Comprehensive Conveyor System Assessment
Details of conveyor systems often fade over time, with specifications and component information frequently lost amid changes in plant ownership, management, and personnel responsibilities. As equipment evolves through replacements and improvements, crucial "nameplate information" about components may become outdated or solely retained by individual memory. Conducting a comprehensive belt conveyor system survey emerges as vital, not only for maintenance but also as a fact-finding mission to enhance system performance, reduce operational costs, and bolster safety.
The initial belt walk requires meticulous data collection, often necessitating involvement from suppliers, contractors, or consultants to conduct a thorough system census. Specialized equipment may be essential for accurate data capture, minimizing return trips for missed details like dimensions or serial numbers.
Tool Functions for Site Survey
- Personal Protective Equipment (PPE): Ensures personal safety during surveys.
- Anemometer: Measures air velocities for dust suppression.
- Angle Finder: Documents structure inclines.
- Decibel Meter: Assesses noise levels.
- Durometer Reader: Evaluates conveyor belt and skirtboard seal hardness.
- Infrared Thermometer: Records component temperatures.
- Level: Checks component alignment.
- Soap Stone: Temporarily marks steel components.
- Tachometer: Measures belt speed.
- Tape Measure: Determines distances.
- Flashlight: Allows inspection of dark or enclosed areas.
- Camera: Captures visual data.
- Pencil & Paper: Records findings.
- Tool Belt/Harness: Safely carries equipment.
Recording and Archiving Information
During the conveyor system census, critical manufacturer, model, and specification data are recorded and archived centrally within the plant's maintenance files. This data encompasses a wide array of system details:
| Conveyor System Census | |
|---|---|
| Performed By: | |
| Basic Data | |
| Conveyor ID [name or number] | |
| Location | |
| Length-Pulley Centers [m (ft)] | |
| Conveyor Capacity [tons/h (st/h] | |
| Total Lift (Elevation Change) [+/-m (ft)] | |
| Hours Conveyor Runs/Day [hours] | |
| Days Conveyor Operates/Week [days] | |
| Belt Width [mm (in.)] | |
| Belt Speed [m/sec (ft/min)] | |
| Trough Angle [degrees] | |
| Belting | |
| Belt Manufacturer & Type | |
| Belt Rating [kN/mm (PIW)] | |
| Belt Installation [date] | |
| Belt Thickness [mm (in.)] | |
| Belt Splice Type [mechanical or vulcanized] | |
| Number of Splices (Joints) in Belt | |
| Cargo | |
| Material Conveyed | |
| Material Size (Maximum Lump) [mm (in.)] | |
| Material Temperature [Celsius (F°)] | |
| Material Drop Height [m (ft)] | |
| Moisture Content (Maximum) [%] | |
| Moisture Content (Normal) [%] | |
| Conveyor Drive | |
| Manufacturer & Model | |
| Power Output [kW (hp)] | |
| Idlers | |
| Make, Model, & CEMA Class | |
| Carrying Idlers | |
| Impact Idlers | |
| Impact Cradles | |
| Belt-Support Cradles | |
| Return Idlers | |
| Airflow | |
| Loading-Zone Exit Area [m2 (ft2)] | |
| Max Loading-Zone Exit Air Speed [m/s (ft/min)] | |
| Components | |
| Make & Model | |
| Sampler | |
| Belt Scale | |
| Magnet | |
| Rip-Detection System | |
| Pull-Cord Safety Switches | |
| Misalignment Switches | |
| Carrying-Side Training Devices | |
| Return-Side Training Devices | |
| Primary Belt-Cleaning Systems | |
| Secondary Belt-Cleaning Systems | |
| Tail-Protection Plows | |
| Dust Collectors | |
| Dust-Suppression Systems | |
| Chute Flow-Aid Devices | |
| Access Doors | |
Centralizing Information
It's prudent to consolidate this information into a centralized library that includes maintenance manuals, service procedures, parts lists, operating instructions, supplier details, and drawings related to the belt conveyor system. This centralized digital repository can integrate with a computerized maintenance management system (CMMS), facilitating swift access for both plant personnel and contractors, thereby streamlining maintenance operations.
Specialized Services and Updates
Certain maintenance contractors and suppliers offer specialized data collection services, which can be integrated into routine assessments or implemented separately as part of CMMS selection and deployment processes. Regular updates to system data, including original design information and change records, are essential practices to maintain accuracy and effectiveness in ongoing maintenance cycles.