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Conveyor Health Assessment Overhead/Inverted Power & Free Systems

An inquiry by our customer requesting a Health Assessment of a conveyor, transfer or other automation should include the following project specific information: Location of equipment: assembly plant, shop(s) Approximate quantity and type of conveyors per shop Desired timing Work time availability at facility shifts/ hours, production calendar information Last assessment date and by who (reports are helpful.)

The following outlines the critical requirements and deliverables for a thorough on-site inspection and comprehensive health assessment pertaining to both inverted power and free conveyors and overhead power & free conveyors. The intent of a conveyor health assessment process is to identify any parts needing replacement; repair and/or adjustment so that planned improvements can be made to improve reliability, increase uptime, and extend system life. Information gained from this assessment also serves as continuous improvement data relative to system design and maintenance. Typical Contents of a Health Inspection Report OVERVIEW PROJECT SCOPE INTENT GENERAL CONDITIONS DATA COLLECTION AND REPORT FORMATS MECHANICAL INSPECTION CHECKLIST ELECTRICAL INSPECTION CHECKLIST EXECUTIVE SUMMARY BUDGETARY PRICING CHAIN WEAR - Chain wear occurs on the chain pin and center link bearing surfaces, and to a lesser degree, on the inside of the side links. Chain wear is determined by averaging at least three (3) measurements of 20 pitches. (10-0 nominal strand) or by using current (less than 3 months) chain wear monitoring study. New chain measures 10-0 +/- 1/32. The maximum recommended chain wear is 4.2 % (125). Once a 20 pitch conveyor chain length reaches 125, it should be replaced. Caterpillar drive chains should also be replaced, at the same time, since worn cat chain will not engage properly with new conveyor chain. LUBRI CATION - The wear pattern on the chain pin or center link bearing surfaces can be used to determine the effectiveness of lubrication. Highly polished surfaces,

without sign of grooving (galling), demonstrates adequate lubrication. Rough surfaces with distinctive galling, indicates poor lubrication. A combination of galled and polished surfaces indicates insufficient lubrication, usually caused by dirty chain or poorly functioning lubricating equipment. TROLLEY WHEELS - DMW recommends random inspection of 10% of conveyor trolley wheels to determine lubrication conditions. Chain assemblies that use a closed trolley wheel (capped and sealed bearings) should be inspected by removing the inner cap on the wheel. The trolleys should also be checked for sluggish or frozen wheels, bent trolley brackets and any unusual noises. STRAIGHT TRACK, CURVES, TURNS AND TRACK CONNECTI ONS - Random wear checks of the rolling surfaces (both sides of flange and web) on the straight track, vertical and horizontal curves are required as part of the Health Assessment. Straight track usually shows minimal wear. Vertical and horizontal curves generally exhibit higher degrees of wear. On vertical curves, the lower flange wears on t he upper curve, and the upper flange wears on the lower curve. Both upper and lower curves should be replaced simultaneously. The assessment should root cause the wear, e.g. curve not hung straight, inadequate supporting/bracing, twisting of the I-beam or chain, over chain tension. ANTI BACK-UPS AND ANTI RUNAWAY DEVI CES - Check for worn components, worn pivots, broken welds and limit switch functionality. DRIVE SPRING PRE-LOAD AND TORQUE OVERLOAD SETTI NGS - DMW recommends taking drive spring compression and torque overload trip point measurements and calculate the drive spring pre-load and torque overload settings (pounds of chain pull.) These calculations are included in our report. Should the conveyor drive begin to float/bounce substantially, causing nuisance torque overload faults, additional drive spring preload can be added. This will not affect the torque overload limit switch setting or cut-out point. However, changing compression spring rates will affect the settings/cut-out point and the drive will have to be re-calibrated. ALIGNMENT OF THE DRIVE COMPONENTS - A poorly meshing cat chain can indicate improper alignment of the backup bar/roller nest, drive and take-up sprockets, and/or power track relative to the conveyor chain. A poorly positioned backup bar can cause wear and/ or damage to the cat chain, backup bar, roller nest, drive or take-up sprockets, power track or conveyor chain. Side link wear can cause a cat chain to fail prematurely. DRIVE COMPONENTS- DMW makes visual inspections of the caterpillar chain dogs, backup bar, sprockets, backup rollers, sheaves and belts, as well as the speed reducer. This inspection includes noting the condition of the drive and name plate data.

The caterpillar chain dog will wear on the leading edge where they come in contact with the conveyor chain. The backup bar will wear along the length of the bar where it comes in contact with the caterpillar chain. Abnormal wear will be indicated by patterns on the top or bottom of the bar or shallow depressions along its length. The sprocket teeth will wear at each point of contact with the caterpillar chain. Sprockets should be replaced along with any cat chain replacement. Backup rollers will wear along the outside surface where they come in contact with the conveyor chain (shallow grooves or depressions in the pattern of the chain) and internally on the roller bearing races (wobbling/frozen rollers). Drive belts riding at the bottom of the sheave are indications of worn drive belts/sheaves. Always replace belts in matched sets. Play or backlash indicates a worn worm gear in the reducer. TORQUE OVERLOAD DMW will inspect the torque overload limit switch position/operation. Each drive is equipped with a torque overload limit switch based on design chain pulls (force required to overcome all frictional resistance). During the start-up and commissioning of a new system, the torque overload is set to a relative value (e. g. 500 l bs t o 1000 lbs) higher than the maximum loaded conveyor chain pull or based on the reducers maximum allowable capacity. The torque overload setting should NOT be altered once a drive has been calibrated. Routine checks of the torque overload limit switch operation will prevent potential reducer damage and/or serious drive failures. TAKE-UPCOMPONENTS DMW inspects the fixed frame, the floating frame with load/guide wheels and restraining chains, the traction wheel assembly, I-beam boots or expansion joints, connection chains, air cylinder(s) and air pressure settings. The floating frame will typically move or float when properly set to the recommended air pressures. Chain pressure set higher than recommended will cause excessive chain and component wear, reducing their life expectancies. It is our intent to compare the existing air pressure settings for each take-up against the current design pressure and document the differences. The remaining stroke available on the cylinder will determine our recommendation to adjust the take-up by shortening the connection chains. The traction wheel rim and hub are the major wear point s on a take-up assembly. To a lesser extent, the I-beam expansion joints, load/guide wheels will exhibit some wear but typically will not require any maintenance/replacement other than lubrication. Some conveyor manufacturers take-up frames may have become twisted or damaged in service and may require correction for proper take-up operation.

Rod seals can wear allowing pressure drops in the air cylinder. The restraining chains limit the travel of the floating frame in the event of air loss to the cylinder, preventing excessive slack in the chain. Excessive chain slack could result in a jam or a runaway condition from telescoping onto itself and possible chain disassembly. Due to normal chain growth, the restraining chains may need periodic adjustment when the floating frame displays more than 2 to 3 of travel or the floating frame has reached the end of travel. MAXIMUM TRAVEL LIMIT SWI TCH - Inspect the maximum travel limit switch position. As chain growth becomes larger, the floating frame of the take-up moves back towards the cylinder. The maximum travel limit switch will detect this maximum travel condition and stop the conveyor. Some system controls use a warning limit switch. The assessment is to include functional testing of all limit switches. TRACTION WHEEL TURN ASSEMBLI ES- Inspect all Traction Wheel Turn Assemblies. The traction wheel is a circular flat faced wheel mounted to a hub bearing used to guide the power chain and trolleys through horizontally curved sections. The principal wear points on a traction wheel are: the I-beam; t he traction wheel; and the traction wheel hub bearing. The rolling surfaces of the traction wheel Ibeam will exhibit similar wear as the straight track. The hub bearings will show signs of vertical movement (wobble) during production. To properly test the hub bearing, the conveyor must be not running, locked out, the take-up air pressure released and the traction wheel rocked back and forth to see if there is evidence of wear in the bearing or shaft. Proper alignment of conveyor chain to the traction wheel should be checked. The trolley bracket will interfere with the rim, if the chain is too low. Several factors can contribute to misalignment of the chain to the traction wheel: traction wheel is not level; hub bearing/shaft is worn; improper chain centerline to traction wheel rim centerline alignment. The amount of chain wrap governs the load limitation of traction wheel assemblies with the mounting hub being the weak link. DMWs inspection with a valid chain pull can include an analysis of each traction wheels capacity as installed. HORIZONTAL ROLLER TURN ASSEMBLI ES DMW will inspect all Horizontal Roller Turn Assemblies and can include a combination of visual and random sampling of turn rollers. A series of these rollers mounted vertically within a frame and are used to guide the power chain and trolleys around horizontally curved sections of conveyor track.

The principal wear points on a roller turn are: the I-beam; and the rollers. The rolling surfaces of the roller turn I-beam will exhibit similar wear as the straight track. The rollers will wear on rolling surface (wear pattern from the chain upper/lower side links and the center link) and the internal bearing raceway. A bad roller is any roller that is frozen, wobbles, damaged, noisy or sluggish. 2 GENERAL CONDI TI ONS A DMW Health Assessment project consists of an on-site visual inspection of the specified equipment or conveyor systems by trained and qualified individuals. The scope of this inspection includes the major mechanical and electrical items as defined by our customer. Items inspected will be documented and if permitted may be photographed to clarification its condition. This original documentation is presented as part of our report deliverable. The customer will need to provide existing assembly drawings of equipment or layouts of conveyor systems. These drawings will be interpolated by the Health Assessment Team to create inspection maps to insure collected data is an accurate representation of the included conveyor system or equipment. Our Health Assessment observations and measurements will not interfere with production operations. In addition to observing the system during its operation, it will be necessary to plan access to the conveyor during operation and at times when the conveyors can be shut down and locked out. The assessment can be performed while under normal operating conditions. Most major/ heavy wear or damage can be determined by visual inspection; however, some disassembling of components may be required to determine marginally or slightly worn components. These inspections must take place during nonproduction periods and with the system locked out. Lock-out Tag out procedures and contact information should be discussed with our customer beforehand. DMW has special tools allowing for the measurement of the free track and the power track but these measurements must be done while the conveyor is not operating and the system is locked out. Our Health Assessment Team will provide our customer advanced notification of scheduled work including a detailed scope of work, and the number and types of trades to be used as well as schedule and coordinate entry to inaccessible areas within the plant; request lock-out, tank transfers, confined space permits, etc. Our plan will allow sufficient timing to allow for tank drainage, scaffolding, shroud removal, weld inspection, etc. Our Health Assessment Team will not access into the screen guard without written authorization from our customer.

Control panels may require visual inspection during production hours and our customer will need to provide a plant electrician during production times. Function verification, within control panels will be done during nonproduction times. During our inspection, any items or areas observed by the Health Assessment Team to be in need of immediate attention shall be reported immediately to our customer. Please note that our Health Assessment does not otherwise address issues regarding ergonomics, health and safety, and/or plant maintenance performance. DELIVERABLES - All data and information collected during the Health Assessment will be compiled into a detailed and comprehensive report that includes, but may not be limited to the following: Assessment Overview Layout(s) of assessment areas (11x17 hard copy) Number of conveyor systems List/ show areas not assessed, and reason why _ Timeframe assessment conducted _ Names of personnel on assessment t ea m Executive summary (*critical items) _ Matrix of all RED issues, by conveyor, including recommended actions _ Separate matrix of all YELLOW issues, by conveyor, including recommended actions *Critical items include any structural issues or imminent failure issues. Budgetary pricing for material and labor to correct issues Detailed mechanical inspection results _ Include photographs for clarification Detailed electrical inspection results _ Include photographs for clarification Conveyor Chain Growth Chart Conveyor Track Gap and Track Wear Chart Conveyor Power Track Wear Chart Power & Free Carrier Log Chart DATA COLLECTION AND REPORT FORMATS - The Health Assessment Team will use a suitable formats provided by DMW or may be desired by our customer for

collection and reporting purposes. Actual checklists and charts as well as samples as used by DMW Health Assessment Teams are available from DMW. All mechanical/electrical checklist items shall be inspected, and all issues documented. Photographs will be taken if needed t o help clarify an issue respecting our customers limitation on the use of cameras or recording equipment.

MECHANICAL INSPECTION CHECKLI S T Structural Steel: Condition of hanger connection to support steel Condition of clamp at header Hanger spacing Adequate sway bracing Conveyor Drive: Motor/reducer noise Floating frame bouncing, cat chain rough engagement Cat chain misalignment Cat dog wear, roller wear, poor lubrication High reducer temp, low oil level, oil leakage V-belt/ sheave wear, loose belt s, missing guards Brake functionality Back-up bar wear, roller nest wear Missing manifold lubrication block, missing automatic cat chain oiler Missing drip pan, spare v-belts, shear pins or overload limiter (if equipped) Missing service rail or hoist Missing conveyor identification Debris/ oil on drive platform Conveyor Take Up: Air pressure setting Oil level (air/oil type) Design pressure labeled on take-up Air leaks, air by-passing regulator Traction wheel wear / broken welds Expansion joint wear / not lubricated Remaining cylinder travel _greater than expansion joint travel _greater than worn-chain shutoff limit ramp length Slack in restraint chain greater than take-up-collapsed shut off limit Missing drip pan Clevis loose on rod Debris/oil on take-up platform Outer & Inner Frame condition, freedom of movement Conveyor Chain: Measure chain length and calculate percent of life used Refer to Chain Growth Chart Wheels not rotating / flat spots on wheels Bent links / bent trolleys Debris at pin/link joint interfering with chain pin lubrication

Chain Lubricator: Oiler not operational No oil in reservoir Nozzles not set correctly No lubrication evidence Chain Trolley Lubricator: Greaser not operational No grease in reservoir Nozzles not set correctly No lubrication evidence Free Trolley Lubricator: Greaser not operational No grease in reservoir Nozzles not set correctly No lubrication evidence Chain to Chain Transfers: Chain dog cam wear Incorrect pusher operation (if equipped) Poor track condition Vertical Curves: Measure flange and calculate percent of wear Refer to Track Gap & Track Wear Charts Record free track gap if more than guide wheel dia. Refer t o Track Gap & Track Wear Charts Wear at quick rise Broken welds Worn wear bar on toe of channel Anti-Runaway Conveyors: Improper carrier engagement Poor lubrication of chain or dogs Dog wear Slack chain Brake not operational Anti-Runaway Devices: Improper carrier engagement Leak in hydraulic cylinder Recovery winch not operational Power & Free Horizontal Turns: Measure flange at middle & ends of turn, calculate percent of wear Record free track gap if more than guide wheel dia. Broken welds

Roller Turns: Bad/ missing rollers Missing grease fittings Segment bar wear Traction Wheel Turns: Rim wear Ri m t o wheel welds Chain alignment with rim Loose mounting bolts Poor bearing condition Missing catch frame (overhead) Missing drip pan Power & Free Straight Track: Measure flange every 40 feet, calculate % wear Refer t o Track Gap & Track Wear Chart s Record free track gap if more than guide wheel dia. Refer t o Track Gap & Track Wear Charts Misaligned track splices Poor welds Switches: Record free track gap at switch if more than guide wheel diameter. Worn pivot, missing tongue tip supports Clevis loose on rod Stops: Flow controls improperly adjusted Air by-passing regulator Missing anti-backup Bent/worn blade Track Expansion Joints Expansion joint worn Expansion joint i n need of lubrication Expansion joint no longer moves freel y Carrier Positioners: Flow controls improperly adjusted Air bypassing regulator Damaged/ bent positioner blade Carrier components t hat affect conveyor Log randomly inspected carriers and issues Refer to Power &Free Carrier Log

Note oscillating carriers and their position in the system Bad tow bar shock absorbers Sticky retract able dog actuators Bad trolley wheel s Bad side guide rollers Safety cable is bad Bent or broken decline tripper bars CPU, Drive, and Sequence Panels: Measure/record conveyor motor amps for typical and maximum load conditions. Check condition of control ground lights and measure voltage. Verify safety lockout signage matches components on conveyor relative to location and device type. Check panel doors for missing tags, missing pilot light lenses covers, etc. Push to test all pilot lights and note where replacements are required. Note any fault lights that remain on or are blinking. Verify all devices on doors match electrical drawing door layouts. Verify presence and accuracy of conveyor map on door panel. Verify proper display of Panel Views (if installed). Verify overall condition of panel such as dented doors, and that guard posts are secure. Verify that up to date drawings are in the panel door (note date and rev level). Verify rigidity of external cables and conduits. Verify thermal overload heaters, current relay settings, and fuse sizes match panel electrical drawings. Check that all installed sub-plate components (relays, I/O cards, starters, etc.) match electrical drawings. Verify protective 480 V covers are in place with proper tagging. Verify and note any unlabeled jumpers. Verify proper operation of air conditioner if present. Note spare I/O and rack capacity of the panel. Verify all devices on sub plate match electrical drawing sub plate layouts. Visually inspect panel interior for: Wires disconnected from terminals or relays Wiring external to wire ducts Wire way covers, shields, drive covers not in pl ace Perform I/ R analysis Field Devices: Check for proper mounting of devices. Check that all cords are in good condition, connected and are properly secured. Note any missing device tags for any devices. Note any missing globes, lights or related tags. Verify that safety decline controls are operating properly (speed feedback signal) and note trip settings. Open junction boxes, check condition, and note any unlabeled jumpers.

Check condition and rigidity of switch actuators. Check for contamination on devices (prox. switches, limit switches, etc.). Check for secure mounting of photo eyes and reflectors. Check for rigidity of cable tray, conduit, and support brackets. Check that safety mats are secured. Check that light screens are mounted securely. Walk the conveyor to verify accuracy of the drawings. Drives and Take-ups: Check adjustment of switches such as take-up, torque overload, drive engaged, etc. Note any missing device tags. Verify condition and operation of oiler and lubricator system. Examine condition of disconnect switches for drive and brake. Check for operation of lighting such as drive platforms, and pits. Check for condition of gate plugs. Check for condition of globe lamps, covers, and related field device tags under platforms. Operator Stations and Run/Stops: Check for proper mounting of devices Check that all cords are in good condition, connected and are properly secured. Push to test all pilot lights and note where replacements are required. Not e any non-auto mode selections such as manual, bypass, gap, etc. Verify proper tagging is in place. Note where new tags are required and the necessary nomenclature. Verify and note any unlabeled jumpers. PLC Logi c Note PLC type and revision level. Note memory used and spare. Note any forces. Note any test edits. Panel Views, Intellution, and RS Views (Master Control Consoles): Verify overall maps match current system. FIS Monitoring Obtain customer run OAPA report for the previous month. CHAIN GROWTH CHART - Chain growth is determined by averaging three measurements chain, and converting the measurements to a nominal 10-0 strand. New chain measures 121 (industry standard), with a recommended maximum length of 125 or approximately 3.3 percent growth. TRACK GAP AND TRACK WEAR CHART - Track Gap is determined by using calipers or Owner approved gage, and measuring the Free Channel Track Gap at the

yokes every 40 ft. min. around the entire system. These gaps will be identified on an 11x 17 layout and recorded in a chart. POWER TRACK WEAR CHART - Track Wear is determined by using calipers or a specially designed gage, and measuring the Power Track wear on the top and bottom flanges and web every 40 ft. min. around the entire system. These measurements will be identified on an 11x 17 layout and recorded in a chart. POWER & FREE CARRIER LOG - All Power & Free carriers will be listed by their carrier number along with issue status coding including: Assembly Plant / Shop; Date, Conveyor #: Red, Yellow & Green monitoring codes draw quick attention to status of parts. Status Coding: exceeds limits, replace not applicable not an issue Carrier No. Bad Tow Bar Shock Absorber Stuck Retractable Dog Actuator Bad Trolley Wheels Bad Safety Cables Comments EXECUTIVE SUMMARY REPORT DMW will create and Executive Summary Report to drawing attention to issues in order of importance. We will identify Red issues requiring the customers immediate attention and describing recommended action and follow up. We will also indicate Yellow issues which are issues that should be addressed, planned for and monitored as well as Green issues which may require only additional monitoring. BUDGETARY PRICING DMW can provide budgetary pricing options upon completion of our Health Assessment to inform our customer of the cost to restore, repair, or replace worn, damaged or missing parts.