Upper strand
Lower strand
Bend pulley
Take-up
pulley
Counterweight
The tail pulley provided at the end of the belt is aligned at 90° to the center
of the belt. Here, misalignment can only be remedied by adding shims on
one side of the bearing housing. The aligning of the conveyor belt is
determined by the plate thickness.
Notice
As with all adjustments made at bearing housings for the aligning
of pulleys, the air gap of the labyrinths of the seals has to be
controlled. If the labyrinths grind against each other, the bearing
will heat up. The bearing grease then heats up and leaks which
results in damages to the bearing.
9.6 Interferences, faults and repair
9.6.1 Correct fixing of belt forming idler

conyeing direction
fixing of beltformingidler
first panel
A
A B
first panel
B fixing for beltformingidler
section A- A section B- B
a
a
a: for idler and running belt between 20mm and 25mm
Notice
Contact of overlapping belt (above) and belt forming idlers must
be avoided. Little adjustment of the settings may be carried out
during run-in (tilting of the belt forming idlers).
The belt forming idlers must always be positioned in a right angle to the top
edge of the belt.
9.6.2 Belt twist
conveying direction
A
conveying direction
section A- A
upper
belt
normal unloaded loaded
lower
belt
The cross section A-A shows the ideal belt position.
Notice
If it cannot be obtained in every operation mode, the belt may
make a light torsion during unloaded operation mode.
If loaded, the overlapping must be above in the carrying belt and
below in the return belt.
9.6.3 Overlapping of the belt
As seen from running direction of the carrying belt the overlapping of the
belt must be shown as follows:
Example 1 (curve to left)
section A- A co n ve yo r direc tio n
u pp e r be lt
A
lo w e r b elt
Example 2 (curve to the right)
A
section A-A
upper belt A
conveyordirection
lower belt
Both types of overlapping may be applied in case of straight pipe lines and/or
s-bends. The final decision should depend on the main direction of wind
and/or rain.
9.6.4 Belt correction at twisted belt
The above sketch shows an overlapping located too far left. Correction is to
be carried out by adjusting the carrying idler (as shown).
Notice
The selection of idler(s) to be adjusted depends on the local line
and the pressing of the belt on each idler. The supervisor specifies
the idler(s) to be adjusted.
The above sketch shows the effect of adjustment of the idlers for the belt
torsion.
9.6.5 Correction of belt running
Drive station:
Before start up the drive pulley must be mounted in line.
The adjustment of the belt alignment is carried out by adjusting the carrying
idler station.
The sketch shows that rotation of the carrying idler station counter clockwise
leads to the belt moving to the left side.
A rotation of the carrying idler station clockwise therefore leads to the belt
moving to the right side.
Reverse station:
Before the start up, the return pulley must be mounted in line.
The adjustment of the belt alignment is carried out by adjusting the return
pulley.
The sketch shows that rotation of the return pulley counter clockwise leads
to the belt moving to the right side.
A rotation of the reverse pulley clockwise leads to the belt moving to the left
side.
9.6.6 Belt tension
Signs for too low belt tension are:

 the belt runs discontinuously
 the belt does not form properly into the pipe shape (hexagon)
 the overlapping changes within the pipe forming zone (reversal of the
belt)
 the belt moves along the drive pulley in the opposite direction of the
tensioned, overlapping belt.
The pretension must be increased.
Signs for too high belt tension are:

 the belt shape in the area of the curve is much narrower than
elsewhere
 the belt moves along the drive pulley in the opposite direction of the
tensioned, overlapping belt.
The pretension must be decreased.
9.7 Installing the attached equipents with conveyor
To be done if any other equipment (belt scale, maintenance hoist,

etc.)
9.8 Installation of cable trays and cables
The layout of cable trays must be based on the "arrangement drawings for
external equipment and cable ways". The cable ways are fixed to the
installation supporting structures which are made of angle or U-profiles, by
means of special fastenings.
After welding all parts, which are made of iron, they have to be protected by
a special painting against corrosion. Since the cable ways are firmly fixed to
the supporting structures, they will not be screwed up by means of
connecting or bend parts but will be only jointed at these points.
To reduce danger of injuries, the cable ways are provided with protective
bushes of synthetic material on both ends.
These are only general information regarding the laying of cable trays. The
exact course and fastening method of the cable ways has to be decided
individually from the erection supervisor.
The cabling is based upon the cable list, and the arrangement drawings for
the external devices and cable ways. The cable numbers have to be
permanently fixed at both cable ends by means of designation plates. The
cable lengths indicated in the cable list only serve for determination of the
total cable requirement and are not binding for the various cable lengths
actually required for installation.
The cables must be laid directly from the reel and must only be cut when
both destinations have been reached taking into account the cable length
needed for connection to the terminals.
Everywhere where cables are not laid via cable trays, they are led through
steel armoured conduit with bushes on either side. The cross section of the
cable in the conduit must not exceed 40 % of the clear conduit cross section.
To facilitate the laying of cable, bends are not performed with steel conduit.
At these points the conduit is cut off and provided with bushes and the cable
is laid freely in the bend area. If a cable with reduced load is concerned -
such as control cables - several cables can be laid jointly in one conduit.
Power cables are generally to be laid separately. Screened cables and signal
cables are to be laid separately and moreover, with a certain distance to the
power cables.
Cable inlets on devices, connecting boxes etc. have to be provided with

cable screw joints. As additional sealing, the cable screw joints are filled with
a sealing material before end of assembly. As the cable screw joints are not
designed to support the cable weight, the cables are supported, if necessary,
before introduction into the cable screw joints. If a cable crosses the lateral
part of a cable tray, sharp edges have to be covered and the cable has to be
fixed in such a way that friction during operation is avoided. It may occur
that the cable inlets of several machines are too large for the cable cross
sections. In these cases, the cable inlets have to be adapted by means of
the supplied reducers.
As far as the installation of the lights is concerned, the supply is made by

only one cable which will be led from the jointly screened groups of lamps or
groups of sockets. The further distribution of cables is then provided by
means of junction boxes which are to be installed locally on the
corresponding points.
Connection of the cables must only be carried out by qualified personnel and
on the basis of the terminal diagram, the circuit diagram and the
manufacturers' operation and installation instructions.
On removing of the cable sheath, care has to be taken that the insulation of
the core is not damaged. Only such stripping tools may be used for stripping
of the insulation at the core ends which ensure that the blanked conductor is
not damaged which might cause a reduction on cross section or later rupture
points.
Before connecting the flexible cables, the blanked core end has to be
covered with a core end sleeve which must be pressed on with the aid of a
pinch tong with locking device. Soldering of the core ends has to be avoided.
Only two cores per clamp may be connected. In the case of screw joints, as
for example in the case of the feeding cables to the power circuit breaker
into the feeder panel, cable lugs have to be plugged onto the blanked core
ends and pressed with marking pliers.
Layout of cables and all connections have to be checked by the erection

supervisor in charge before notice is given that the plant is ready for
commissioning.
Tools and residual material have to be removed from the plant, and inside of
switch cabinets and connecting boxes etc. has to be cleaned. All
modifications carried out during installation have to be exactly introduced
into the Electrical Documentation. These documents must be available for
commissioning and future revision of drawings.
9.9 Final assembly
Fill in lubricants into the gear reducers acc. to Operation and Maintenance
Manual or (manufacturer’s specification).
Check all lubrication points for their initial filling of oil and grease
respectively and rectify findings.
Check that all protective equipments are installed and rectify findings.
Inspect the mechanical assembly regarding completeness and rectify

findings.
Inspect the electrical installation regarding completeness. and rectify

findings.
Perform the adjustment of the counterweight.
Remove all auxiliary structure, if still remaining.
After completion of erection and electrical installation, all damages of the

coating have to be repaired.
9.10 Pre-operational verification
Check all components with respect to good and proper commissioning

practice. (Equipment not yet energized)
9.11 Test on mechanical completion
The purpose of the tests on Mechanical Completion is to demonstrate, that

the system has been supplied and erected according to the specification and
drawings.
The testing starts with single components, for instance a drive unit.
Afterwards functional units will be tested. Finally the complete operating unit
will be tested. The achievement of the Mechanical Completion has to be
witnessed in a "Mechanical Completion Certificate".
9.12 Commissioning
The Commissioning will include all no-load and load testing. Loop
testing and verification works for run-in operation of the system,
including testing of controls, verification of alignment, calibration of
instruments (where applicable), etc.
9.13 General conclusion
Please note the following remarks:
The information instructions in this are not necessarily complete.
The erection staff must take utmost care in order to assemble the machine
according to the valid rules of technique.
Instructions and indications on the drawings must be exactly observed.

Modifications need a previous approval by FLSmidth.
All works have to be carried out in accordance to the applicable standards

(i.e. welding, electrical installation).
10 START-UP / COMMISSIONING / OPERATING INSTRUCTIONS
10.1 Check list
Notice
The following check list is valid for all the conveyors. It must be
adapted by the supervisors for each kind of conveyors and for
each kind of check list before start-up or commissioning or
operation.
List of abbreviations
H Hold point / Haltepunkt

W Witness point / Informationspunkt
X Execution / Durchführung
V Verifying / Prüfung
CO Client/Owner
CC Construction Company / Montagefirma
FLS FLSmidth
Scope of test Tested Test result Date/Signature

by
C C F
C O L
S
Precondition
Review civil cert. & release note. X V V
Verify punch list items are complete
Review steel structure. Verify punch X V V
list items are complete
Structure and Columns
Verify fixing, holding down bolts are X V
installed and secure
All bolts torqued X V
Verify all danger/warning signs are X W
in place
Check camber of bridges (if X V V
required) before lifting
Idler
Check all idlers are mounted X H V
correctly, fixing bolts are fitted and
tight
Chutes
Check that bolts tight X V V
Check the lining is complete and X V V
fixed glued to the plates
All pulleys
Check pulley and plummer block X W H
alignment
Verify bearings are mounted, X H H
secured correctly to specification
Verify bearings are greased X H H

by
C C F
C O L
S
Verify tension arrangement X H H
complete and secure
Gearbox
Verify the gearbox base is securely X H H
bolted
Check gearbox oil correct X H H
Check if transport breather plugs is X H H
removed
Coupling (if applicable)
Check coupling alignment X V H
gearbox/ motor
Check coupling oil filling correct X V H
Electric motor
Verify rating X H H
Check correct direction of rotation X H H
Verify/check earthing continuity X H H
release
See also electrical documentation
for more details
Brake (where applicable)
Verify the brake function X H H
Verify the thruster function X H H
Verify the brake gap and spring X H H
adjustment
for more detail
Belting
Verify correct location of belt cover X V H
plates (running surface)
Check splicing is complete. Release X H H
certificate
Verify correct belt tension X H H
Check installation of belt scraper, V- X V W
plough and adjustment
Verify skirtboard rubbers fitted and X V W
correctly set
Check correct qty. of impact idlers X V W
under feeding chute
Instrumentation
Verify installed equipment as X V W
applicable is operational & installed
to specigication
a. Belt alignment sensors

b. Emergency pullcord switch
c. Speed switches
d. Tilt switches
e. Proximity switches
f. Limit switches
Verify all emergency stops, trip X V H
wires are installed and operational
including electrical power testing

by
C C F
C O L
S
for more details
Safety check
Walk entire length of conveyor. X V H
Check conveyor is clear of
obstructions & foreign materials is
removed from the conveyor belt
Ensure warning signs are in place, X V H
inform all personnel in area of
starting and system alive
Stop/Start motor (bump start) X V H
Check belt running direction is
correct
Start conveyor X H H
Check for unusual sounds from X V H
rotating parts i.e. motors,
gearboxes, bearings
Walk the conveyor length to identify X V H
unusual sounds from idlers and
return idlers
Verify correct training of belt over X V H
head pulley, tail pulley and tension
pulleys
Check training of belt X V H
Verify belt scraper/ v-plough is X V H
operational
Check clearance on skirtboard seals X V H
Final release and acceptance X V H
10.2 General remarks
Carry out test run in local operation without material.

Carry out automatic operation from the local control desk (without material).
After the mounting of the complete installation or plant respectively, carry
out the operation with material and the performance test.
For further information, refer to “Electrical instructions”.
10.3 Procedure
The personnel must be positioned at drive and reverse pulley, as well as in

the middle of the Pipe Conveyor.
It is highly recommended that the start-up procedure is carried out by a

supervisor of FLSmidth.
10.4 Positioning of personnel
The supervisor advises if he needs one or more workers for help. The
supervisor is positioned at the discharging station, and should be connected
via radio set with the personnel. During operation, he can inspect different
parts of the plant.
10.5 Preparation
Before start-up the following items must be checked:
 Correct quantity of oil in the gear box.

 Correct quantity of oil in the fluid coupling.
 Connection between drive and pulley.
 Scrapers must not interfere.
 Freedom of movement for the counterweight box.
 Sufficient belt tensioning.
 All bearings greased.
 Belt runs centred over every pulley.
 All electric safety devices as to their proper working condition.
 Skirt boards are fixed.
 Adjusting bolts are fixed to the adjustable pulleys.
 No parts are on the belt.
 No contact pressure of any foreign part on the belt.
 All carrying idlers are fixed.
 No parts in the chute and in the feeding area.
 The fixing bolts for the troughing station must be tightened lightly
(possibility for adjusting must be given).
 The personnel is positioned correctly.
 Perfect communication between supervisor and operating personnel,
as well as among the operating personnel, is secured.
If necessary, the supervisor states more items to be checked.
10.6 Activation
For activation the following items must be checked:
 Direction of rotation.
 Current input.
 Power consumption.
 Non-slip start.
The supervisor decides, if necessary, for more items to be checked.
10.7 1st Test run
The following items must be checked during 1st test run:
 The belt is free of obstacles.

 No heat, vibration of the drive elements.
 No strange noises out of the plant.
 The belt runs centred over the pulleys.
 Speed monitor in function.
 Overlappings of carrying and return belt are equal.
 The belt forming idlers and the idlers in the adjustable idler station
are well positioned.
 Belt torsion.
 Current input.
 Power consumption.
The supervisor specifies additional items to be checked, if necessary.
10.8 2nd Test run
The following items must be checked during 2nd test run:
 Unusual movement of the belt.

 Spinning of the belt.
 Caking in the chute.
 Position of the scrapers.
If necessary, the supervisor specifies more items to be checked.
10.9 3rd Test run
The following items must be checked during 3rd test run:
 Fastening of the bolts at the bearings.

 Fastening of the bolts at the drive unit.
 Fastening of the bolts at supporting parts.
 No unusual noises from the plant.
 Correct belt position (no torsion).
 No vibrations.
 The belt must be running centred over the pulleys.
The supervisor specifies more items to be checked, if necessary.
10.10 Run-in
The following items must be checked during run-in:
 All safety devices are properly fixed and in proper working condition.
 The regulations for the purchased parts (motor, gearbox, scrapers,
etc.) are met.
 No belt torsion.
 The belt runs centred over the pulleys.
 No vibrations.
 No strange noises in the plant.
 No heat in drive unit and bearings (check at least every hour).
The supervisor specifies more items to be checked, if necessary.

In case of fault see chapter 9.6 “Interferences, Faults and Repair”
10.11 Operation
With regard to the switch-over to manual/automatic operation for the drive

units of the conveyors, reference is made to separate documentation for the
electrical equipment in the “Electrical Instructions”.
10.12 Pre-operational check
Warning
Before test and/or operation, a check around the conveyors and
adjacent equipment must be carried out in order to assure that
nothing or nobody is left at places on the machinery where there
will be risk of damage either to the machinery or personnel.
10.13 Trial-run with application of material
Decide and check with the entral Control Room (CCR),, which amound of
material should be conveyed. Run the conveyor in manual mode. Control the
material flow at the feeding and discharging points.
Check the bearing and gear temperature and relubricate if necessary. Also
check the belt alignment and quiet running of the idlers.
Switch to automatic operation and check the material feed along the
conveyors, through the discharge chutes. It is very important that the
material is led exactly down onto the central part of the belt.
Check that the material doesn’t cause a belt misalignment. Re-adjust the
baffle plates at the discharge points if necessary.
It will be possible to start and stop the pipe conveyors filled, without any
problem.
10.14 Start
For start procedures, refer to the “Functional Description” of the conveyor in

the "Electrical Instructions”.
10.15 Shutdown procedures
In connection with any maintenance work deemed to involve risks for the
person assigned to the task, the pipe conveyor must be de-energized via a
disconnecting switch in the control room.
Lockout of the main switch can be ensured by means of a padlock to prevent

the pipe conveyor from being inadvertently started by any unauthorized
person.
Gravity force:
 It must be ensured that neither mechanical components nor media

may move and thereby constitute a risk to any person.
Manually operated components:
 Manual lock must be activated.
10.16 Operation modes
For operation and maintenance of the conveyor system, three different

operating modes are available:
 Remote mode
 Local mode
 Off mode
Remote mode
In remote mode, all operating conditions, interlocks and fault evaluations
are active.
Remote operation can only be performed from the DCS.
A remote operation is only possible if all drives, belonging to the selected
transport route, are set to remote mode.
Local mode
In local mode, each conveyor drive can be operated individually from its
local control station, independent of all interlocks and non-safety devices.
Only competent and properly trained persons should operate the system in
Local mode, under continuous supervision of the equipment.
Off mode
The off mode is used to lock the conveyor drives for e.g. maintenance
purposes, which means that the drive can be started neither in remote nor
in local mode as long as it is in off mode.
10.17 Emergency shutdown
Notice
Emergency stop must not be used for normal stopping. It is not a
normal operating mode! It must only take place in emergency
situations (e.g. danger to the life and limb of persons, danger to
the conveyor/plant or fire hazard).
Warning
Prior to restart the conveyor after an emergency shutdown, the
operator must ensure conscientiously that the cause(s) for the
emergency situation has (have) been removed and that there is
not safety risk which prohibits the restart of the conveyor!
Warning
Inspect visually the overall conveyor prior to restart any
functions. After an emergency stop, never restart directly in
automatic mode. Move / put the conveyor in conditions / positions
allowing its safely restart. Test all functions in
manual/local/maintenance mode prior to start in automatic mode.
For more information on operation modes & emergency shutdown, refer to

the “Functional Description” in the "Electrical Instructions".
10.18 Local control stations
A Local Control Station is provided in vicinity of the conveyor drive. It

consists of a lockable junction box with an emergency stop push button.
Push buttons for start / stop are attached to the box and a selector switch
provided inside the box.
The following functions are available with the Local Control Stations:
 Operating mode selection – Remote / Local / Off. The mode selection

is displayed at the operator stations in the control room.
 Local mode operation: Start / Stop
11 GENERAL MAINTENANCE INSTRUCTIONS
Notice
The following general maintenance instructions are a guideline for
the maintenance of the pipe conveyor. Those maintenance
instructions are for special equipment or parts which are installed
on the conveyor. Apart from that, there are the standard
purchase parts supplied by sub-suppliers, like gearboxes, pulleys
idlers, and scrapers etc. as described in the technical section of
the equipment. Please refer to Part C1 “Suppliers' documents”.
In addition for special advice of dismantling and re installation of

any kind of equipment related to the equipment please refer to
the “Assembly instructions” (chapter 9).
11.1 Introduction
Trouble-free operation and a longer service life of the unit basically depend
on thorough execution of the maintenance works.
In accordance with the documentation, the specifications and instructions of
the various manufacturers shall apply to the maintenance works (see also
Part C1) as well as the “Assembly instructions” (chapter 9) of this contract.
In addition, an inspection of the complete equipment is required every 2.000

operating hours or at least once a year and (whichever occurs first) in
accordance with the given instructions in this document.
The inspections of both, the mechanical and electrical equipment, should be
carried out by qualified personnel only.
A well-organized program of preventative maintenance is the best way to

ensure system reliability for the conveyor. A small group of people, well
trained and impressed with the importance of their responsibility, can
accomplish this task.
11.2 Regulations for maintenance works
The person authorized or his representative (foreman, supervisor, fitter etc.)

must observe the required safety measures for all construction, installation
and maintenance works according to the applicable accident prevention
regulations(see Part A General safety instructions).
The head of the department who is in charge of the equipment during normal
operation is responsible for the execution of these safety measures, if
workers or groups of workers of several departments are involved in this
work.
Works on the plant including work within the operating range of the
equipment must only be carried out after informing the person in charge or
his representative. The persons involved must follow his instructions.
The following safety measures should be carried out depending on the type
and scope of the work:
 If possible, the work should be carried out during times of non-

operation.
 The works should be carried out from the catwalks, maintenance and
auxiliary frameworks as far as possible. If required, secure auxiliary
scaffolding should be erected and used. In the working range of the
crane, the locations where works are to be carried out should be
properly secured.
 The equipment should be switched off, if required by disconnection of
the main supply lines.
 Care should be taken when carrying out work on any equipment to
ensure that collisions with other equipment are avoided.
 The operators of neighbouring equipment, even those of neighbouring
halls, should be informed of the type and location of the work to be
carried out.
 The area beneath the equipment should be closed-off or clearly
marked out as a danger zone.
 The above mentioned information must be passed on to the person in
charge in case of a shift change. Only the person responsible may
release the equipment for regular operation. First he must ensure has
been definitely completed, that the equipment is in a proper condition
according to the regulations and that the personnel involved in the
work has left the equipment.
 Test runs after repairs must only be carried out by personnel who are
acquainted with the operation of the equipment.
11.3 General inspection and maintenance routine instructions
Notice
The following general inspection and maintenance routine
instructions are the overall maintenance guideline. Those
instructions are used as a guideline only. For more detailed
instructions please refer to the separate descriptions in the
technical chapters in Part C1 of this documentation.
An inspection and maintenance schedule guideline is provided in

chapter 13 “Specific instructions and information”.
11.4 Maintenance & assembly instructions for standard

equipment
Notice
This section refers to detail maintenance instructions and
assembly as well as re-assembly instructions for standard
purchase parts from our sub-suppliers. The specific maintenance
instructions of each different type of equipment fitted to the
machine is detailed elsewhere in the Operating and Maintenance
Manuals in Part C1.
11.5 General maintenance instructions for pipe conveyors
A pipe conveyor will serve better when operated correctly and maintained
properly. Regular lubrication is the most important maintenance point to be
looked after.
A strict maintenance schedule is to be drawn out and enforced effectively, for

keeping the pipe conveyor working efficiently. When the pipe conveyor is
newly installed, maintenance should be carried out daily. The schedule may
be changed later, to suit the site conditions and operational requirements.
But, in no case, should check up schedule extend beyond indication in
chapter 13 “Specific Instructions and Information”.
Whilst not necessarily covering all contingencies, it is recommended that the

following checks shall be carried out regularly and action shall be taken as
necessary:
 Check that the feed to the conveyor is central and the belt is running
centrally and straight. If not, establish the cause and rectify.
 Inspect skirt plates and seal strips and ensure they are adjusted close
enough to the belt to prevent spillage and materials jamming between
the seals and the belt, but not bearing hard on the belt.
 Check the belt generally for central and straight running on both
loaded and return strands.
 Inspect the condition of the belts and joints; arrange the earliest
possible repair of any damage, this alone can make a worthwhile
extension to the useful life of the belt.
 Check that there is no belt slip at the drive pulley and no undue sag
between idlers. These are symptoms that the belt is not sufficiently
tensioned; adjust take-up if necessary.
 Inspect the gravity tension device, if fitted, to ensure there is
sufficient take-up movement available to cater for the start-up
condition and it does not bottom before full starting tension is applied
as this can result in severe damage to belt. Should this situation seem
likely to arise, the belt has to be shortened. Grease all rope sheaves
and counterweight guides.
 Check all idler rolls and non-driving pulleys for free rotation and all
self-aligning idlers for pivoting. Rectify or replace defective items to
avoid belt tracking problems and wear. Inspect rollers and pulleys
regularly and arrange for damaged ones to be replaced.
 Check that belt cleaning equipment is functioning regularly and
efficiently. Ensure scrapers are pivoting freely and are not choked
with a build-up of material. Also check that the blades are not bearing
on the belt with more pressure than is necessary and any blades
unevenly worn or in a condition likely to cause damage to the belt are
replaced immediately.
 Grease or oil all bearings and moving parts requiring lubrication. It is
important that bearings should not be over-greased as this can cause
over-heating and consequent damage.
 In the case of gearboxes, check the oil level and replenish as
necessary. Fill with clean oil as recommended by the sub-suppliers.
 Inspect the driving gear following the sub-suppliers’ maintenance
instructions for the various components. Ensure that brakes are
correctly adjusted to avoid snatching when running or slipping when
at rest.
 In the interests of efficiency and optimum service life it is important
that operating conditions should be as clean as possible. Any spillage
should be cleaned up regularly and not be allowed to build up on
decking plates or on the floors to the point where it obstructs running
equipment.
 Chutes should be inspected regularly and any build-up of material
removed in order to minimize the possibility of eventual chute
blockage.
 It is important that any equipment requiring repair or replacement
should be dealt with as soon as possible to avoid the possibility of a
chain reaction of damage. If in the course of inspection any
abnormality in operation is observed for which there is no obvious
reason, it should be noted and reported immediately.
 The doors to the Cabin and the Cabinets must be kept closed, and the
Cabin must be cleaned regularly inside to keep dust away from the
electrical components.
 Electrical equipment installed on the machine, like motors, must be
kept clean to insure proper cooling of the equipment.
 All switches and sensors must be regularly inspected to ensure they
are still firmly installed.
 Instructions for further maintenance of electrical components see
Sub-supplier instructions
11.5.1 Cleaning
Check that the rails are clean; clean the rails, if required.
General cleaning of the machine is to be carried out.
Air condition unit:
 Clean filter for air condition unit as required.
11.5.2 Steel structure
Check all beams and bracing for wear and corrosion.

In case of rust, remove it and paint rapidly.
Check the steel structure for damage, buckling or defection.
11.5.3 Bolts
Check all bolted joints and re-tighten as necessary. A torque wrench must be
used where tightening torques are indicated on drawings.
In case of HV/HR bolts loosening, the screws, nuts and washers have to be
changed before re-tightening as indicated on drawings or general
specifications, using a torque wrench.
HV bolts are defined in the following standards e. g. DIN 6914, DIN 6915,
6916 and DIN EN 14399-4/6. They are permanent bolts tightened more than
85% of the yield stength.
Refer also to chapter 9.3.4 "Tightening torque and tensile force".
11.5.4 Gear, gear motor
Check the gear for tightness and replace the seal rings if necessary.
Check frequently for unusual noise and temperature during operation.
Refer to the supplier’s documentation in Part C1!

Supplier: SEW
11.5.5 Motor
Check the motor temperature and noise during operation.

Check the cooling air channel, clean if necessary.

Supplier: SEW/WEG
11.5.6 Brake
Check the brake lining.

Care should be taken of the min. brake lining thickness. The brake lining has
to be replaced when worn. Replacement and adjusting according to the Sub-
supplier’s instructions!

Supplier: SEW/SIBRE
11.5.7 Fluid coupling
Check scaling of coupling.

Supplier: SEW/TRANSFLUID
11.5.8 Flexible coupling
Check flexible intermediate links for wear.

Supplier: ????
11.5.9 Shrink disk
The tightening torque of the bolts has to be checked when carrying out the
inspection.

Supplier: SEW
11.5.10 Bush at torque arm
Check for cracks and wear.

Replace as necessary.
11.5.11 Roller bearings
Check the temperature of the bearings and listen for abnormal noise.
11.5.12 Sealing ring
Check the tightness and wear of rings.

If necessary, change the rings
11.5.13 Pulleys
Check rubber lining and the bearings.

Supplier: LORBRAND
11.5.14 Idler stations
Check the individual idlers for wear of the rubber rings.

Check the individual idlers for wear and free rotation.
The rings should be exchanged or the complete idlers should be changed in

case of excessive wear. The idlers are lifetime lubricated. Therefore care
should be taken to ensure that the idlers turn properly. If this is not the
case, the idlers must be replaced.

Supplier: LORBRAND
11.5.15 Rubber belt

Supplier: ON HOLD
Belt guide
By belt guide we understand all measures taken to ensure that the belt run is
straight, and that the belt is not overstrained. In addition to tractive forces
and gravitational forces, various forces also act on the moving belt laterally
to the direction of the movement and vertically to the surface of the belt. If
the equilibrium of the forces is disturbed, the belt moves either to the side,
or is raised from the carrying idlers. Skewing of the belt often leads to
damages of the belt edges and cover plates.
Belt misalignment
Causes of belt misalignment
The cause of belt misalignment may be attributed to the design or

construction of the belt conveying system. For your information we have
listed below some deficiencies that often occur:
 Carrying structure insufficiently aligned:

If the carrying structure (i.e. steel structure) is already misaligned, then this
means that the position of the belt drive and the carrying elements is
incorrect as well. However, correct positioning of these elements is a
prerequisite for the correct operation of the belt.
 Inadequately aligned idler assemblies:

The idler assemblies must be counted in true alignment and parallel to the
axis of the pulleys. Uneven stress points occur in the belt thus causing
misalignment especially when the troughed idler assemblies are inaccurately
mounted.
 Belt raised from the carrying idler assemblies:

The troughed belt is guided through the sets of troughed idlers so that minor
unevenness has no effect at all when the belt is running, as long as pulleys
and carrying idler assemblies are correctly aligned. The risk of belt lifting is
most likely at the transition point between conveyor sections of various
inclination angles. This equally applies to the transition points of ascending
and descending gradients.
 Incorrect endless connections:

In order to exclude this cause of belt misalignment, the information given by
the belt manufacturer for vulcanizing of the belts should be observed
exactly.
Besides, the aforementioned faults on the plant equipment, the operating
conditions described below can also cause misalignment of the belt.
 Incrustation of the bulk material on pulleys and carrying idlers:

Failures of this type are often difficult to rectify. Sticky bulk materials such
as for example iron ore, cohesive materials (like loam, clay, chalk), slurry,
chemicals fertilizer, unrefined sugar and similar materials tend to stick to the
belt. In the return run of the belt, these dirt particles stick to the carrying
idlers thus resulting in uneven caking. Due to the varying peripheral speed
along the length of the idlers, rubbing of the idler cannot be avoided.
 Feeding of material out of centre:

Especially in case of troughed belts, out-of-centre feeding results in forces
acting laterally to the longitudinal axis of the conveyor system that cause
the belt to drift outwards („belt wandering“). Therefore, the feeding
equipment design has to ensure that the material stream is in the centre of
the belt. However, out-of-centre loading of flat-guided belts does not
influence the belt run that negatively.
 Uneven friction points over the belt width:

If one side of the belt surface is wet, e.g. by rain falling on one side, then
the friction with the pulleys is reduced on one side. The degree of friction
loss depends on the two materials coming into contact. The friction loss is
higher for the combination of rubber / steel than for the combination rubber
/ rubber, rubber / plastic or rubber / ceramic coating.
 Belt slip:
Foreign bodies between the belt and the support frame can become jammed
in structure and rub on the belt. This often causes misalignment and
damages to the belt edges. Jamming carrying idlers can also lead to belt
slip.
 Slip over the drive pulley:

Check belt tension.
 Effects of wind:
Strong side winds cannot only lead to belt misalignment, but - under certain
circumstances - can also raise the belt from the support rollers thus
throwing the belt off the substructure.
Measures against misalignment
If correct alignment of the support frame, the pulleys and the carrying idler
assemblies, central material feeding and protection of the belt contact
surface against moisture do not correct the misalignment of the belt, straight
belt run must be forced by special measures.
 Inclined carrying idlers:

Inclining the straight carrying idlers often guarantees straight running of the
belt. These idlers are alternately set higher right and left so that they are
inclined at approx. 4° to the horizontal thus forming a slight guiding trough.
Cleaning the belt system

Spacing and idler stations must be cleaned in regular time intervals. Pulleys
and idlers must be cleaned from caked material.
Belt damages
The belt has to be inspected in view of damages. The belt must be renewed if
the damages and/or natural wear do not meet the requirements for safe
operation any more.
Installation and vulcanization of the belt should be carried out in accordance
with the manufacturer’s recommendations.
Belt tension
The belt tension has to be checked within the scope of inspection, re-tension
if necessary and check for straight running during the tensioning procedure.
The set tension should not be greater than that required for slip-free
transmission of forces.
Wear protection
Care should be taken that all wear plates and other plates show an adequate
material thickness so that the flow of material does not contact and then
weaken the base structure. Replace the lines off, before they are completely
worn out.
Belt cleaner and V-cleaner

Please ensure during inspection that the position of the belt cleaner is
adjusted to the wear of the rubber section of the cleaner. The scraper rubber
must be set corresponding to the wear or renewed if necessary.
Ensure that the steel sections of the cleaner do not come into contact with
the rubber belt.
Material guidance
The side rubber seals should be checked for leaks and readjusted or renewed
depending on the extent of wear. Replace the seals only with material of an
identical hardness. Never use belt strips for laterals seals! They will damage
the belt.
11.5.16 Status check of roller bearings
Dismantle the covers of bearing housings and degrease the roller bearings.
Check the roller bearings for any visible ruptures and cracks.
Check the radial backlash of roller bearings.
Then fill the bearing housings halfway up with grease and remount the
covers.
11.5.17 Functional test
Belt speed monitor

Check the function of the speed monitors.
Limit switch
Check the function and adjustment of the limit switches for travelling,
slewing and hoisting movement.
chute sensor
Check the function and adjustment of the tilt switch control sensor.
Clean if necessary.
Emergency pull cord switch & stop button

Check the function and adjustment of the emergency pull cord switches &
stop buttons.
Belt misalignment switch

Check the function and adjustment of the belt misalignment switches.
11.5.18 Electrical equipment
A check should be made in the scope of the inspection to ensure that these
specifications given in the description of the units are maintained for all the
travel ways and interlocking chains.
Limit switches & sensors
Check the function and adjustment of the limit switches and sensor.
Position and function of the limit switches and their actuating elements are
not to be changed.
Fastening of the limit switches with star lock washers or spring washers must
be checked regularly, even in between normal inspection intervals.
Switch cabinets
All terminals and cable mounts are to be checked in the switch cabinets as
part of the inspection work.
Dust deposits should be removed.
Cable fixtures
The terminals and cable fixtures elements should also be checked on all the
electrical devices and distributing elements.
Cables
The cables should be checked for external damages when carrying out the
inspection. See documentation for the assembly instructions of the cables.
Care should be taken to ensure that the cable are installed free of stress,
avoid bends, use only cable trays or another approved installation system.
A check should also be carried out in the scope of the inspection to ensure
that the cables pass through the cable funnels and cable release system.
Further information: refer to separate "Electrical Instructions”.
11.5.19 Maintenance and modification works on and around pipe

conveyors and its secondary structures
By all maintenance and modification works on and around the pipe conveyor,
an assigned safety person from the operator / owner shall supervise the
following points:
 The pipe conveyor shall be shut down and secured against

unauthorized switching on, movement etc.
 When the danger of falling objects exists, the working area under and
around the pipe conveyor shall be secured and cordoned off against
access of personnel
 The operator of neighbouring machines or equipment shall be
informed of the types and times of maintenance works being done.
This is valid for the replacement personnel at change of shifts etc.
 Maintenance personnel shall make sure that with works on and
around electrical equipment, especially when protection covers are
open, the power supply to the pipe conveyor is not energized.
When the above mentioned safety measures are not conformed to, or cannot
be negotiated on due to production reasons, the operator / owner / user
shall define and supervise other appropriate safety measures.
Warning
All personnel shall wear protection helmets and shoes during
works on and around the pipe conveyor. When necessary, other
Personal Protective Equipment (PPE) shall additionally be worn.
11.5.20 Commissioning after maintenance and modification works
The pipe conveyors shall only be cleared for operation after all maintenance
and/or modification works are completed and the operator/owner/user has
given the clearance. The responsible for giving clearance shall be sure that:
 The works are completely finished and documented.

 The whole pipe conveyor and associated equipment are completely in
working safety status.
 All maintenance work personnel have left the pipe conveyor.
 PRIOR to commissioning, all damage to structural, electrical and
corrosion protection shall be appropriately repaired.
 PRIOR to commissioning, all material and waste shall be disposed of
and the site area cleaned.
11.5.21 General description on maintenance works in case of belt

misalignment
Refer to chapter 9.5.7 “General description on works for pipe conveyors in

case of belt misalignment”.
11.5.22 General description on maintenance works in case of fault
Refer to chapter 9.6 “Interferences, faults and repair”.
11.6 Dismantling and disposal
11.6.1 Dismantling work
Warning
Before carrying out any dismantling work, block access to the
work area for unauthorized persons. Put up or stick a notice that
draws attention to the dismantling works.
Incorrect disassembly can lead to serious injuries!
Disassembly may only be accomplished by trained and authorised

technical personnel!
Only qualified electrical technicians may carry out dismantling

work on the electrical equipment of the machine.
All personnel shall wear protection helmets and shoes during

dismantling works. When necessary, other personal protective
equipment (PPE) shall additionally be worn.
Notice
For detailed dismantling instruction, request assistance from FLS
or a dismantling specialist. As this process depends mainly of the
age and condition of the machine (corrosion, wear out, stability,
etc.).
For specific dismantling instructions of each different type of

equipment fitted to the machine, refer to the suppliers' manuals
in Part C1.
It is mandatory that all steps for dismantling the machine are carried out in
the indicated sequence:
 Secure the working area for dismantling, leaving plenty of space.

 Remove all operating materials.
 Put machine completely out of service, and switch it off so that it is
electrically dead.
 Read and follow the Part A General safety instructions.
 Disassembly could be carried out in reverse order to the assembly.
Request FLS assistance (see Warning & Attention above).
11.6.2 Disposal
All replaced materials and parts must be disposed of in a proper manner.
In addition to locally applicable, pertinent, statutory and other requirements

and guidelines, the following applies:
 Prevent oils, greases, coolants and other liquid containing solvents

and harmful substances from contaminating soil and do not discharge
to the sewage system.
 Always fill used oil and grease into the relevant containers.
 For detailed information about lubricant disposal, refer to chapter 12.4
“Disposal of waste lubricants”.
 Dispose of metal parts, plastics and glass separately, as far as
possible.
 After disassembly, ensure that the disposal of the equipment and any
materials it contains is carried out in accordance with environmental
regulations.
 During all dismantling work, the legal responsibilities for avoiding
waste and proper recycling/removal must be fulfilled.
Possible location of recyclable materials or components:

Material Possible location
Copper Cables, motors
Nodular iron, cast iron Gearboxes, bearing bodies
Steel Beams, casings, supports
Plastic Seals, wear plates
rubber Seals, skirts,
Electronic wastes Electrical cabinet or component
Caution
REFERENCE TO ENVIRONMENTAL PROTECTION.
Ensure materials are disposed of in a manner that will that
materials and not harm the environment, and comply with the
applicable regulations for proper recycling and disposal of waste.
The materials and supplies of the machine must not leak onto the
ground or reach the groundwater!
12 INSTRUCTIONS FOR THE LUBRICATION OF THE EQUIPMENT
Notice
The following general lubrication instructions are the overall
lubrication instructions for the equipment. Those lubrication
instructions are not complete regarding the actual lubrication
requirements of the installed equipment. The actual detail
lubrication instruction for equipment is described in the technical
section of equipment. Please refer to Part C1.
The lubrication schedules should give the operator and the

maintenance people an overview about the requirements of the
necessary maintenance and lubrication work. They are provided in
chapter 13 “Specific instructions and information”.
12.1 General safety instructions
Warning
Read all safety instructions in this manual carefully and observe
them during the work. Please also refer to Part A General safety
instructions.
Before starting the installation work, it is mandatory that you

disconnect the plant from the main power supply! During
installation works, observe the regulations which apply to the
country where the plant will be installed.
During operation, maintenance, servicing, inspection and repair works, the

following has to be respected:
Process materials (Oils, Greases, and Chemical Substances)
 Oils, greases, and other chemical substances shall be handled taking

into consideration the safety instructions applicable to the respective
product.
 When handling hot process materials, special caution is necessary to
avoid the risk of scalding or burning.
 Client shall ensure that the process materials are safely disposed of
with minimum impact on the environment. This also applies for
replaced items.
Lubricants
 In order to ensure a smooth operation of the facility, only the

lubricants specified by the supplier shall be used. Also refer to the
product-related documentation.
12.1.1 Personal safety - Health and safety instructions
Any user of a lubrication product must be familiar with all relevant health and
safety instructions from the lubrication supplier. Health and safety
instructions are supplied together with the product or may be downloaded
from a website from the supplier in question.
12.1.2 Personal protective equipment
It is of great importance to practice a high standard of personal and

workshop hygiene.
Any physical contact with lubricants or breathing of vaporised oil must be

avoided. Oil with additives is toxic and must be handled with care. The toxic
parts of the oils can be absorbed through the skin.
During handling of lubricants use of the following equipment is advisable:
 Waterproof, oil proof apron, gloves, goggles.

 Extraction ventilation.
 Hand washing equipment with hand protection cream.
12.1.3 Regulations for the prevention of accidents
During inspection and repair works, all unauthorized persons are prohibited
from entering the operation area of the equipment.
Prior to starting any inspection or repair works, the main power supply has to
be switched off and locked to avoid unauthorized action.
With regard to machines and conveyors, in some cases, the lubricating

points can only be accessed when the equipment has been completely
switched off (main power switch). Exceptions may be lubrication points:
 Which are accessible via lubrication strips.

 Which are lubricated via a central lubrication system or in certain
cases (to be specified).
12.2 Storage of lubricants
All types of lubricant must be stored under clean, vented, fireproof and safe
conditions. It is important that the labelling of each product is clear and
legible. Basically, all lubricants must be stored indoors (certain products do
not tolerate frost).
Oil barrels may be stored in the open. If so, place the barrels in a horizontal
position to prevent water penetrating the thread sealing. Any thermal
contraction in the barrel will suck water through even sealed plugs. The plugs
must be at low level to ensure they are covered with oil. Store the barrels in
an indoor climate for up to 48 hours before use. For example if an ISO VG >
150 oil barrel has to be used and it is below 10°C, it should be kept in a
heated room for 2 days before use.
Pumps, canisters, etc. must be clean. Do not use a canister for different
types of lubricants since certain types of additive may have a harmful effect
on a foreign lubricant.
Use a waste tray under the barrel tap and keep the surfaces clean, especially
around the taps.
The storage time of lubricants may be limited. The packaging or the

accompanying documents provide information about the durability of the
lubricant. A first-in, first-out policy should be adopted.
If possible, the barrels should be lifted/moved with a forklift truck.
12.3 Cleaning of machines
Before emptying and refilling with lubricants, it may be necessary to clean

machines with a cleaning agent.
Notice
Take the necessary precautions to avoid damage to painted
surfaces and not to cause fire when using cleanser.
Warning
Cleaning agent may be harmful to personnel and may cause fire.
12.4 Disposal of waste lubricants
Before scrapping machines, the oil and grease must be emptied into
approved waste canisters and disposed of according to approved procedures.
Warning
Emptied lubricants will normally constitute a more dangerous
product than fresh lubricants due to contamination with metal
particles and foreign chemicals. The original health and safety
instructions may not be sufficient to protect against any danger
12.5 Types of lubricants
12.5.1 General application of oil and grease
In addition to the general requirements from the machine manufacturer, the

criteria applied by the manufacturer of the lubricant to determine the
suitability of any lubricant also include factors such as low particle
contamination and filterability.
12.5.2 Methods of lubrication
In principle, there are the following methods of lubrication:
 Lifetime lubrication.
 Oil bath lubrication.
 Grease lubrication by means of grease nipples.
 Grease lubrication by a manually operated central lubrication system
(lubrication of several lubrication points by one lubrication point -
progressive system).
 Oil lubrication by an electrically operated central lubrication system
(lubrication of several lubrication points by one lubrication pump –
progressive system).
 Grease lubrication by an electrically operated central lubrication
system (lubrication of several lubrication points by one lubrication
point – progressive system).
 Oil reservoir (e.g. hydraulic unit).
 Grease lubrication by hand after dismantling.
 Grease lubrication by hand.
12.5.3 Oil
Oil may not be of sufficient cleanness. Contamination may occur from either
packaging or filling from packaging to equipment. In particular hydraulic oil
may show contaminants.
12.5.4 Grease
With regards to compatibility and wherever possible, greases of different

types should not be mixed. The change-over of grease types should be
deferred until shutdown of the equipment, when the bearings and other
greased components may be cleaned thoroughly of the old grease and the
new grease then introduced.
12.5.5 Synthetic lubricants
The machinery must be flushed before commissioning at the prescribed

temperature and with the prescribed media. Filtering must be checked during
the flushing process.
Flushing must be done for new machinery and when changing to a different
type of lubricant in the machinery.
Polyalphaolefin (PAO)
Polyalphaolefin lubricant must not be mixed with mineral or Polyglycol
products or any other oil type.
The following table shows examples of compatibility and is for guidance only:
Nitrile rubber (Buna N) Below 100 ºC

Butyl rubber Not appropriate
Polyisoprene Not appropriate
Chlorine sulforic polyethylene Not appropriate
Polyurethane ether Appropriate
Ethylene acryl Appropriate
Polysulfide Appropriate
Chlorined polyethylene Preferred above 100 ºC
Polyacrylate rubber Preferred above 100 ºC
Fluorocarbon (Viton, Teflon) Preferred above 100 ºC
Polyglycol (PG)
Lubricants based on Polyglycol must not be mixed with mineral or
polyalphaolefin products or any other oil type.
Notice
Changing the lubricant to PG oil requires a complete flushing of
the gear with thin PG oil before filling with the operational PG
lubricant.
Polyglycol products have the ability to absorb water and, since it is difficult to
segregate water from Polyglycol, the design of the machinery should prevent
water from coming into contact with Polyglycol lubricants. The density of
Polyglycol is higher than that of water.
Circulation and filtering systems must be designed to treat the high viscous
Polyglycol lubricant.
Polyglycol is not compatible with ordinary paints. Polyurethane or epoxy

paints must be used.
Compatibility between Polyglycol and rubber sealings is fairly poor. FKM

(Viton) or PTFE (Teflon) should be used.
Aluminium may be discoloured on contact with Polyglycol lubricants.
12.6 Lubrication plans
FLSmidth establishes the lubrication plans in order to facilitate the choice of

lubricant suppliers as well as the choice of the lubricant itself.
The lubrication plans should give the operator and the maintenance people
an overview about the requirements of the necessary maintenance and
lubrication work. They are provided for equipment in chapter 13 “Specific
instructions and information”.
Any equipment instruction manual of sub-suppliers takes precedence over

these present lubrication plans.
Where a specific lubricant is specified in the lubrication plan, only this

product must be implemented in the said equipment.
12.6.1 Use of lubrication plans
The following groups or persons are users:
 Client.
 Lubricant supplier.
 Procurement personnel.
 FLSmidth mechanical and commissioning engineer.
Notice
The directions in the instruction manual for given machinery take
precedence over directions given in the lubrication plans.
12.6.2 Factory filling
The supplier or the manufacturer of mechanical equipment may choose to

deliver machines filled with oil and grease before dispatch from the
manufacturing and testing workshop. In this case, the manufacturer shall
specify the lubricant used.
In addition, the manufacturer shall indicate if the lubricant has to be

completely exchanged before commissioning of the equipment.
12.6.3 General lubrication instructions
Trouble-free operation and life of the equipment depend on observing of the

lubrication and maintenance instructions!
The given lubrication intervals of the various equipment suppliers are a

RECOMMENDATION. Due to external effects for example higher temperature,
working times (shift work), local conditions etc. it may be necessary to
change the lubrication and inspection intervals. This SHALL be considered by
the responsible maintenance personnel of the conveyor operator / owner.
During all lubrication works, the conveyors shall be shut down at the E-house
/ main switch.
The given data for the various oils and greases may be replaced with
equivalent makes of the same cinematic viscosity according to ISO VG
51519.
All lubrication points, the method of lubrication and the lubricants can be
seen in the lubrication plans. Also refer to chapter 13 “Specific instructions
and information”.
Clean carefully all nipples and the mouth piece of the gun before lubrication.
Notice
Observe the instructions of the supplier of installed equipment,
refer to Part C1.
The oil quantities indicated in the lubrication schedules are to be considered

as an approximate value only.
Information on the type, viscosity and quantity of the oil is given on the
rating name plate on the gear unit.
The quantity of oil stated on the rating plate is an approximation only. The
markings on the oil dipstick or oil level indicator have always to be observed.
The oil level has to be at the upper mark of the oil level device.
13 SPECIFIC INSTRUCTIONS AND INFORMATION
13.1 Assembly drawing list
Drawings are not part of these instructions.

They should be delivered in a separate folder by the FLS engineering
department.
Equipment: Pipe conveyors
Item No. Description Drawing No.

0320-PC-1012 Pipe conveyor GA 1/2 TISUR-320-045-DWG-01221
13.2 Technical data
Attention
The following main technical data give only an overview of the performance
of the equipment, including technical data like speed, installed power etc. 
Equipment: Pipe Conveyor Item: 0720-PC-1021

Client: TISUR Supplier: FLSmidth
Islay Bay Date: 04.06.2014
Plant: Islay province,
Arequipa, Peru
Description Unit Supplier Data Remarks
FEED
Copper
Material
concentrate
Material caracteristics See chapter 4.3 in Part B1
GENERAL
Specifications acc. to DIN / CEMA /
D/C/O
Other
Make / supplier FLSmidth
Capacity, maximum t/h 2300
Capacity, volumetric m3/h 1278
Conveying speed m/s 3,8
Belt width mm 1600
pipe diameter mm Ø400
Center distance horizontal m 372,3
Total lift mm -4,13
Gantry with walkways yes/no Yes
Cover - approx. m
SPECIAL DESIGN
Reversible / Travelling / Slewable R/T/S N.A.
Gravity
Method of take-up
counterweight
Tension way mm 8 587 For 2,5% elongation
Tension force (calculated) kN 160
Belt elongation for calculated force % 0,3 Set at 80% for
Take-up weight total Kg 15 700 commissioning
BELT
Make / Supplier PHOENIX
EP1600/5 -
Type & no. of plies
6+3
Thickness - top cover / bottom cover mm 6+3
Total length of belt m 687
PULLEYS
Make / supplier LORBRAND
Rubber / Ceramic lagging R/C R
Ø-Drive pulley / Ø-Bearing mm 1000/163,51
Ø-Snub pulley / Ø-Bearing mm 505/80,9
Ø-Tail pulley / Ø-Bearing mm 800/163,51

Arequipa, Peru
Ø-Take-up pulley / Ø-Bearing mm 800/163,51
Ø-Bend pulley / Ø-Bearing mm 800/139,7
CARRYING IDLERS
Make / Supplier LORBRAND
Type / Design fixed
Pipe carrying idler roller diameter mm Ø133
Pipe carrying idler roller length mm 350
Safety panel special idler roller
mm Ø133
diameter
mm 350
length
Transition idler roller diameter mm Ø133
Transition idler roller length mm 600
Impact idler roller diameter mm Ø133
Impact idler roller length mm 600
Finger roller diameter mm Ø110
Finger roller length mm 310
Number of rolls per half panel 3
Number of rolls per idler station 3
Lubrication for lifetime yes / no Yes
Pipe idler spacing mm 1300
Idler spacing at feeding point mm 300
Quantity of pipe carrying idlers 2241
Quantity of safety panel special
54+41+8
idlers
Quantity of transition idlers 87
Quantity of impact idlers 27
Quantity of finger roller 4
RETURN IDLERS
Type / Design Fixed
Roller diameter mm Ø133
Roller length mm 1800
Lubrication for lifetime yes / no yes
Idler spacing mm
Quantity of return idlers 1
BELT CLEANING
Make / Supplier MARTIN
Primary Material discharge side -
QC#1
type

Arequipa, Peru
Reversing Material discharge side -
type
Belt return side - type V scraper
MOTOR
Make / Supplier SEW/WEG
Type / design 280S
Quantity of motors 1
Installed motor power kW/HP 200
Motor speed 1/min 1500
GEAR BOX
Make / Supplier SEW
Type / Design X3KH170/B
Quantity of gearboxes 1
Service factor
Reduction ratio
Backstop yes / no Yes
COUPLING
Fluid coupling yes / no no
Type / Design
Flexible coupling yes / no Yes Input / Output
Type / Design GH214
BRAKE - incl. Thruster
Disc / Drum brake (Scheibe /
S/T S
Trommel)
Make / Supplier SEW/VULKAN
FEHD-II-AEH-
Type / Design
80/6
BELT WEIGHER
yes / no no
Make / Supplier
MAGNETIC SEPARATOR
yes / no no
Make / Supplier
METAL DETECTOR
yes / no no
Make / Supplier

Arequipa, Peru
FEED
Copper
Material
concentrate
Material caracteristics See chapter 4.3 in Part B1-
GENERAL
Specifications acc. to DIN / CEMA /
D/C/O D
Other
Make / supplier FLSmidth
Capacity, maximum t/h 500
Capacity, volumetric m3/h 278
Conveying speed m/s 2,2
Belt width mm 1000
pipe diameter mm Ø 250
Center distance horizontal m 115,35
Total lift mm 14000
Gantry with walkways yes/no Yes
Cover - approx. m N.A
SPECIAL DESIGN
Reversible / Travelling / Slewable R/T/S N.A.
Gravity
Method of take-up
counterweight
Tension way mm 3.375 For 2,5% elongation
Tension force (calculated) kN 30
Belt elongation for calculated force % 0,3 Set at 80% for
Take-up weight total Kg 2 943 commissioning
BELT
Make / Supplier PHOENIX
Type & no. of plies EP500/3 - 6+3
Thickness - top cover / bottom cover mm 6+3
Total length of belt m 270 Without splicing
PULLEYS
Make / supplier LORBRAND
Rubber / Ceramic lagging R/C R
Ø-Drive pulley / Ø-Bearing mm 820 x 1200/140
Ø-Snub pulley / Ø-Bearing mm 531 x 1200/70
Ø-Tail pulley / Ø-Bearing mm 630 x 1600/80
Ø-Take-up pulley / Ø-Bearing mm 630 x 1600/80
Ø-Bend pulley / Ø-Bearing mm 630 x 1600/80
CARRYING IDLERS

Arequipa, Peru
Type / Design fixed
Pipe carrying idler roller
diameter/bearing diameter (at mm Ø89/20
panel)
Pipe carrying reinforced idler roller
mm 240
length
Pipe carrying reinforced idler roller Marked by another
diameter/bearing diameter (at mm Ø89/25 color than the idlers to
panel) panel
Pipe carrying reinforced idler roller
mm 240
length
mm Ø89
(reinforced)diameter
mm 251
length
mm Ø89
(reinforced)diameter
mm 626
length
Transition idler roller diameter (at
mm Ø133
adjustable station)
Transition idler roller length mm 406
Impact idler roller diameter mm Ø133
Impact idler roller length mm 406
Finger roller diameter mm Ø85
Finger roller length mm 240
Number of rolls per half panel 3
Lubrication for lifetime yes / no Yes
Pipe idler spacing mm 1500
Idler spacing at feeding point mm 350
Quantity of pipe carrying idlers (at
780
panels)
Quantity of panel reinforced idlers 54
Quantity of safety panel reinforced
20+1
idlers
Quantity of transition idlers (at
36
adjustable station)
Quantity of impact idlers 27
Quantity of finger roller 4
PRESSURE IDLERS
Type / Design Fixed
Roller diameter mm Ø133
Roller length mm 1182
Number of pressure idlers 1

Arequipa, Peru
Lubrication for lifetime yes / no yes
Idler spacing mm
BELT CLEANING
Make / Supplier MARTIN
Primary scraper QC#1
Secondary scraper SQC#2
Belt return side - type V scraper
MOTOR
Make / Supplier SEW/WEG
Type / design 250S/M
Quantity of motors 1
Installed motor power kW/HP 56
Motor speed 1/min 1785
GEAR BOX
Make / Supplier SEW
Type / Design X3KH140
Quantity of gearboxes 1
Service factor 1,76
Reduction ratio 35,8
Backstop yes / no Yes
COUPLINGS
Fluid coupling SEW/TRANSFLUID
Type / Design 13CKRG
Flexible coupling yes / no Yes Input
Type / Design GH214
BRAKE - incl. Thruster
Disc / Drum brake (Scheibe /
S/T S
Trommel)
Make / Supplier SEW/SIBRE
USB2-05 EB120-
Type / Design
40 ED12/4
BELT WEIGHER
yes / no no
Make / Supplier
MAGNETIC SEPARATOR
yes / no no
Make / Supplier
METAL DETECTOR
yes / no no
Make / Supplier
13.3 Spare parts
Attention
The following Equipment Schedule is not a general spare parts catalog for all parts which are used on the equipment. With
regard to all spare parts, please refer to the technical sections for equipment as described separately in Part C (sub-supplier
documentation). 
Unit: means how the parts are supplied, i.e. in pieces (Pcs), meter (m), litre (L) or square meter (m²).
S/W: means that the listed part is considered as spare or wear part.
Information in column "Remarks":

a. Also refer to the sub-supplier's documents in Part C.
b. Also see the electrical documentation.
The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
13.3.1 Spare parts catalog for Pipe conveyor 0720-PC-1021
Contract No.: Name: Date:

2.2135 Spare part catalog MIFU-DE 03-04-2014
Item No.: Equipment: Customer:
0720-PC-1021 PIPE CONVEYOR TISUR
All cells highlighted in yellow must be checked Islay province, Arequipa, Peru
and adapted with supplier data, etc (colour to be
deleted after completion).
Length /
DIN / ISO / Drawing &
S/W
area
Unit
Pos. Qty Designation Type / dimension Supplier Material Remarks
FLS Codes part No.
TISUR-720-
I 1 DRIVE STATION 200-DWG-
00185-0A
TISUR-720-
Gear unit with
01.00 1 X3KH170/BS SEW Pcs 200-DWG- S a
backstop
00185-0A
IEC355M/L - TISUR-720-
01.01 1 Motor 200kW - 1790 SEW/WEG Pcs 200-DWG- S a
rpm 00185-0A
01.02 1 Elastic coupling Rotex 90 SEW/Rotex S a
TISUR-720-
Torque arm with
01.03 1 ???ø??x??? FLSMIDTH Pcs 200-DWG- S
silent block
00138-0A
TISUR-720-
Silent block for
01.03.01 1 ???ø??x??? SEW 200-DWG- W a
torque arm
00138-0A

Length /
S/W
area
Unit
FLS Codes part No.
Ø1040 x 1800,
TISUR-720-
LL 2300 with
045-DWG-
02.00 1 Drive pulley rubber lagging LORBRAND Pcs S a
02114-0A
Diamond 20 mm
Pos. 01
60° shore A
TISUR-720-
045-DWG-
02.01 1 Set Bearing SNL3136 ???? Pcs S a
02114-0A
Pos. 01
Ø531 x 1800, LL TISUR-720-
2300 with rubber 045-DWG-
03.00 1 Snub pulley LORBRAND Pcs S a
lagging plain 13 02114-0A
mm 45° shore A Pos. 05
TISUR-720-
045-DWG-
03.01 1 Set Bearing FSNL518-615 ???? Pcs S a
02114-0A
Pos. 5
TISUR-720-
200-DWG-
04.00 1 Discharge chute
00136/137-
0A
TISUR-720-
200-DWG-
04.01 Wear plate Thk??? W
00136/137-
0A

Length /
S/W
area
Unit
FLS Codes part No.
TISUR-720-
200-DWG-
04.02 Wear plate Thk ??? W
00136/137-
0A
ISUR-720-
200-DWG-
04.03 Rubber sheet Thk?? W
00136/137-
0A
05.00 1 Deflector plate
TISUR-720-
HARDOX 200-DWG-
05.01 Wear plate Thk 20 W
500 00142/143-
0A
TISUR-720-
Type: QC#1-
06.00 1 Primary scraper MARTIN Pcs 200-DWG- S a
XHD
00185-0A
MARTIN TISUR-720-
06.01 1 Tensioner ????? Pcs 200-DWG- S a
00185-0A
MARTIN TISUR-720-
06.02 Blade ????? Pcs 200-DWG- W a
00185-0A

Length /
S/W
area
Unit
FLS Codes part No.
MARTIN TISUR-720-
Secondary
07.00 1 Type: SQC#2- Pcs 200-DWG- S a
scraper
00185-0A
MARTIN TISUR-720-
00185-0A
MARTIN TISUR-720-
07.02 ? Blade ????? Pcs 200-DWG- W a
00185-0A
BELT & IDLER &
II SAFETY PANELS
& SKIRT BOARD
Conveyor belt Type: EP1600/5 PHOENIX TISUR-720-
08.00 1 (including - 6+3 687 m 200-DWG- S
splicing length) Belt width: 1600 00185-0A
LORBRAND TISUR-720-
09.00 2245 Idlers Pcs 045-DWG- S
02115-0A
TISUR-720-
Ø133 x
Carrying idler 045-DWG-
09.01 2022 367/350 ø25 LORBRAND Pcs S
(idlers at panels) 02115-0A
SW 18
Pos. 1

Length /
S/W
area
Unit
FLS Codes part No.
TISUR-720-
Carrying idler Ø133 x
045-DWG-
09.02 54 (reinforced idlers at 367/350 ø30 LORBRAND Pcs S
02115-0A
panels) SW 18
Pos. 2
Carrying idler TISUR-720-
Ø133 x
(idlers at safety 045-DWG-
09.03 41 381/355 ø30 LORBRAND Pcs S
panels + 1 x for 02115-0A
SW 18
return station) Pos. 3
TISUR-720-
045-DWG-
09.04 8 (idlers at safety 926/900 ø30 LORBRAND Pcs S
02115-0A
panels) SW 18
Pos. 4
TISUR-720-
Belt forming idler 045-DWG-
09.05 4 Ø110 x 310 LORBRAND Pcs S
02115-0A
Pos. 5
TISUR-720-
045-DWG-
09.06 87 (idlers at adjustable 626/600 ø25 LORBRAND Pcs S
02115-0A
idler station) SW 18
Pos. 6
Ø133 x TISUR-720-
Impact idler
626/600 045-DWG-
09.07 27 (idlers at adjustable LORBRAND Pcs S
Ø89/ø25 SW 02115-0A
idler station)
18 Pos. 7
Ø133 x TISUR-720-
09.08 1 Pressure idler LORBRAND Pcs S
1832/1800 045-DWG-

Length /
S/W
area
Unit
FLS Codes part No.
Ø40 SW 32 02115-0A
Pos. 8
Ø133 x
TISUR-720-
1832/1800
Return idler with 045-DWG-
09.09 1 Ø40 SW 32 + LORBRAND Pcs S
rubber lagging 02115-0A
10 mm lagging
Pos. 9
- 45° Shore
TISUR-720-
10.00 1 Material guidance FLSMIDTH 200-DWG- S
00148-0A
TISUR-720-
Rubber 200-DWG-
10.01 2 Rubber strip 12x150x3800 Pcs W
40° Sh 00148-0A pos
D14
TISUR-720-
Rubber 200-DWG-
10.02 1 Rubber curtain 6x800x764 Pcs W
40° Sh 00148-0A pos
D12
TISUR-720-
Rubber 200-DWG-
40° Sh 00148-0A pos
D13

Length /
S/W
area
Unit
FLS Codes part No.
TISUR-720-
200-DWG-
10.04 6 Wear plate 12 x 500 x 575 Pcs UHMW??? W
00148-0A pos
D9
TISUR-720-
200-DWG-
00148-0A pos
D10
TISUR-720-
200-DWG-
00148-0A pos
D11
TISUR-720-
11.00 8 Safety panel 200-DWG- S
00149-0A pos
EAS elements
TISUR-720-
M24 x 1 with
11.01 16 Safety elements ???? Pcs 200-DWG- S
sensor type: ???
00149-0A pos

Length /
S/W
area
Unit
FLS Codes part No.
III 1 RETURN STATION

Ø826 x 1800, LL TISUR-720-
Tail pulley with
12.00 1 shaft for speed LORBRAND Pcs S a
lagging plain 13 02114-0A Pos
monitor
mm 45° shore A 02
TISUR-720-
045-DWG-
02114-0A
Pos. 02
TISUR-720-
Disc Brake with FEHD-II-AEH-
12.02 1 SEW/SIBRE Pcs 200-DWG- S a
thrustor 80/6
00185-0A
TISUR-720-
200-DWG-
13.00 1 V Plough cleaner FLS Pcs S
00146-0A
D11
Rubber TISUR-720-
13.01 2 Rubber cleaner 20x250x1021 FLS Pcs with fabric 200-DWG- W
50° Shore 00146-0A
TAKE-UP
IV 1
STATION
Ø826 x 1800, LL TISUR-720-
14.00 1 Take up pulley 2300 with rubber LORBRAND Pcs 045-DWG- S a

Length /
S/W
area
Unit
FLS Codes part No.
mm 45° shore A 03
TISUR-720-
045-DWG-
02114-0A
Pos. 03
Ø826 x 1800, LL TISUR-720-
15.00 2 Bend pulley LORBRAND Pcs S a
mm 45° shore A 04
TISUR-720-
045-DWG-
15.01 1 Set Bearing FSNL532 ???? Pcs S a
02114-0A
Pos. 04
TISUR-720-
Counter weight
16.00 1 FLSMIDTH 200-DWG-
box & guidance
00155-0A
TISUR-720-
16.01 4 Plastic Plate Thk40 40 x 180 x 180 FLSMIDTH 200-DWG- W
00154-0A
FLSMIDTH TISUR-720-
16.02 8 Plastic Plate Thk40 40 x 180 x 60 200-DWG- W
00154-0A
Rubber for counter FLSMIDTH Rubber TISUR-720-
16.03 2 weight box scraper 12 x 1728 x 100 55°±5° 200-DWG- W
Thk12 Shore 00155-0A

Length /
S/W
area
Unit
FLS Codes part No.
ELECTRICAL
V Var.
COMPONENTS
17.00 Pull Cord Switch b
Plugged Chute
18.00 b
Switch
Belt
19.00 Misalignment b
switch
Belt twisting
20.00 b
Switch
Proximity switch,
21.00 b
Safety pannels
Proximity switch,
22.00 b
Take-up station
Rotation speed
23.00 b
sensor

Length /
S/W
area
Unit
FLS Codes part No.
24.00 ???????? b
25.00 ???????? b

Customer: TISUR
Item No.: 0720-PC-1021 Equipment: PIPE CONVEYOR
I - DRIVE STATION
IV - TAKE UP STATION III - RETURN STATION
II - BELT & IDLER & SAFETY PANELS & SKIRT BOARD

Customer: TISUR
I - DRIVE STATION
15.00 with 15.01 III - RETURN STATION
03.00
With
03.01 IV - TAKE UP STATION
12.00
08.00 With
14.00 with 14.01 Conveyor belt 12.01
02.00 with 02.01

Customer: TISUR
I - DRIVE STATION
01.00
01.03/01.03.01
07.00 to 07.02 01.01

05.00
and 06.00 to 06.02
05.01
04.00
to
04.03 01.02
01.00
01.03/01.03.01

Customer: TISUR
16.03
IV- TAKE UP STATION
15.00 with 15.01
14.00 with 14.01
16.00 to 16.02

Customer: TISUR
09.03 II- IDLERS &SAFETY PANELS II- IDLERS &SAFETY PANELS & SKIRTBOARD
10.00 to 10.06 12.00/12.01
09.09
09.04
09.01 09.04
or 09.06
09.02 Or
09.03
09.07
09.06
Or
09.07
09.06
09.04
11.00 and 11.01
13.00 09.07
09.01
and
or
13.01
09.02
12.02
13.3.2 Spare parts catalog for Pipe conveyor 0320-PC-1012

2.2135 Spare part catalog RAGRE-IN 16-12-2014
Length /
S/W
area
Unit
FLS Codes part No.
TISUR-320-
I 1 DRIVE STATION 045-DWG-
01221-0A
TISUR-320-
Gear unit with
01.00 1 X3KH140/BS SEW Pcs 045-DWG- S a
backstop
01221-0A
IEC250 S/M - TISUR-320-
01.01 1 Motor 56kW - 1790 SEW/WEG Pcs 045-DWG- S a
rpm 01221-0A
01.02 1 Elastic coupling Rotex 90 SEW/Rotex S a
Torque arm with
01.03 1 ???ø??x??? SEW Pcs ????? S
silent block
Silent block for
01.03.01 1 ???ø??x??? SEW ????? W a
torque arm
TISUR-320-
SEW/
01.04 1 Hydraulic coupling 13CKRG 045-DWG- S a
TRANSFLUID
01221-0A
TISUR-320-
Disc Brake with USB2-05 EB120- SEW/
01.05 1 Pcs 045-DWG- S a
thrustor 40 ED12/4 SIBRE
01521-0A

Length /
S/W
area
Unit
FLS Codes part No.
Ø820 x 1200, LL
TISUR-320-
1650 with rubber
045-DWG-
02.00 1 Drive pulley lagging Diamond LORBRAND Pcs S a
01207-0A
20 mm 60° shore
Pos. 01
A
TISUR-320-
045-DWG-
02.01 1 Set Bearing FSNL 532 ???? Pcs S a
01207-0A
Pos. 01
Ø531 x 1200, LL TISUR-320-
03.00 1 Snub pulley LORBRAND Pcs S a
lagging plain 13 01207-0A
TISUR-320-
045-DWG-
03.01 1 Set Bearing FSNL 515-612 ???? Pcs S a
01207-0A
Pos. 04
TISUR-320-
045-DWG-
04.00 1 Discharge chute
01244/1245-
0A
TISUR-320-
045-DWG-
04.01 Wear plate Thk??? W
01244/1245-
0A

Length /
S/W
area
Unit
FLS Codes part No.
TISUR-320-
045-DWG-
04.02 Wear plate Thk ??? W
01244/1245-
0A
TISUR-320-
045-DWG-
04.03 Rubber sheet Thk?? W
01244/1245-
0A
05.00 1 Deflector plate
TISUR-320-
HARDOX
05.01 Wear plate Thk 20 045-DWG- W
500
01248-0A
TISUR-320-
06.00 1 Primary scraper Type: QC#1-XHD MARTIN Pcs 045-DWG- S a
01221-0A
MARTIN TISUR-320-
01221-0A
MARTIN TISUR-320-
06.02 Blade ????? Pcs 045-DWG- W a
01221-0A

Length /
S/W
area
Unit
FLS Codes part No.
MARTIN TISUR-320-
Secondary
07.00 1 Type: SQC#2 Pcs 045-DWG- S a
scraper
01221-0A
MARTIN TISUR-320-
01221-0A
MARTIN TISUR-320-
07.02 ? Blade ????? Pcs 045-DWG- W a
01221-0A
BELT & IDLER &
II SAFETY PANELS
& SKIRT BOARD
Conveyor belt Type: EP500/3 - PHOENIX TISUR-320-
08.00 1 (including 6+3; 275 m 045-DWG- S
splicing length) width:1000mm 01221-02
LORBRAND TISUR-320-
09.00 927 Idlers Pcs 045-DWG- S
01208-0A
TISUR-320-
Carrying idler Ø89 x 240/225 045-DWG-
09.01 780 LORBRAND Pcs S
(idlers at panels) ø20 SW 15 01208-0A
Pos. 1

Length /
S/W
area
Unit
FLS Codes part No.
TISUR-320-
Carrying idler
Ø89 x 240/225 045-DWG-
09.02 54 (reinforced idlers at LORBRAND Pcs S
ø25 SW 15 01208-0A
panels)
Pos. 2
Carrying idler TISUR-320-
(idlers at safety Ø89 x 251/225 045-DWG-
09.03 21 LORBRAND Pcs S
panels + 1 x for ø25 SW 18 01208-0A
return station) Pos. 3
TISUR-320-
Carrying idler
Ø89 x 626/600 045-DWG-
09.04 4 (idlers at safety LORBRAND Pcs S
ø25 SW 18 01208-0A
panels)
Pos. 4
TISUR-320-
Belt forming idler 045-DWG-
09.05 4 Ø85 x 240 LORBRAND Pcs S
01208-0A
Pos. 5
TISUR-320-
Carrying idler
Ø133 x 406/380 045-DWG-
ø25 SW 18 01208-0A
idler station)
Pos. 6
TISUR-320-
Impact idler
Ø133 x 406/380 045-DWG-
ø25 SW 18 01208-0A
idler station)
Pos. 7
Ø133 x TISUR-320-
09.08 1 Pressure idler LORBRAND Pcs S
1182/1150 Ø40 045-DWG-

Length /
S/W
area
Unit
FLS Codes part No.
SW 32 01208-0A
Pos. 8
TISUR-320-
10.00 1 Material guidance FLSMIDTH 045-DWG- S
01224-0A
TISUR-320-
Rubber 045-DWG-
10.01 2 Rubber strip 12x150x3800 Pcs W
40° Sh 00148-0A pos
D14
TISUR-320-
Rubber 045-DWG-
40° Sh 00148-0A pos
D12
TISUR-320-
Rubber 045-DWG-
40° Sh 00148-0A pos
D13

Length /
S/W
area
Unit
FLS Codes part No.
TISUR-320-
045-DWG-
00148-0A pos
D9
TISUR-320-
045-DWG-
00148-0A pos
D10
TISUR-320-
045-DWG-
00148-0A pos
D11
TISUR-320-
11.00 8 Safety panel 045-DWG- S
01282-0A
EAS elements
TISUR-320-
M24 x 1 with
11.01 16 Safety elements ???? Pcs 045-DWG- S
sensor type: ???
01282-0A

Length /
S/W
area
Unit
FLS Codes part No.
III 1 RETURN STATION

Ø656 x 1200, LL TISUR-320-
Tail pulley with
12.00 1 shaft for speed LORBRAND Pcs S a
lagging Plain 13 01207-0A
monitor
TISUR-320-
045-DWG-
01207-0A
Pos. 02
TISUR-320-
13.00 1 V Plough cleaner FLS Pcs 450-DWG- S
001288-0A
Rubber TISUR-320-
13.01 2 Rubber cleaner 20x250x623 FLS Pcs with fabric 450-DWG- W
50° Shore 001288-0A
TAKE-UP
IV 1
STATION
Ø656 x 1200, LL TISUR-320-
14.00 1 Take up pulley LORBRAND Pcs S a
TISUR-320-
045-DWG-
01207-0A
Pos. 03

Length /
S/W
area
Unit
FLS Codes part No.
Ø656 x 1200, LL TISUR-320-

15.00 2 Bend pulley LORBRAND Pcs S a
TISUR-320-
045-DWG-
01207-0A
Pos. 03
TISUR-320-
Counter weight
16.00 1 FLSMIDTH 450-DWG-
box & guidance
01265-0A
TISUR-320-
16.01 4 Plastic Plate Thk40 40 x 180 x 180 FLSMIDTH 450-DWG- W
01265-0A
FLSMIDTH TISUR-320-
16.02 8 Plastic Plate Thk40 40 x 180 x 60 450-DWG- W
01265-0A
Rubber for counter FLSMIDTH Rubber TISUR-320-
16.03 2 weight box scraper 12 x 1728 x 100 55°±5° 450-DWG- W
Thk12 Shore 01266-0A
ELECTRICAL
V Var.
COMPONENTS
17.00 Pull Cord Switch b

Length /
S/W
area
Unit
FLS Codes part No.
Plugged Chute
18.00 b
Switch
Belt
19.00 Misalignment b
switch
Belt twisting
20.00 b
Switch
Proximity switch,
21.00 b
Safety pannels
Proximity switch,
22.00 b
Take-up station
Rotation speed
23.00 b
sensor
24.00 ???????? b
25.00 ???????? b

Customer: TISUR
I - DRIVE STATION
IV - TAKE UP STATION

III - RETURN STATION

Customer: TISUR
I - DRIVE STATION
15.00 with 15.01
03.00 With 03.01

02.00 with 02.01

08.00 Conveyor Belt 12.00 With 12.01
14.00 with 14.01

Customer: TISUR
I - DRIVE STATION
07.00 to 07.02
06.00 to 06.02
04.00 to 04.03
01.05 01.04
05.00 & 05.01
01.01
01.02
01.00
01.03/01.03.01

Customer: TISUR
IV- TAKE UP STATION 16.03

15.00 with 15.01
14.00 with 14.01
16.00 to 16.02

Customer: TISUR
II- IDLERS &SAFETY PANELS & SKIRTBOARD
09.04 09.03
09.04
09.01 or 09.02
10.00 to 10.06 12.00/12.01
13.00/13.01

Customer: TISUR
09.04
09.06 to 09.07
09.03
11.00 to 11.01
09.06
09.04 09.01 to 09.02
13.4 Lubrication plan
Attention
The lubrication plan should be read in conjunction with the general lubrication instructions from the sub-suppliers.
We explicitly point out that despite all the indications in this lubrication plan, users have to refer to Part A for Safety
information as well as to Part B for Storage, Assembly, Operating and Maintenance instructions.
It is imperative to make sure that all equipment which is greased or oiled is NOT put into operation and/or operated without
having checked the correct lubricant filling. 
Method of lubrication
LL = Lifetime lubrication GM = Greased manually
OB/GB = Oil bath lubrication / Grease bath lubrication LS = Lubrication by central lubrication system
GN = Greased by means of grease nipples OR = Oil reservoir
Filled: Means that the equipment is supplied with a factory filling.

Unit of oil and grease: Oil in Liter, grease in Kilogram.
Interval: Means interval of re-lubrication in operating hours
Lubricant: The first information is according to DIN 51502 or ISO 6743, the second information is the manufacturer brand
type (preferably SHELL). For all other brands, see the tables of equivalence from the sub-suppliers.
Information in column "Remark":

a. Also refer to the sub-supplier's specifications in Part C.
b. Also follow the information indicated on the power rate plate.
c. No lubrication required.
d. These quantities are rough estimates only. Must be adjusted at use.
e. Check the oil level on the reservoir - refill if necessary.
f. Connected on a centralized lubrication system.
g. Greased at first mounting.
13.4.1 Lubrication plan for Pipe conveyor 0720-PC-1021

2.2135 Lubrication plan MIFU-DE 23-05-2014
Equipment: Pipe conveyor
All cells highlighted in yellow must be filled up , Customer: TISUR
Item No.: 0720-PC-1021
checked or adapted with supplier data, etc (colour Islay province, Arequipa, Peru
to be deleted after completion).
Filled Y/N
First First Re-
Method
Parts to be Suppli Max.

Pos. Qty Type of part filling filling filling Lubricant Interval Remarks
lubricated er interval
/unit /total qty
I DRIVE STATION
Gear unit with
01 1 X3KH170/B SEW ? 54 ?? ?? ??????? ?? ?? a.b
backstop
Taconite seal for SEW/
02 1 ? ? ? ?? ??????? ?? ?? a.b
Gear reducer WEG
280S - 200kW SEW/
03 1 Bearings for Motor ? ? ? ?? ??????? ?? ?? a.b
- 1500 rpm WEG
Ø1040 x 1800,
LL 2300 with
rubber lagging LORB
04 1 Drive pulley
Diamond 20 RAND
mm 60° shore
A
04.01 1 Bearing SNL3136 ???? ? ? ? ?? ??????? ?? ?? a
Ø531 x 1800,
LL 2300 with
LORB
05 1 Snub pulley rubber lagging
RAND
plain 13 mm
45° shore A
05.01 1 Bearing FSNL518-615 ???? ? ? ? ?? ??????? ?? ?? a
LORB Life time
06 2245 Idlers
RAND lubricated
LORBR Life time
06.01 4 Belt forming idler Ø110 x 310
AND lubricated

Item No.: 0720-PC-1021
Filled Y/N
First First Re-
Method

/unit /total qty
II RETURN STATION
Ø826 x 1800,
LL 2300 with
LORB
07 1 Tail pulley rubber lagging
RAND
plain 13 mm
45° shore A
07.01 1 Bearing SNL3136 ???? ? ? ? ?? ??????? ?? ?? a
Articulation for Disc SEW/V
08 1 GH 214 ? ? ? ?? ??????? ?? ?? a.d
Brake with ULKAN
Thrustor for disc FEHD-II-AEH- SEW/V
09 1 ? ? ? ?? ??????? ?? ?? a.d
brake 80/6 ULKAN
Ø826 x 1800,
LL 2300 with
LORB
10 1 Take up pulley rubber lagging
RAND
plain 13 mm
45° shore A
10.01 1 Bearing SNL3136 ???? ? ? ? ?? ??????? ?? ?? a
Ø826 x 1800,
LL 2300 with
LORB
11 2 Bend pulley rubber lagging
RAND
plain 13 mm
45° shore A
10.01 1 Bearing FSNL532 ???? ? ? ? ?? ??????? ?? ?? a

Customer: TISUR
I - DRIVE STATION
IV - TAKE UP STATION III - RETURN STATION

Customer: TISUR
I - DRIVE STATION
11/11.01 III - RETURN STATION
05/05.01
07/07.01
10/10.01
04/04.01

Customer: TISUR
I - DRIVE STATION
01
04/04.01
05/05.01
02 03
02
01

Customer: TISUR
IV- TAKE UP STATION
11/11.01
10/10.01

Customer: TISUR
II- IDLERS &SAFETY PANELS II- IDLERS &SAFETY PANELS & SKIRTBOARD
07/07.01
06
05 06.01
06
06
09/08
13.4.2 Lubrication plan for Pipe conveyor 0320-PC-1012

2.2135 Lubrication plan RAGRE-IN 16-12-2014
Item No.: 0320-PC-1012
Filled Y/N
First First Re-
Method

/unit /total qty
I DRIVE STATION
Gear unit with
01 1 X3KH140/BS SEW ? 33 ?? ?? ??????? ?? ?? a.b
backstop
Taconite seal for SEW/ a.b
01.01 1 ? ? ? ?? ??????? ?? ??
Gear reducer WEG
IEC250 S/M - a.b
SEW/
01.02 1 Bearings for Motor 56kW - 1790 ? ? ? ?? ??????? ?? ??
WEG
rpm
SEW/ a.b
02 1 Hydraulic coupling 13CKRG TRANS ? ? ? ?? ??????? ?? ??
FLUID
USB2-05 a.b
Thrustor for Disc SEW/
03 1 EB120-40 ? ? ? ?? ??????? ?? ??
Brake SIBRE
ED12/4
Ø820 x 1200,
LL 1600 with
rubber lagging LORB
04 1 Drive pulley
Diamond 20 RAND
mm 60° shore
A
04.01 1 Bearing FSNL 532 ???? ? ? ? ?? ??????? ?? ?? a
Ø531 x 1200,
LORB
05 1 Snub pulley LL 1600 with
RAND
rubber lagging

Item No.: 0320-PC-1012
Filled Y/N
First First Re-
Method

/unit /total qty
Plain 13 mm
45° shore A
05.01 1 Bearing FSNL 515-612 ???? ? ? ? ?? ??????? ?? ?? a
LORB Life time
06 927 Idlers
RAND lubricated
Life time
LORBR lubricated
06.01 4 Belt forming idler Ø85 x 240
AND
II RETURN STATION
Ø656 x 1200,
LL 1600 with
LORB
07 1 Tail pulley rubber lagging
RAND
Plain 13 mm
45° shore A
07.01 1 Bearing FSNL 518-615 ???? ? ? ? ?? ??????? ?? ?? a
Ø656 x 1200,
LL 1600 with
LORB
08 1 Take up pulley rubber lagging
RAND
Plain 13 mm
45° shore A
08.01 1 Bearing FSNL 518-615 ???? ? ? ? ?? ??????? ?? ?? a
Ø656 x 1200,
LL 1600 with
LORB
09 2 Bend pulley rubber lagging
RAND
Plain 13 mm
45° shore A

Item No.: 0320-PC-1012
Filled Y/N
First First Re-
Method

/unit /total qty
09.01 1 Bearing FSNL 518-615 ???? ? ? ? ?? ??????? ?? ?? a

Customer: TISUR
V
I - DRIVE STATION

Customer: TISUR
I - DRIVE STATION
09/09.01
05/05.01
04/04.01 IV - TAKE UP STATION
07/07.01
08/08.01

Customer: TISUR
04/04.01
I - DRIVE STATION
05/05.01
03
02
01/01.01
01.02
01.01 01.02
01.01
01

Customer: TISUR
IV- TAKE UP STATION
09/09.01
08/08.01

Customer: TISUR
II- IDLERS &SAFETY PANELS & SKIRTBOARD
07/07.01
06
06

Customer: TISUR
06.01
06
06
13.4.3 SEW Lubricant

Gear unit X series
SEW Lubricant
Gear unit R, F, K, S, W series
SEW Lubricant
Gear unit P002 to P082 series
SEW Lubricant
Bearings & Taconite seals for gear unit X series
13.5 Inspection & maintenance schedule guideline
Pos Work to be carried out /
3 Months
Monthly
Weekly
Daily
Frequency
other
Pipe conveyors
00 General maintenance
Visual check and removal of sticking
X
foreign bodies
Clean according to the degree of
X
contamination
Check mounting of gratings,
protection guards, handrails, stair
treads and ladders on the complete X
machines in particular on all motors,
gearboxes, coupling etc.
Check all mountings of installed
X
equipment
Check all limit switches function X
Check all attachments of electrical
X
equipment
01 Drive units
Gearboxes SEW
Gearbox – Check quiet running X
Gearbox – Check temperature X
Gearbox – Check oil level X
Gearbox – Check leakage X
Gearbox – Check vent plug X
Gearbox – clean according to the
X
degree of contamination
Gearbox – Check screws' tightening X
Gear box – Re grease Taconite seal Every 6 months or
3 000 hours
Gearbox – Carry out complete
Every 2 years
inspection (see Part C1 SEW)
Gearbox – Exchange of oil, see 13.4 10 000 hours
Lubrication plan or 2 years
3 Months
Monthly
Weekly
Daily
Frequency
other
Pipe conveyors
Motors SEW/WEG
Motor – Check quiet running X
Motor – Check temperature X
Motor – Change roller bearings, seals
40 000 hours
if necessary
Motor – Check attachment X
Motor – Check condition X
Motor – Check electrical supply X
Motor – Carry out complete 16 000 hours
inspection (see Part C1 SEW) or 2 years
Motor – Inspect the motor and clean
Yearly
the cooling air channel
Disc brake SEW/SIBRE
Disc brake – Check lining & disk for
X
wear
Disc brake – Check function X
Disc brake – Check attachment X
Disc brake – Check tension of spring X
Disc brake – Check brake torque X
Disc brake – Carry out complete
Every 4 months
inspection (see Part C1 SIEMENS)
Hydraulic coupling
SEW/TRANSFLUID
Coupling – Check alignment X
Coupling – Check condition X
Coupling – Check attachment X
Coupling – Check torque set and
6 months
wear
Coupling – Check oil level After first 20 days/ 6
months
Coupling – Check for leakage X
Coupling – Carry out complete
Every 12 months
Coupling – Exchange oil, see 13.4
10 000 hours or 5 years
Lubrication plan
3 Months
Monthly
Weekly
Daily
Frequency
other
Pipe conveyors
Flexible couplings
Type SEW/????
Coupling – Check alignment X
Coupling – Check conditions X
Coupling – Check attachment X
Coupling – Check wear X
Coupling – Carry out complete
yearly
Shrink disc SEW
Shrink disc – Check condition X
Shrink disc – Check attachment X
Shrink disc – Check screws'
X
tightening
Shrink disc – Carry out complete
yearly
Base plates (drive station)
Base plate – Check condition X
Base plate – Check attachment X
Base plate – Check guards
X
installation
Bearings / Pins / Connections
Bearing – Check quiet running X
Bearing – Check grease
X
contamination
Idlers and brackets
02
LORBRAND
Idlers
Idler – Check quiet running X X
Idler – Check idler damage X X
Idler – Check general cleanliness X X
Idler – Check adhering material and
X X
if necessary clean
Brackets
Bracket – Check attachment X
Bracket – Check alignment X
3 Months
Monthly
Weekly
Daily
Frequency
other
Pipe conveyors
Pulleys and bearings

03
LORBRAND
Pulleys
Pulley – Check adhering material and
X
if necessary clean
Pulley – Check rubber lagging wear X
Pulley – Check quiet running X
Pulley – Check bearing plate
X
attachment
Pulley – Check pulley body condition X
Pulley – Check locking joint set
1 500 hours
(attachment and torque moment)
Pulley bearings
Roller bearing – Check quiet running X
Roller bearing – Check lubrication X
Roller bearing – Check temperature X
Roller bearing – Check grease
X
contamination
Roller bearing – Re-lubricate, see
X Or 500 hours
13.4 Lubrication plan
Pulley & bearing – Carry out
complete inspection (see Part C1 yearly
LORBRAND)
04 Belt scrapers and belt ploughs
Belt scrapers MARTIN
(primary, secondary)
Scrapers – Check cleaning effect X
Scrapers – Check wear of blades X
Scarpers – Check working angle and
X
if necessary re adjust
Scrapers – Check attachment and
X
support
Scrapers – Remove complete unit
X
and inspect
Scrapers – Carry out complete
inspection (see Part C1 MARTIN)
3 Months
Monthly
Weekly
Daily
Frequency
other
Pipe conveyors
Scrapers – Check blades' wear X
V-Plough
V-Plough – Check cleaning effect X
V-Plough – Check adhering material
X
and if necessary clean
V-Plough – Check blades' wear X
V-Plough – Check attachment and
X
support
05 Conveyor belt PHOENIX
Belt– Check for damage X
Belt – Check adhering material and if
X
necessary clean
Belt – Check proper belt cleaning and
X
scraping, if necessary adjust
Belt – Check for misalignment X
Belt – Check for longitudinal edges X
Belt – Carry out complete inspection
(see Part C1 PHOENIX)
06 Counterweight boxes
Counterweight – Check the function
X
and the guidance smooth running
Counterweight – Check the belt
tension, shorten the belt if the take X
up distance is exceeded
Counter weight – Clean according to
X
the grade of contamination
08 Chutes, baffle plates and skirt
boards
Chutes and baffle plates
Chute – Check the function, check
X
for material spillage
Chute – Check for adhering material
X
and clean if necessary
Chute – Check the attachment X
Chute – Check the liners for wear X
Chute – Check and adjust the rubber
X
strips
3 Months
Monthly
Weekly
Daily
Frequency
other
Pipe conveyors
Skirt boards
Skirt board – Check the function,
X
check for material spillage
Skirt board – Check for adhering
X
material and clean if necessary
Skirt board – Check and adjust the
gap between the rubber strips and X
the belt
Skirt board – Check the liners for
X
wear
09 Steel structures
Structure – Check the attachment X
Structure – Check the condition X
Structure – Check the corrosion
X
protection
Structure – Check the walkways and
X
the handrail system
10 Electrical equipment
General
Visual check for damage and
X
tightness
Check the support of all electrical
X
attachments
Local control devices
See detailed instruction in "Electrical
Instructions”
Emergency pull cord switches
Check the function X
Check the attachment X
Check pull wire (free and accessible) X
Misalignment switches
Speed switches
3 Months
Monthly
Weekly
Daily
Frequency
other
Pipe conveyors
Emergency stop switches
Level detector switches
Position limit switches
See additionally detailed instruction
in the electrical documentation
For other electrical equipment
see the "Electrical Instructions”

3 Months
Monthly
Weekly
Frequency
Daily
other
Belt conveyor additional
equipment
11 For example Magnetic
separator if existing
12 For example Belt scale if

existing
13 For example Maintenance

hoist if existing
14
13.6 Troubleshooting chart
The troubleshooting chart regards all those faults which are to be expected after
experience of FLSmidth, most frequently.
But, it is not possible to predict all circumstances that may require

troubleshooting. Therefore, the troubleshooting chart makes no claim to be
complete.
It also can not include all facts and circumstances that can be possible, or cause
further faults or danger situations, in case of a reasonably foreseeable misuse at
the place of installation.
If a fault develops that is not described in the troubleshooting chart, or if

experiencing faults other than those listed, or in which for the operator exists
any doubt in handling the machine, we recommend the immediate contact with
FLSmidth for the clarification of suitable measures.
For further information also refer to the suppliers' documents in Part C1.
Notice
Do not return the machine including its equipment to operation,
until the problem has been identified and corrected!
13.6.1 General
Section Pipe conveyor
Device General
Remark A pipe conveyor is designed for high performance continuous
conveying of a wide variety of bulk material with different
characteristics. It is an enclosed conveying system for dust and
spillage free transportation and can be used in problematic
topographic areas. Pipe conveyors typically perform under
extreme operating and/or environmental conditions.
Fault Possible cause Remedy

Damaged track idlers Change idlers
Damaged bearings Change bearing
Damaged belt Repair or change
Changed noise Damaged belt splices Renew splicing
Damaged steel structure Contact FLSmidth
Collateral moving of the belt Align belt drums
Foreign parts within conveyor road Clean conveyor
Electric supply failure Check and repair
electric fuse has blown Replace fuse
Control.
Emergency stop occurs Determine and eliminate
causes
Control error Check and/or reset
electric drive does not work Check drive
No start up
Conveyor belt is broken Repair or change
Belt is not correctly tightened Adjust belt tension
Wear of drive pulley lagging Check and change drum
Tighten screws with
Loosening of the shrink disc
torque wrench
Remove the overfilled or
Safety panel swivelled
oversized material
Bad forming of Incorrect fixing of belt forming
Adjust fixing
tubular shape idlers
Contact of
Adjust the settings
overlapping belt
Bad position of the forming idler (tilting of the belt
and belt forming
forming idlers)
idlers
Belt turn to the Overlapping not in the right
Adjust the carrying idlers
right or the left position
Belt does not form
properly into the
Too low belt tension Increase the pretension
pipe shape
(hexagon)
Belt shape is
narrower in the
Too high belt tension Decrease the pretension
area of a curve
than elsewhere
13.6.2 Gear unit
Device Gear unit

Remark A gear unit is typically a bevel helical gear unit. The gear unit is
used to reduce the motor speed according to the needed
conveying speed. It is designed for continuous high performance.

Damaged gear teeth
Changed running
Excessive bearing play Contact FLSmidth
noise
Damaged bearing
Replace damaged
Noise of the gear Gear unit mounting has worked screwing
unit mounting loose Tighten screwing to
specified torque
Increased Oil level too high or too low Adjust oil level
temperature at the Expired oil Change oil
bearing Damaged bearing Contact FLSmidth
Housing is soiled
Leaky sealing Seal the housing
with oil
Oil is leaking of the
Leaky sealing Seal the housing
housing
Oil is leaking out of
Oil level too high Adjust oil level
the breather valve
Unlocked oil filler cap Change oil
Water in the oil Condensed water Change oil
Climatic conditions Contact FLSmidth
Preservation agent is not
Change oil
completely drained
Shut down and let oil
Oil is foaming in Operation temperature is too low
outgas
the housing
Water in oil Change oil
Expired oil Change oil
Mix up of incompatible oils Change oil
Oil level too high or too low Adjust oil level
Increased operating
Expired oil Change oil
temperature
Badly contaminated oil Change oil
13.6.3 Motor
Device Motor
Remark A motor is typically a three-phase asynchronous motor. The
motor is used to actuate the Pipe conveyor. It is designed for
continuous high performance.

Electric supply failure Check electric supply
Electric fuse has blown Replace fuse
No start up Control error Check and/or reset
Motor protection has triggered Check protection
Motor protection does not switch Check protection control
Measure power. Reduce
Overload
load
Correct cooling air
supply. Clear cooling air
Insufficient cooling
passages. Retrofit forced
Motor heats up cooling fan if necessary
excessively Take temporary
Ambient temperature too high
measures for cooling
Motor in delta connection instead
Correct connection
of star connection as provided for
One phase missing caused by a
Rectify loose contact
loose contact in the cable
Wrong connection Correct connection
Motor starts badly Voltage or frequency deviate from Provide sufficient electric
set point power supply
Motor rotates in
wrong direction
Motor protection Short circuit in line Repair short circuit
trips or fuses blow Short circuit in motor Send the motor for
Ground fault on motor repair
Motor hums and Damaged winding
Send the motor for
has high current
Rubbing of the rotor repair
consumption
Motor loses speed Overload Check Pipe conveyor
under load Voltage drop Check electric supply
Ungreased bearing Grease bearing
Inspect & replace if
Damaged bearing
necessary. Align motor
Rectify cause of
Rotating parts vibrations
Motor excessively imbalance
loud Foreign bodies in the cooling air Clean cooling air
passages passages
Reduce speed for the run
Too much or too few grease in the
in and/or regrease
bearing
Clean and regrease
13.6.4 Fluid coupling
Device Fluid coupling

Remark A fluid coupling connects the motor to the gear. It transmits the
torque, permits variable speed start and/or controlled start-up
without shock loading. The fluid coupling also acts as a torque
limiter. It typically performs under extreme operating and/or
environmental conditions.

Realign drive
Excessive misalignment
components
Changed running
Damaged coupling parts Replace parts
noise and/or
Unbalance Balance coupling
vibrations
Insufficient quantity of operating
Refill operating fluid
fluid
Replace safety fuse
Check function of
Safety fuse has blown
thermal monitoring
Leaks / spurting out
equipment
of operating fluid
Replace or repair
Damaged coupling cover
coupling cover
Damaged sealing Replace sealing
Loose blockage and
Increased Blockage or overload of the driven check function
temperature machine Check function of "fuse
switch"
Replace safety fuse
Check function of
Safety fuse has blown
thermal monitoring
equipment
Loose blockage and
Blockage or overload of the driven check function
machine Check function of "fuse
Less or no torque switch"
Repair leaks if possible
Replace damaged
spurting out of operating fluid
parts
Insufficient quantity of operating
fluid
Coupling damage Replace coupling
13.6.5 Disc brake
Device Disc brake

Remark A disc brake is typically used to stop the belt run by stopping the
gear box in case of emergency stop and/or normal operation
stop. It typically performs under extreme operating and/or

Wear of lining or
Realign or remove
non-parallel wear of Brake misalignment or brake jam
cause of obstruction
lining
Brake instable when Refurbishment of the
Wear of bushings
opened brake
Check surface of brake
Defects of the surface of the brake
disc and linings and
disc and linings
replace if necessary
Balance relevant
Changed noise when Unbalance
components
braking
Replace damaged
mounting bolts
Brake mounting has worked loose
Tighten screwing to
specified torque
Insufficient adjustment of the
Adjust braking torque
braking torque
Insufficient adjustment of the Adjust and check
reserve stroke of thrusters during operation
Linings to be run-in
Slipping of brake
too small contact to the linings against the rotating
disc
disc
Replace linings and/or
Worn linings or brake disc
brake disc
When closing, brake is acting Check & adjust limit
against mechanical limit stop stop or brake stroke
Damaged parts Replace damaged parts
Disc brake does not Mechanical blockage Remove foreign bodies
release or close Correct electrical
Wrong electrical connection
connection
13.6.6 Thruster at disc brake
Device Thruster at disc brake

Remark A thruster forms part of the disc brake. It releases the brake by
acting against the spring force. The energy required for release
may be generated by electro-hydraulic, solenoid, hydraulic or
pneumatic means. It typically performs under extreme operating
and/or environmental conditions.

Replace thruster
Operating fluid Damaged thruster caused by
Repair and refill with
leakage external effects
operating fluid
Terminal box not
Damaged sealing Replace sealing
tighten
Damaged parts Replace parts
Thruster does not Mechanical blockage Remove foreign bodies
operate Correct electrical
connection
13.6.7 Elastic coupling
Device Elastic coupling

Remark An elastic coupling connects the motor to the gear. It transmits
the torque and absorbs misalignment and vibrations. It typically
performs under extreme operating and/or environmental
conditions.

Realign drive
Excessive misalignment
Changed running components
noise and/or Worn or damaged coupling parts Replace parts
vibrations Unbalance Balance coupling
Elastic part damage Change elastic part
Axial moving of the Tighten screwing to
Loose clamp connection
coupling specified torque
13.6.8 Shrink disc
Device Shrink disc

Remark A shrink disc is typically used with frictional connections of drive
components and shafts. The clamping force is generated by
tightening of tapered rings. This way, the inner ring shrinks onto
the shaft. The tightening screws of the shrink disc must be
tightened to the specified torque by a torque wrench.

Replace damaged
screwing
Screwing has worked loose
No torque Tighten screwing to
specified torque
Incorrect mounting Correct mounting
13.6.9 Silent block
Device Silent block

Remark A silent block is typically used to degenerate mechanical
vibrations between movable parts and steady mounted
structures. It usually consists of a rubber body vulcanized on
fastening elements.

Shocks or Damaged silent block Replace silent block
vibrations Wear of silent block Replace silent block
13.6.10 Pulley
Device Pulley
Remark The conveyor belt runs over the pulleys and changes direction.
Pulleys are usually provided with lagging. They consist of a drum
fitted on a shaft with a bearing on each side of the shaft. They
typically perform under extreme operating and/or environmental
conditions.

Damaged bearing Change bearing
Too much or too few grease in the Reduce speed for the
Changed running bearing run in and/or regrease
noise Dirt accumulation on the pulley
Clean the pulley
lagging
Damaged lagging Replace the pulley
Replace damaged
Noise of the bearing Bearing mounting has worked screwing
mounting loose Tighten screwing to
specified torque
Too much or too few grease in the Reduce speed for the
bearing run in and/or regrease
Increased operating
Expired grease Change the grease
temperature
Mix up of incompatible greases Change the grease
Remove adhering
Adhering material Dirt accumulation on the belt
material
Damaged belt Repair belt
Wear of pulley Damaged belt splices Renew the belt splices
lagging Dirt accumulation on the belt Clean the belt and the
and/or the pulley pulley
Unbalance Change pulley
Damaged lagging Change pulley
Vibrations Replace damaged
screwing
Loose fixation of the bearings
Tighten screwing to
specified torque
Slipping on the Tighten screwing to
Loosen shrink joint
shaft specified torque
13.6.11 Belt
Device Belt
Remark The belt is the most important part of a pipe conveyor. The belt
must not have any damages. Belt splices and mends are to be
inspected regularly. The alignment of the belt drums and the
adjustment of the belt tension are basic requirements for the
performance of the complete conveyor system.

Caused by the bulk material Repair or change the belt
Overlapping not in the
Belt turn to the right or the left
right position
Damaged belt Damaged belt splices Renew the belt splices
Exceedance of the belt life time Change the belt
Damages caused by external Protect the conveyor belt
effects against external effects
13.6.12 Belt cleaner
Device Belt cleaner

Remark A belt cleaner is designed to clean the conveyor belt on the outer
and inner side, at the head or the tail of the conveyor. A belt
cleaner typically performs under extreme operating and/or

Pressing force of scraper is set too
Insufficient Adjust tensioner setting
low
cleaning
Blades are worn Check and replace
Too high pressing force Adjust tensioner setting
High rate of blade Damaged belt Check belt and repair
wear Check belt splices and
Damaged belt splices
repair
Damaged belt Check belt and repair
Damage of blades Check belt splices and
Damaged belt splices
repair
Blades pop out of
Pressing force set too high Adjust tensioner setting
track
Noise or vibrations Pressing force not correctly set Adjust tensioner setting
Repair.
Impact by heavy particles of the
Check that particle's size
bulk material
Bent or broken is according to design
main frame or Damages caused by external
Contact FLSmidth
support frame effects
Overload by exceeding the design
Contact FLSmidth
capacity
13.6.13 Idler
Device Idler
Remark Idlers are supporting rollers on which the conveyor belt moves.
They support the carrying and return part of the belt. They are
usually lifetime lubricated and perform under extreme operating

capacity
Damaged idlers Change damaged idlers
bulk material
Damaged support
capacity Contact FLSmidth
steel structure
External damages
Bearing damages
No free movement Deformed drum body Replace idlers
Damaged lagging
13.6.14 Belt forming idler
Device Idler
Remark Idlers are supporting rollers on which the conveyor belt moves.
They support the carrying and return part of the belt. They are
usually lifetime lubricated and perform under extreme operating

capacity
Damaged idlers Change damaged idlers
bulk material
Damaged support
capacity Contact FLSmidth
steel structure
External damages
Bearing damages
No free movement Deformed drum body Replace idlers
Damaged lagging
13.6.15 Tension guidance with take-up station
Device Take-up station

Remark A take-up station is designed to guarantee friction between
conveyor belt and drive pulley. It doesn´t allow to align the belt.
It typically performs under extreme operating and/or

Loss of counterweight Ropes break
Blockage in counterweight Loose blockage and
guidance check function
Loss of belt tension Damage of the counterweight Repair damaged parts.
facility Restore function
Expired travel way of the
Shorten the belt
counterweight
13.6.16 Skirt board
Device Skirt board

Remark Skirt boards are designed to keep the material onto the belt in
the feeding area. They typically perform under extreme operating

Material caking Remove material caking
Material over filling Repair or replace wear
or overflow Damaged skirt board plates and/or rubber strip
/ curtain
Remove adhering
Adhering material Dirt accumulation on the surface
material
Worn parts of wear plates Check and replace
Repair.
Damaged skirt Check that particle's size
bulk material
board is according to design
Damages caused by external
Contact FLSmidth
effects
Damaged support Overload by exceeding the design
Contact FLSmidth
steel structure capacity
13.6.17 Dust sealing equipment
Device Dust sealing equipment

Remark Dust sealing equipment is designed to avoid the dust escaping
from the feeding and discharging area. This is for health, safety
and environmental reasons. It typically performs under extreme
operating and/or environmental conditions.

Sealing damage Repair or replace
Dust escaping or Spray nozzles defect Repair or replace
built up Check and repair or
Dedusting unit malfunction
maintain
13.6.18 Discharge hood and chute
Device Discharge hood and chute

Remark A discharge hood and chute transfers the conveyed material to
following equipment. Chutes shall be kept free of material caking
so that the adjusted flow of material does not change. They
typically perform under extreme operating and/or environmental
conditions.

Material flow is
Material caking Remove material caking
changed or stopped
Dirt accumulation on the surface of Remove adhering
Adhering material
the inner chute material
Worn parts of wear plates Check and replace
Repair.
Damaged chute or Check that particle's size
bulk material
baffle plate is according to design
Damages caused by external
Contact FLSmidth
effects
Damaged support Overload by exceeding the design
Contact FLSmidth
steel structure capacity
13.6.19 Belt scale
Section Belt conveyor
Device Belt scale

Remark A belt scale is specifically designed for weighing the material
conveyed through belt conveyors. It typically performs under
extreme operating and/or environmental conditions.

Electric supply failure Check electric supply
Damaged load cell Replace and/or repair
No signal Control module failure Check and/or reset
Correct electrical
connection
Correct electrical
Speed transducer Wrong electrical connection
connection
failure
Wheel does not turn Clean or change
13.6.20 Additional equipments (belt scale, maintenance hoist, etc.)

B1 0 Pipe Conveyor en 2

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Page 1 of 246 Original version

Assembly, Operating & Maintenance

Contract No.: 2.2135 / 6074M

Supplier: FLSmidth Wadgassen GmbH

Assembly, Operating &

Plant: Islay Bay

Location: Islay province, Arequipa,

Client No.: 6074M

Contract No.: 2.2135

Design Year: 2014

FLSmidth Equipment: Materials handling equipment

All sentences or words highlighted in yellow must be

2 Equipment according to material flow / Flow Sheet...............12

4 Technical Parameters .............................................................14

5 Instructions for Transport......................................................19

6 Instructions for the Storage of the Delivery ...........................22

7 Description of Equipment .......................................................26

7.7 Pipe Conveyor components......................................................... 31

8 Scope of works by the construction company ........................58

8.6 Fastening of bolts...................................................................... 61

9 assembly and disassembly Instructions .................................67

9.4.18 Preparing the tests .................................................................... 94

10 Start-up / Commissioning / Operating Instructions.............128

10.7 1st Test run............................................................................ 133

11 General Maintenance Instructions........................................138

11.6 Dismantling and disposal.......................................................... 152

12 Instructions for the Lubrication of the Equipment................154

13 Specific Instructions and Information ..................................162

13.6.9 Silent block ............................................................................ 239

Consequently, if a situation should arise, the occurrence of which is not

All references to relevant safety standards are given at the EC declaration of

Reference by seller to any international or national standard does not incur

Hence, any recipient, reader or user of the documentation is expected – at

See Part A “General safety instructions” and the separate equipment-specific

1.2 Definitions and abbreviations

Authorized person A person who is qualified and who, by the

1.3 Safety legend

In this instruction manual dangerous situations are indicated by the

Structure of safety warnings

Signal word panel

Additional safety signs

2 EQUIPMENT ACCORDING TO MATERIAL FLOW / FLOW SHEET

Equipment: Pipe conveyors

E.G.: 2.2135 - 0320-PC-1012

The present operating manual is valid for pipe conveyors.

This assembly, operating and maintenance manual will help you to

For further information or spare parts inquiry please contact us on the

FLSmidth Wadgassen GmbH

4.1 Environmental conditions

Site .......................................................Arequipa, Peru

4.2 Electrical parameters

3 phase voltage MV:................................10 000 VAC 60Hz

4.3 Material characteristics

Material .................................................Copper concentrate

4.4 Plant data

Operating conditions ..............................24 hrs per day, 7 days per week

4.5 Scope of Supply for Pipe Conveyor

Skirt boards & safety panels

Engineered by FLSmidth (mean not supplied by FLS)

1. Framework for drive station

5 INSTRUCTIONS FOR TRANSPORT

The procedure for transporting personnel and equipment establishes