Belt Conveyor LG 2005-06-06 DGL

Field Operator Certification
Belt Conveyors
Learner Guide
Belt Conveyors – Learner Guide
Introduction
This lesson on Belt Conveyors, as with your other lessons on Auxiliary Equipment, consists of two
main learning components: a self-directed/instructor-led and self-paced component and an on-the-
job component. You are expected to complete both components as part of your Certification
Program.
Review the remaining information contained in the Introduction section of this document prior to
beginning the Content section. If you have any questions about this information, speak with your
Kiln Coach.
Objectives
Your learning objectives are broken down into two categories  learning objectives for the self-
directed/in-class portion of your learning; and, learning objectives for the on-the-job portion of your
learning. They are listed below for your information.
Self-Directed/In-Class Learning Objectives

 State the purpose of a Belt Conveyor
 Name and describe the main components of a Belt Conveyor
 Explain the principle of operation of a Belt Conveyor
 Describe the types of Belt Conveyor configurations
 State applications for Belt Conveyors
 Describe the running and static inspections for Belt Conveyors
 Identify common problems with Belt Conveyors and their possible solutions
 State safety concerns related to Belt Conveyors
On-the-job Learning Objectives

 Perform an inspection on an operational Belt Conveyor
 Perform an inspection on a static Belt Conveyor
Field Operator Certification 12/31/2023 1

Lesson Outline
The first portion of the lesson, the self-directed/in-class portion, involves reviewing the following
information:
 The purpose and basic principle of operation of a Belt Conveyor
 A listing and description of the various components of a Belt Conveyor
 Various applications of a Belt Conveyor
 Inspection points of a Belt Conveyor and basic troubleshooting
 Safety concerns related to Belt Conveyors
Pictures and graphics are included where appropriate to help you understand how a Belt Conveyor
functions. At the end of this section, there are a series of questions that you will be required to
answer and review with your Instructor.
The second portion of the lesson, the on-the-job portion, primarily involves the completion of
several inspections on Belt Conveyors, including both an operational and static Belt Conveyor
inspection and lockout procedures. When you are ready to perform these inspections, inform your
Instructor.
If you are a new Field Operator, you will complete a series of steps in your OJT portion of this
lesson. These steps are listed below for your information.
 Step One
 Your Instructor will ‘walk through’ an inspection procedure with you. At that time
you can ask questions and take down any notes required.
 This walkthrough may be completed out in the field or during a meeting with your
Instructor.
 Step Two
 Your Instructor will demonstrate an inspection procedure in the field.
 Step Three
 You will conduct an inspection procedure in the field under the supervision of your
Instructor.
 Your Instructor will provide you with feedback about your performance during the
inspection.
2 12/31/2023 Field Operator Certification

 Step Four
 You will complete a full inspection procedure without any assistance from your
Instructor.
 This inspection will be assessed against the inspection checklist contained in this
document. If you achieve 100% on the inspection, you will be certified on it. If you do
not achieve 100% your Instructor will provide you with further feedback and you will
have the opportunity to be re-assessed.
If you are an experienced Field Operator, you may already be quite familiar with inspection
procedures. Discuss this with your Instructor and you may only be required to actually complete
Step Four as discussed above.
Reference Material
 NA
Pre-requisites
 NA

Belt Conveyors – Learning Content

Purpose of a Belt Conveyor
 The primary purpose of a Belt Conveyor is to transport material from one location to another
B ELT C ONVEYOR

Components
B ELT C ONVEYOR
 Conveyor Belting
 Splices
 Pulleys
 Lagging Idlers / Beds
 Take Ups
 Chutes/Hoppers
 Skirtboards and seals
 Conveyor Covers
 Automatic Belt Protection

Conveyor Belt
 There are three major components to a Conveyor Belt:
 Top Cover
 Carcass
 Bottom Cover
C ONVEYOR B ELT
Top and Bottom Covers

 Made of natural gum rubber or synthetic elastomer
 Purpose is to protect the “carcass” from abrasion and impact
 Top cover is typically thicker than bottom cover
Carcass
 Comprised of one or more plies of woven fabric or steel cables
 The belt carcass is the tension element in a conveyor belt
 Provides tear and impact resistance, load support and mechanical fastening ability

Selection Criteria for Covers and Carcass

 Required tension – based on design forces
 Troughability – ability to conform to troughing angles
 Load Support – load control at a given troughing angle
 Application – abrasiveness, impact resistance, material temperature
Conveyor Splices
 Belting is made endless by using either mechanical fasteners or vulcanized splices
 Usually belting is made at the job site
C ONVEYOR S PLICES


Vulcanized Splices
 Vulcanized Splices are created by two different methods
a. Hot Method - Incorporates a high temperature mechanical press to activate chemical
bonding agent for superior adhesion between belting layers
b. Cold Method – This method uses “cold” contact adhesion under mechanical pressure to
create bond between belting layers
V ULCANIZED S PLICES `1
 Advantages:
 Highest practical strength
 Long service life
 Is smooth and continuous (material
cannot seep through it)
 Does not damage or interfere with belt
wipers
 Disadvantages
 Greater initial expense (heavier, difficult to move, requires supports)
 Requires a long take-up
 Renewing is time consuming and costly
Mechanical-Fastener Splice
M ECHANICAL S PLICE
 Advantages
 Quick to make and install
 Low initial expense (usually only hand-
tools are required)
 Minimal take-up travel required
 Disadvantages
 Low practical strength in comparison to
vulcanized splice
 Can damage or interfere with Belt wipers
 High wear on support components

Stretch or Elongation
 There are three types of stretch or elongation that can occur with a Belt Conveyor
 Elastic Stretch
 Happens during starting acceleration or braking deceleration
 Is almost entirely recovered when the applied pull or stress is removed
 Constructional Stretch
 Happens because of type of fabric weave more than because of the type of
textile material used
 In conventionally woven fabric, warp strands which are crimped tend to
straighten out as the load is applied. This results in Belt growth, a portion of which
can never be recovered
 Permanent Length Change
 Includes changes in length due to elongation in the basic fibre structure and
the portion of elastic stretch and constructional stretch which is non-recoverable
Pulleys
S MOOTH O R B ARE P ULLEY
 Are several types of pulleys:
 Standard Steel Pulley
 Most common type
 Manufactured in wide range of
sizes
 Consists of continuous rim and
two end discs fitted with compression
type hubs

 Wing-Type Pulley
W ING P ULLEY
 A cast or fabricated pulley
with a discontinuous surface between
the cross bars which are inclined
valley-shaped recesses that prevent
fine or granular material from being
caught between the tail pulley and the
return belt
 Negative Crown Pulley

 A pulley with raised areas set
equally in from each end. - Aids in belt tracking, commonly used on tail pulleys
N EGATIVE C ROWN

 Curved or Crown Pulley

 A pulley that tapers equally from both ends toward center, the diameter being
greatest at the center.
C ROWNED P ULLEY
 Snub Pulley
 Increases degree of belt wrap at drive pulleys in order to increase friction
 Bend Pulley
 Used to change belt direction as required (e.g., gravity take ups)
B END AND S NUB P ULLEYS

Pulley Lagging
 Pulleys can be covered with rubber or fabric
material
 Lagging is used on driving pulleys to increase the
coefficient of friction between the belt and the
pulley
 Lagging also helps to reduce abrasive wear on the
pulley face and to create a self-cleaning action on
the surface of the pulley
 Pulleys should always be lagged
Lagging Types
 Three types of lagging:
 Vulcanized
 Cold Bonded
 Mechanical
P ULLEY L AGGING

Idlers
 Located at the top and bottom sides of the framework
 Supports the Belt and keeps it centered on the framework
 Idlers require proper support and protection for the Belt and proper support for the load being
conveyed
 Frictional resistance of the idler roller can influence belt tension and consequently, the
horsepower requirement
 Two basic types of idlers:
 Carrying Idlers
 Return Idlers
Carrying Idlers
 Supports the loaded run of the Conveyor Belt
 Have two general configurations:
 One is used for troughed Belts and usually consists of three rolls
 Second is used for support flat Belts
Troughing Idler
I NLINE & O FFSET IDLERS
 Carry far greater tonnages than flat Belts, for
the same width of Belt and Belt speed
 Have two general styles:
 In-line
 Offset
 Most common is composed of three in-line
rolls of equal length

T ROUGHING AND R ETURN I DLER
Impact Troughing Idler

I MPACT T ROUGHING I DLER
 Also known as “cushion idlers”
 Have rolls made of resilient material
 Used at loading points where impact resulting
from lump size and weight of the material
could seriously damage the Belt if it were
rigidly supported
Impact Bed
I MPACT B ED
 Supports the entire loading zone of the
conveyor
 Eliminates belt deflection between rolls
enhancing seal capabilities

Belt Training Idlers, Carrying
 Helps to maintain Belt alignment

 Typically has the carrying roll frame mounted on a central pivot approximately perpendicular
to the Belt Conveyor
B ELT T RAINING I DLER
 Carrying rolls can become skewed with
respect to the centerline of the Conveyor
 As the Belt traverses the skewed rolls, they
urge the displaced Belt to return to the
Conveyor centerline and this helps the rolls
return to the proper alignment
 Fixed guide rolls placed perpendicular to the
edge of the Belt Conveyor are not
recommended because continuous contact
with the edge can accelerate Belt edge wear
and reduce Belt life
 In general, the greater the Belt tension, the less effective the training idlers
Suspended Idlers
 Also known as catenary, garland idlers
S USPENDED I DLER
 The rolls (typically 3 or 5) are linked and
suspended from the Conveyor frame stringers
 Is tolerant of both poor alignment and abuse
by lumps because of the flexible connection
between rolls

Return Idlers
 Supports the empty return run of the Conveyor Belt
 Are usually horizontal rolls
Flat Return Idlers

 Consists of a long single roll, fitted at each end with a mounting bracket
R ETURN I DLER
Self-Cleaning Return Idler

 Materials can stick to the carrying surface of a Belt Conveyor and can increase the wear on
the top cover.
 As such, there are self-cleaning return idlers to remove material
 These idlers can be rubber-disc or rubber-coated helically shaped which present a very
narrow surface for adhesion and thus reduce the tendency for material build-up
 This type of idler is sometimes incorrectly called a “Belt cleaning idler”. Even though these
idlers do “track off” material adhering to the Belt surface on the return idler, they are not Belt
cleaning devices.

S ELF C LEANING R ETURN I DLER
Belt Take-up
 Some form of take-up is required on all Belt Conveyors for the following reasons:
 Ensures proper amount of slack-side tension at the drive pulley to prevent Belt
slippage
 Ensures proper Belt tension at loading and other points along the Belt Conveyor
(prevents loss of troughing contour of the Belt between idlers and avoids spillage of
material from the Belt)
 Compensates for changes in Belt length
 Allows Belt storage for making replacement splices (without storage, small sections
of new belt would have to be added, requiring two splices for each splice repair)
Take-up Movement
 Take-up should:
 Provide sufficient movement to accommodate acceleration or deceleration surges
without having the take-up strike against its stops
 Allow for some “live” storage of belting so that, in the case of an accident, it may not
be necessary to splice in a short length of Belt
 Allow for changes in Belt length due to stretch or shrinkage

Manual Take-up
 Is compact and low cost, but because the take-up is at best periodic, the Belt tensions are
almost always too high or too low
M ANUAL T AKE U P
 A manual take-up is not recommended unless
an automatic take-up is not feasible because
of space limitations or if take-up
considerations are not as critical
 Types of manual take-up include:
 Screw
 Ratchet
 Jack-operated
Automatic Take-up
G RAVITY T AKE U P
 More desirable
 Can be installed horizontally, vertically or on an
incline
 Can be gravity or power-operated by hydraulic,
electric or pneumatic means
 Most common type is gravity
H YDRAULIC T AKE U P

Chutes/Hoppers
Design Goals
 Feeding receiving conveyor in its direction of travel

 Center the material on receiving conveyor
 Minimize impact on receiving belt
 Supply material at speed of receiving conveyor
O FF C ENTER L OADING
Skirtboards
 To shape and settle the load after transfer

 The skirting retains material on Belt after it leaves loading Chute and until it reaches Belt
speed
 Skirting is attached to the framework at the loading points and should be fabricated as low as
practical to the surface of the belt
 Skirting should be self-relieving i.e., Base of skirting tapers upwards in the direction of belt
travel to ensure material does not wedge between the belt and the skirting
 Greater distances are required to stabilize the material when loading on an incline

S KIRTBOARD AND S EAL
S KIRTBOARDS

Skirtboard Rubber-Edging
S KIRTBOARD R UBBER E DGING
 Lower edges of the skirtboard are positioned
some distance above the Belt and the gap
between the skirtboard bottom edge and the
Belt surface is sealed with a rectangular
rubber strip which is bolted or clamped to the
exterior of the skirtboard
 The rubber strip should rest lightly on the Belt surface, both initially and after wear has taken
place
 Edging should contain no fabric
 Strips of old rubber belting should never be used for edging skirtboards
 Prevents leakage of fines through the clearance between the lower edge of the skirtboards
and the moving Belt
Covers
 Belt Conveyors need to be protected to some degree from the weather (depending on the
climate, type of material being handled and the type of operation)
 Material being handled can be affected by rain or from freezing (if the material contains
moisture)
 Rain on the pulley side of the Belt or on the drive pulleys may cause slippage between the
belt and the pulley
 Ice and snow on the surfaces can completely stop a Belt Conveyor
 The life of the rubber covers can be shortened by the effect of intense sunlight
 As such there are a number of weather protection devices available

Half Covers
H ALF C OVER
 Semicircular in shape
 Made of flat or corrugated sheets (galvanized
iron or aluminium)
 Fastened to stringers and situated over the
Belt
Three-quarter Covers
 Less than a complete semi-circle
T HREE Q UARTER C OVER
 On a walkway or access side of a Belt
Conveyor, the lower edge of the cover may
terminate slightly above the high edge of the
troughed Belt

Wind Breaks
W IND B REAK
 A simple installation of a suitable reinforced
metal sheet on the windward side of the
conveyor stringers
 The sheet should extend above and below the
stringers to protect both the carrying and
return runs of the Belt
Wind Hoops
W IND H OOP
 Used to prevent the empty or lightly loaded
Belt from being blown off the idlers
 Hoops should be spaced at regular intervals
along the Belt Conveyor

Automatic Belt Protection
Types of Belt Protection

 Electrical
 Control System Interlocks
 Side Travel / Drift Switches
 Zero Speed / Motion Sensor
 Overloads
 Plug Detectors
 Mechanical
 Training Idlers
 Guide Rolls
 Belt Cleaners
 Turnover Schemes
 Backstops / Holdbacks
 Torque limiters
Automatic Belt Protection – Electrical

 Interlock
 Conveyor control strategy that shuts down all upstream conveyors in the event of a
fault
 Prevents loading onto static conveyor
I NTERLOCK

 Side Travel / Drift Switch

S IDE T RAVEL / D RIFT S WITCH
 Used to detect if a belt conveyor has
moved too far away from its centerline in
either direction
 A fault is then displayed, or the
equipment is shutdown in order to prevent
damage to the belt and conveyor structure
 Zero Speed / Motion Switch
Z ERO S PEED / M OTION S WITCH

 Senses rotation of conveyor’s tail
pulley
 Calibrated against speed of head
pulley
 Shuts conveyor down at
predetermined differential
 Example
 Head pulley slipping
 Belt torn in two
 Overloads
 Used primarily to protect electrical components associated with the conveyor drive
from excessive current draw
O VERLOADS
 Example
 Jammed or overloaded
conveyor
 Overloads are located in the Motor
starter and interrupt current flow until
reset manually

 Plug Detectors
P LUG D ETECTORS
 Used on belt conveyors to signal a
plugged chute condition
 Conveyor shuts down to prevent
damage associated with overloading and
running in material
Automatic Belt Protection – Mechanical

 Training Idlers / Guide Rolls / Disks
 Maintains proper alignment of belt conveyor preventing damage to belt and conveyor
structure
T RAINING I DLERS / G UIDE R OLLS / D ISKS
 Belt Cleaners
 Help to prevent:
 Material build up on the Belt
 Misalignment
 Belt binding
 Examples of cleaning devices include:
 Single or Multiple-Blade – scrape material from the Belt surface
 Rotary Belt Cleaners – power driven shafts or tubes to which brush bristles or
blades are attached

 Water Spray and Wipers – a high pressure spray can be directed against the
surface of the Belt Conveyor by means of nozzles with control valves and a rubber-
bladed scraper is installed
B ELT C LEANERS
 Deck Plates and Return Belt Scrapers

 Spillage can occur at the loading point or elsewhere on the Belt Conveyor and the
spillage could become trapped between the Belt and tail pulley and Belt Cleaner Location
and can cause damage or misalignment
 Two devices help to prevent this from happening:
 Deck Plates
 Flat, bent or curved plates or metal sheets
 Placed between the carrying and return run of the Belt
 Protects the return run of the Belt from spilled material and from the weather
 Return Belt Scrapers
 Located on the upper side of the return Belt, just forward of the tail pulley
 Scrapes any material that may have spilled on the return run and prevents the
material from becoming trapped
 Should be a “V”-type with a 60 degree angle

R ETURN B ELT S CRAPERS
Belt Cleaner location

 Should be located so that the material which is removed can fall into the discharge chute or
can be collected for disposal
Belt Turnover Scheme

B ELT T URNOVER S CHEME
 To eliminate problems caused by dirty Belts in

contact with return idlers, the belt can be
twisted by 180 degrees after it passes the
discharge point
 This brings the clean surface of the Belt in
contact with the return idler rollers
 Ideal for long distance conveying of wet /
sticky materials

 Backstops and Holdbacks

O VER -R UNNING C LUTCH B ACKSTOP
 A loaded inclined Belt Conveyor of
sufficient slope tends to move backward
when forward motion is stopped or
interrupted. If this happens then material
would pile up at the tail end of the
Conveyor
 If the Belt Conveyor stops when
loaded, it is the Backstop that prevents the
Belt from moving backwards
 Backstops (aka hold backs) are used on the drive or snub pulleys of steep inclined
Belts and they allow the drive shaft to move in only one direction
 Three types of Backstop designs:
 Ratchet and pawl
 Differential band brake
 Over-running clutch
O VER -R UNNING C LUTCH

R ATCHET & P AWL B ACKSTOP
D IFFERENTIAL B AND B RAKE B ACKSTOP

 Torque Limiters
 Used to reduce the acceleration stress associated with conveyor start ups to within
acceptable limits
 Fluid Couplings – most common
 Wound-Rotor Motors with Step Starting
 Squirrel-Cage Induction Motor with Autotransformer
 Eddy-Current Couplings
 Variable-Speed Hydraulic Couplings
T ORQUE L IMITERS

Principle of Operation
 Material is loaded onto the belt conveyor from a hopper or bin
 The belt conveyor’s loading point is designed to contain and settle the load centrally on the
belt with minimal wear and spillage
 Conveyor framework has both carrying idlers on material side and return idlers on the bottom
or return side
 Head and Tail pulleys are mounted at their respective ends to reverse belt direction
 Head pulleys in most applications are also used to apply motive force
 Material assumes dynamic angle of repose as it settles past loading point
 Material is transported the length of the belt conveyor and finally discharged over the head
pulley
Belt Conveyor Design

 Three basic designs for Belt Conveyors
 Horizontal
 Incline
 Decline
 Can be designed for practically any desired path of travel including curved radius
 Horizontal & incline most common
 A successful Belt Conveyor design requires consideration of the materials to be transported
and consideration of the following:
 Angle of Repose
 Angle of Surcharge
 Flowability of Materials

B ELT C ONVEYOR D ESIGN
Belt Conveyor Design

 Angle of Repose
 Defined as the angle which the surface of a normal, freely formed pile makes to the
horizontal
 Angle of Surcharge or Dynamic Angle of Repose
 Defined as the angle to the horizontal which the surface of the material assumes while
the material is at rest on a moving Belt Conveyor
 Angle is usually 5-15 degrees less than the angle of repose, though in some materials
it may be as much as 20 degrees less
 Flowability
 As measured by its angle of repose and angle of surcharge, the flowability of
materials determines the cross section of the material load which can be safely carried on
a Belt
 Flowability is determined by a number of material characteristics:
 Size and shape of particles and lumps
 Roughness and smoothness of the surface of the material particles

 Proportion of fines and lumps present

 Moisture content of the material
 Standard Edge Distance
 CEMA minimum standard / Material load to edge of belt
 (.055* belt width +0.9 inches) Ex. 36 inch belt = 2.88 in. minimum edge
A NGLE OF R EPOSE AND S URCHARGE
Forces on a Belt Conveyor

 Forces that affect Belt tension include:
 Gravitational load to lift or lower the
material being transported
 Frictional resistance of the Conveyor
components, drive and all accessories
while operating at design capacity
 Frictional resistance of the material as
it is being conveyed
 Force require to accelerate the
material continuously as it is fed onto the
Belt Conveyor by a chute or feeder

Force to Drive Conveyor

F ORCES ON A C ONVEYOR B ELT
 Must be transmitted from the drive pulley to

the Belt by means of friction between their
two surfaces
 This same force is used to restrain
regenerative or decline conveyors
 There must be a difference in Belt tension as
it approaches and leaves the drive pulley
 The difference in tension is supplied by the
conveyor’s drive system which translates to
motive force
Transmitting Drive force

T RANSMITTING D RIVE F ORCE
 Belt has an angle of wrap around the drive
pulley of about 180 – 240 degrees
 Angle of wrap enhanced by properly
positioning snub pulley
 Best place for the drive of a Belt Conveyor is
at the location which results in the lowest
maximum belt tension
 Usually discharge end for horizontal or
inclined
 Usually loading end for declined

Belt Configurations
Standard Belt Conveyor

 Represents the majority of belt conveyors used in the Cement manufacturing
 Standard Configurations include:
 Horizontal
 Incline
 Decline
 By including Concave, Convex and curved, any configuration is possible
C ONVENTIONAL B ELT C ONVEYOR

Steep Angle Conveying

 Moulded Cleat Belts
 Moulded pattern on top cover of Belt increases Belt’s ability to carry materials up
greater inclines
 90 degree conveying possible
 Less parts required in high angles
 Conveyor can be twisted in vertical sections to re-orient discharge point as required
M OULDED C LEAT B ELT

 Pocket Belts
P OCKET B ELT
 Corrugated side walls added to Belt
edge
 Forms complete rectangular
partitions or ‘pockets’ to carry material
 Less parts required in high angles
 Conveyor can be twisted in vertical
sections

 Totally Enclosed Belts

 Also known as “pipe” Conveyors, these Belts completely cover the material and can
easily negotiate tight horizontal and vertical curves
 Allows for steeper inclines up to 30 degrees
P IPE B ELT

 Sandwich Belts
S ANDWICH B ELT
 Totally encloses material between 2
standard Conveyors
 Applies pressure to secure it
 Standard conveying components
S ANDWICH B ELT

Applications
 Typical applications for Belt Conveyors include:
 Quarry and Raw Material Handling
 Raw Grinding
 Clinker Evacuation
 Bulk Loading

Inspection Points
Belt Conveyor – Running Inspection

Check For OK
Inspect the drive motor for material build up on cooling fins and cooling fan inlet screen. Remove
build up
Inspect drive motor electrical connections for damage or strain
Inspect the condition of the final drive. V-belt condition, tensioning, sheaves, direct coupling
Listen for abnormal noise or vibration in all drive system components
Inspect the drive’s mounting base for damage, cracks, loose bolts
Inspect the condition and support integrity of all safety guards
Inspect the condition of all rollers (troughing, return, training, and snub) for build up, wear, and
damage. Identify any seized, worn or damaged rollers
Inspect the condition of the Conveyor Belt. Check for cuts, damaged splices, holes
Inspect the Belt Conveyor for proper tracking along the full length (both the loaded and return runs)
Inspect the condition and integrity of the Conveyor support structure
Inspect condition of head and tail pulley. Note condition of lagging, build up
Inspect the discharge chute for material build up, obstruction, wear, or damage
Inspect safety cord switch for damage, corrosion, and proper setting
Inspect the Belt Conveyor’s take-up system ( screw type , gravity, hydraulic)
Inspect the conditioning of the loading skirts and skirt seals
Verify proper material loading onto the Conveyor Belt (i.e. centered, not overloaded)
Inspect the Belt Conveyor’s inlet chute hopper or bin for proper material delivery, build-up,
obstruction, wear, or damage
Inspect the adjustment and condition of belt cleaning devices (belt or pulley scrapers, return plows)
Inspect field control station for damage or cable strain
Inspect Belt Conveyor protection devices for damage or signs of wear. Inspect electrical connections
on protection device for damage or strain. (i.e. Drift switches, plug detectors, motion switches)

Belt Conveyor – Static Inspection

Check For OK
Inspect the drive motor for material build up on cooling fins and cooling fan inlet screen. Remove
build up
Inspect drive motor electrical connections for damage or strain
Inspect the condition of the final drive. V-belt condition, tensioning, sheaves, direct coupling
Verify the lubrication level of drive reducer. Fill to required level if necessary
Inspect the drive’s mounting base for damage, cracks, loose bolts
Inspect the condition and support integrity of all safety guards
Inspect the condition of all rollers (troughing, return, training, and snub) for build up, wear, and
damage. Identify any seized, worn or damaged rollers
Inspect the condition of the Conveyor Belt. Check for cuts, damaged splices, tracking, holes
Inspect the condition and integrity of the Conveyor support structure.
Inspect condition of head and tail pulley. Note condition of lagging, build up
Inspect the discharge chute for material build up, obstruction, wear, or damage
Inspect safety cord switch for damage, corrosion, and proper setting
Inspect the Belt Conveyor’s take-up system (screw type, gravity, hydraulic)
Inspect the conditioning of the loading skirts and skirt seals
Inspect the equipment for general condition – cleanliness, damage
Inspect the Belt Conveyor’s inlet chute hopper or bin for proper material delivery, build up,
obstruction, wear, or damage
Inspect the adjustment and condition of belt cleaning devices (belt or pulley scrapers, return plows)
Inspect field control station for damage or cable strain
Inspect Belt Conveyor protection devices for damage or signs of wear. Inspect electrical connections
on protection device for damage or strain. (i.e. Drift switches, plug detectors, motion switches)

Belt Conveyors – Troubleshooting
Problem Probable Cause(s) Action

 Belt runs off at tail pulley  Counterweight too light  Recalculate weight required and adjust counterweight
accordingly (if using screw take-ups, increase tension)
 Idlers or pulleys out-of-square with center line of  Realign
conveyor  Install limit switches for greater safety
 Idler rolls not turning  Correct or replace stalled rollers
 Improve maintenance
 Improper loading, spillage  Feed should be in direction of belt travel and at belt speed,
centered on the belt. Control flow with feeders, chutes and
skirtboards
 Material build up  Remove accumulation. Install cleaning devices, scrapers and
inverted “V” decking
 Improve housekeeping
 Entire belt runs off at all  Side loading  Load in direction of belt travel, in center of conveyor
points of the line
skirtboards
 Idlers or pulleys out-of-square with center line of  Realign
 Belt strained on one side  Allow time for new belt to ‘break in’. If belt does not break in
properly or is not new, remove strained section and splice in a
new piece
 Idlers improperly placed  Relocate idlers or insert additional idlers spaced to support
belt


 One belt section runs off at  Belt improperly spliced or wrong fasteners  Use correct fasteners. Retighten after running for a short
all points of the line while. If improperly spliced, remove belt splice and make
new splice.
 Set up regular inspection schedule
 Edge worn or broken  Repair belt edge
 Remove badly worn or out-of-square section and splice in new
piece
 Belt bowed  Avoid telescoping belt rolls or storing them in damp locations
 A new belt should straighten out when ‘broken in’ or it must
be replaced
 Belt runs off at head pulley  Idlers or pulleys out-of-square with center line of  Realign
 Pulley lagging worn  Replace worn pulley lagging
 Use grooved lagging for wet conditions
belt
 Belt runs to one side  Idlers or pulleys out-of-square with center line of  Realign
throughout entire length at conveyor  Install limit switches for greater safety
specific idlers
belt
 Belt slips  Insufficient traction between belt and pulley  Increase wrap with snub pulleys
 Lag drive pulley

 In wet conditions, use grooved lagging
 Install correct cleaning devices on belt
 Install centrifugal switch for safety
 Counterweight too light  Recalculate weight required and adjust counterweight
 Belt slips on starting  Insufficient traction between belt and pulley  Increase wrap with snub pulleys
 Counterweight too light  Recalculate weight required and adjust counterweight
 Drive underbelted  Recalculate maximum belt tension and select correct belt
 If conveyor is over-extended, consider using two-flight-system
with transfer point
 If carcass is not rigid enough for load, install belt with proper
flexibility when service is lost
 Excessive belt stretch  Excessive tension  Recalculate and adjust tension
 Use vulcanized splice within recommended limits


with transfer point
 Counterweight too heavy  Recalculate weight required and adjust counterweight
accordingly
 If using screw take-ups, reduce take-up tension to point of
slip, then tighten slightly
 Differential speed wrong on dual pulleys  Make necessary adjustment
 Damage by abrasives, acid, chemicals, heat, mildew, oil  Use belt designed for specific condition
 For abrasive materials working into cuts and between piles,
make spot repairs with cold patch or with Permanent Repair
Patch
 Seal metal fasteners or replace with vulcanized step splice
 Enclose conveyor for protection against rain, snow and sun
 Belt breaks at or behind  Belt improperly spliced or wrong fasteners  Use correct fasteners. Retighten after running for a short
fasteners; fasteners tear while. If improperly spliced, remove belt splice and make
loose new splice.
 Pulleys too small  Use larger diameter pulleys
 Excessive tension  Recalculate and adjust tension
 Material between belt and pulley  Use skirtboards properly

 Remove accumulation
with transfer point
 Vulcanized splice  Excessive tension  Recalculate and adjust tension
separation  Use vulcanized splice within recommended limits
with transfer point
 Belt improperly spliced or wrong fasteners  Use correct fasteners. Retighten after running for a short
while. If improperly spliced, remove belt splice and make
new splice.
 Differential speed wrong on dual pulleys  Make necessary adjustment
 Excessive wear, including  Excessive impact of material on belt or fasteners  Use correctly designed chutes and baffles
rips, gouges, ruptures and  Make vulcanized splices
tears
 Install impact idlers
 Where possible load fines first
 Where material is trapped under skirts, adjust skirtboards to
minimum clearance

 Relative loading velocity too high or too low  Adjust chutes or correct belt speed
 Consider use of impact idlers
skirtboards
Patch
 Breaker strip missing or inadequate  When service is lost, install belt with proper breaker strip
 Excessive bottom cover  Material build up  Remove accumulation. Install cleaning devices, scrapers and
wear inverted “V” decking
 Insufficient traction between belt and pulley  Increase wrap with snub pulleys

 Excessive edge wear,  Side loading  Load in direction of belt travel, in center of conveyor
broken edges
 Belt strained on one side  Allow time for new belt to ‘break in’. If belt does not break in
properly or is not new, remove strained section and splice in a
new piece
skirtboards
Patch
 Belt bowed  Avoid telescoping belt rolls or storing them in damp locations
 A new belt should straighten out when ‘broken in’ or it must
be replaced
 Cover swells in spots or  Damage by abrasives, acid, chemicals, heat, mildew, oil  Use belt designed for specific condition
streaks  For abrasive materials working into cuts and between piles,
Patch
 Belt hardens or cracks  Damage by abrasives, acid, chemicals, heat, mildew, oil  Use belt designed for specific condition

Patch
 Improper storage or handling  Refer to belt manufacturer for storage and handling tips
 Covers become checked or  Damage by abrasives, acid, chemicals, heat, mildew, oil  Use belt designed for specific condition
brittle  For abrasive materials working into cuts and between piles,
Patch
 Improper storage or handling  Refer to belt manufacturer for storage and handling tips
 Longitudinal grooving or  Skirts improperly placed  Install skirtboards so that they do not rub against belt
cracking of top cover
 Idler rolls not turning 6  Correct or replace stalled rollers
 Excessive impact of material on belt or fasteners  Use correctly designed chutes and baffles
 Make vulcanized splices

minimum clearance
 Longitudinal grooving or  Idler rolls not turning  Correct or replace stalled rollers
cracking of bottom cover  Improve maintenance
 Fabric decay, carcass  Excessive impact of material on belt or fasteners  Use correctly designed chutes and baffles
cracks, ruptures, gouges  Make vulcanized splices
(soft spots in belt)
minimum clearance
with transfer point
 Radius of convex vertical curve too small  Increase radius by vertical alignment of idlers to prevent
excessive edge tension
 Ply separation  Excessive tension  Recalculate and adjust tension


 Edge worn or broken  Repair belt edge
 Remove badly worn or out-of-square section and splice in new
piece
Patch
 Belt speed too fast  Reduce belt speed

Safety - Work Page

Safety
 Never working on a moving Belt
 Follow all lock out procedures
 Never cross over Belts
 Don’t work under a moving Belt
 Never use a “Safety Cable” or “Over Travel” switch as a lockout
 Never shovel material onto a moving Belt
 Always double check that the Belt you are working on is actually locked out
Caution:
A fully loaded belt conveyor stops like a train!!
Example - 36 inch wide x 1000 foot long conveyor
Material Mass 132 kg/ meter x 305 meters = 40000 kg or 40 metric tonnes
Belt Mass 16 kg/ meter x 630 meters = 10000 kg or 10 metric tonnes
Total = 50 metric tonnes
 Never rely on the safety cord to stop a belt quickly
“You will surely be disappointed!”

Review Exercise
Complete each of these questions and review your answers with your Instructor
1. State the purpose of a Belt Conveyor
2. Describe 5 components of a Belt Conveyor
3. What are the two main types of splices used to join Belt Conveyors?

4. List four types of automatic protection devices used on Belt Conveyors to prevent damage
5. Define the term “Angle of Repose” of a material
6. Define the term “Surcharge Angle” of a material
7. What are the two main functions of lagging used on head pulleys?

8. What is the purpose of a backstop used on Belt Conveyors?
9. State 3 applications for Belt Conveyors in cement manufacturing
10. Describe 5 inspection points for a Belt Conveyor
11. Describe 3 conditions that could cause a Belt Conveyor to run off at the tail pulley

12. State 3 safety hazards associated with Belt Conveyors

Belt Conveyor LG 2005-06-06 DGL

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Field Operator Certification

Self-Directed/In-Class Learning Objectives

On-the-job Learning Objectives

Field Operator Certification 12/31/2023 1

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Field Operator Certification 12/31/2023 3

Belt Conveyors – Learning Content

4 12/31/2023 Field Operator Certification

Field Operator Certification 12/31/2023 5

Top and Bottom Covers

6 12/31/2023 Field Operator Certification

Selection Criteria for Covers and Carcass

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 Negative Crown Pulley

Field Operator Certification 12/31/2023 11

 Curved or Crown Pulley

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T ROUGHING AND R ETURN I DLER

Impact Troughing Idler

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Belt Training Idlers, Carrying

 Helps to maintain Belt alignment

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Flat Return Idlers

Self-Cleaning Return Idler

Field Operator Certification 12/31/2023 17

S ELF C LEANING R ETURN I DLER

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 Feeding receiving conveyor in its direction of travel

 To shape and settle the load after transfer

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S KIRTBOARD AND S EAL

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22 12/31/2023 Field Operator Certification

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Automatic Belt Protection

Types of Belt Protection

Automatic Belt Protection – Electrical

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 Side Travel / Drift Switch

 Zero Speed / Motion Switch

Z ERO S PEED / M OTION S WITCH

26 12/31/2023 Field Operator Certification

Automatic Belt Protection – Mechanical

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 Deck Plates and Return Belt Scrapers

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R ETURN B ELT S CRAPERS

Belt Cleaner location

Belt Turnover Scheme

 To eliminate problems caused by dirty Belts in

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 Backstops and Holdbacks

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R ATCHET & P AWL B ACKSTOP

D IFFERENTIAL B AND B RAKE B ACKSTOP

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