Phoenix Conveyor Belt India

Pvt. Ltd.
Inspection Visit Report
Dated - 25.08.2017

Project : DHAR CEMENT WORKS – OLBC

UltraTech Cement Limited
A/C : Macmet Engineering Ltd.
ABOUT THE COMPANY - Phoenix Conveyor Belt India Pvt Limited

Phoenix Conveyor Belt India (P) Limited (PCBI) is a part of globally renowned Phoenix
Conveyor Belt Systems (PCBS) of Continental AG.

The company’s manufacturing plant is located at Kalyani near Kolkata, WB.

Apart from Belting manufacturing facility, they also have their own cord manufacturing
plant which caters to some of the requirement of the steel cord belting requirement.

PLANT CAPACITY –

Textile Belting : 550 KM per annum.

(45 KM per month)

Steel Cord Belting : 360 KM per annum.

(30 KM per month)
UTCL Order – Steel Cord Belting for OLBC at Dhar Cement Works

Belt Type : Steel Cord Rubber Belting

Belt Specs : 1000 mm wide, ST1400 6/5 M24, EOB, Moulded Edge
Quantity : 16550 meter (Manufacturing status : completed)
Total No. of rolls : 42 Nos
Length : 41 Rolls are of 400 meter length and one roll is of 150 meter length.

Each roll has a Unique five digit identification number : 12834,12808,12805,12807 etc.
 BELT NOMENCLATURE

Belt Specification : 1000 ST 1400 6/5 M24 / EOB, ME

Moulded Edge
Supplier’s
Width of the Belt
abbreviation
For Low
Steel cord belt
Rolling
Tensile strength/Breaking strength Resistance
Of the belt Belts
Top / Bottom cover
thickness

Grade of cover compound

 STEEL CORD BELT CONSTRUCTION

A Typical Steel Cord Conveyor belt has three

distinct components, and a fourth optional
protective element. These are the steel cable, the
bonder layer and the top & bottom covers.
The function of the bonder(core) rubber is to
maintain a bond between the metallic cords and
the rubber polymer in the Steel Cord Belt.
To prevent longitudinal rips an optional component
such as sensor loop or breaker may be
incorporated.
STEEL CORD BELTING MANUFACTURING PROCESS
Rubber Compound Manufacturing Rubber Compound Raw Mix
Rubber conveyor belting essentially consists of various fabrics like all CONSTITUENTS
PERCENTAGE
cotton, cotton/nylon, rayon/nylon, all synthetic etc. with a cover of CONTRIBUTION
various rubber grades like oil resistant, flame resistant etc. Natural rubber 52.44%

The design of conveyor belt cover compound is most important in Accelerator 0.63%
determining the service life of the belt in any particular
application. Anti ageing agent 0.52%

Zinc Oxide Type-I 26.22%

HAF Carbon Black 18.88%

Sulphur 1.31%

This composition is a general

example for1600 ST1600 6/6 Belt.

It can vary as per

Belt rating/specifications
STEEL CORD BELTING MANUFACTURING PROCESS
Rubber Compound Manufacturing

A weighed quantity of rubber, chemicals and oils are mixed homogeneously on open mixing mills/
Banbury machines. To get suitable cover compounds, mixing temp varies from 900c to 1200c. Cover
compounds are properly cooled by immersing in cool water and then in soap solution to avoid
sticking with each other.
Top and bottom covers are also sheeted out from Calender machine as per required length, width
and thickness. Care is taken of at Calender M/C so that covers sheeted out are smooth and free
from air pockets.
 STEEL CORD BELT MANUFACTURING PROCESS

TOP COVER/BONDER

STEEL CORDS

Cord guidance comb

Mobile construction unit with construction press
It helps maintain the Pitch of the cords The construction unit is used to apply the BOTTOM COVER/BONDER
extruded layers of core rubber and cover sheets
PCBI in-house Research and Development Building & Test Laboratory
BELT INSPECTION TESTS

Inspection Test is done as per the following Standards: ISO 15236, DIN 53516

PARAMETER TESTS/CHECKS
Surface Quality & Finish
Belt Width
Total Thickness
Top Cover Thickness
Bottom Cover Thickness
Visual & Dimensional Checks Cord Diameter
Cord Construction
Pitch of the cord
No. of cords
Edge Width
Roll Length
Peeling Resistance
Shore Hardness
Cover Rubber Properties
Abrasion Loss
Tensile Strength (before & after ageing)
Cord Pull Out Test (before & after ageing)
Cord Testing
Cord Breaking Strength
VISUAL & DIMENSIONAL CHECKS

Belt is Unrolled from the drum through a

electrical drive and is made to pass
through the finish press and rolled onto
another drum on the other side.

- Surface finish & quality is inspected.

- Dimensional measurements are done.
- Cover hardness is checked.
- Roll length is measured.
VISUAL & DIMENSIONAL CHECKS

VISUAL INSPECTION of width, thickness, hardness and any abnormalities Like air gaps,
Wear tear, scratch, pores etc. on finishing Press
Laboratory Tests
Rubber Compound Tests – Rubber Properties
This test is done through a Rheometer. The test identifies the problems in a rubber compound in respect of
the desired properties for the particular belt.
Test procedure:
An uncured sample is placed between two dies. The lower die oscillates. The upper die is connected to a
sensor to measure the torque response of the rubber at the deformation during the vulcanization process at
a constant temperature.
Laboratory Tests
Rubber Compound Tests – Abrasion Resistance / loss

The abrasion resistance is measured by moving a test piece across

the surface of an abrasive sheet mounted to a revolving drum.
Loss in weight of the rubber compound is measured for both top
cover and bottom cover.
A lower values indicates better abrasion resistance.

Initial Weight Weight after Weight Average in mg

abrasion Loss
1.8477 1.6323 0.2154 (0.2154+0.2052)/2
=0.2103 gms
1.7534 1.5482 0.2052
= 210.3 mg

Weight Loss of a standard sample test pc. On the abrasion machine,

with emery paper of grade 60. the Weight loss should be typically
within 170 mg to 220 mg.
Abrasion Volume Loss is calculated as:
∆V = (∆m x So) / (Q x S)
So = Value of nominal abrasive power – (as per DIN)
S = Abrasive power of test piece
Abrasion volume loss as per DIN 53516 should be ≤ 200 mm3
Laboratory Tests
Rubber Properties – Tensile Test

The total belt elongation consists of an elastic (which

recovers) and a plastic (which remains) portion.

length = 25mm
Section : 6mm Wide X 2mm thick
Cross section area = 6 X 2 = 12 mm²
Sample break at 31.12 Kg ( 31.12 X 9.8 = 304.97 N)
Tensile Strength (N/mm²) = 304.97 / 12 =25.41
N/mm²
Elongation at break : 160 mm

Percentage elongation = (160-25)/25 X 100 = 540 %

For ST 1400 Belt

Top cover thickness : 6 mm
Tensile strength ≥ 24 N/mm²
Elongation at Break ≥ 450 %
Bottom Cover Thickness : 5 mm
Tensile strength ≥ 18 N/mm²
Elongation at Break ≥ 400 %
Laboratory Tests
Steel Cord Pull Out Test

Test Procedure

static (just pull) or dynamic (10.000 cycles),

without reheating or with reheating (to simulate
splicing).

The cyclic load ranges from 3.6 percent to 36 percent of

the nominal static pull-out strength for a given cord
diameter.

The test is carried out until the number of required

cycles is achieved or till failure of the bond occurs.

Chord Pull out strength (N/mm):

Length of Sample : 100 mm
Force : 14249 N
Strength = Force / Length of sample
= 14249 / 100
= 142.49 N/mm
Laboratory Tests
Troughability Test
The Test Sample is clamped onto the roller brackets on
the test bed, the free roller is given a movement. When
the roller stops moving the deflection is measured and
troughability is calculated as per the specified formula.

width of belt measured : L = 1005 mm

a = 725 mm
b = 345 mm
Deflection measured : F = a-b = 725 – 345 = 380 mm

Troughability = Deflection/ Belt width in mm

= (725-345) / 1005 = 0.378

Troughability F/L (minimum)

30 Degree 0.12
35 Degree 0.14
40 Degree 0.16
45 Degree 0.18
Laboratory Tests
Steel Cord Breaking Strength

The actual steel cord breaking strength is ascertained

by tearing the entire rope until it breaks.
Result stated in kN

As per specs Strength should be ≥ 24 kN

Tested : 26.5 KN at 3 % Elongation

Cord Specifications

No. of cords : 63 Nos

Diameter of Cord : 4.8 mm
Construction of chord : 7 X 7
Steel Core
Laboratory Tests (sample photographs)

DENSITY PEELING STRENGTH/ADHESION TEAR RESISTANCE HARDNESS

Following physical Inspection are also carried out :

1. Width of the Belt : 1000±10 mm

2. Thickness measurement at every regular distance :15.8 (+1.5 mm/ -1.0 mm)
3. Harness measurement : 65±5 Shore ˚A
Test Report
Test Report
THANKYOU !!