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Belt Conveyor System Census

First Steps: Fact Finding

Too often, the details of a conveyor system—the specifications of components, even basic information about their make and model—are lost or forgotten over time. Plant ownership or management changes; operations, maintenance, and engineering personnel change responsibilities or leave the company. Even the components of a conveyor system will change from the original equipment, evolving as replacement parts or improvements are incorporated into the system. The “nameplate information” about various components will not have been kept up to date in the maintenance department, the engineering office, or the purchasing department. The file becomes outdated, or perhaps, worse, the information is retained only in the mind of one person.

A comprehensive belt conveyor system survey can identify opportunities to improve system performance, increasing productivity, lowering the cost of operation, and improving safety.

Consequently, the capture of current information in a consistent format should be a principal requirement of a plant’s first belt walk or initial conveyor survey. The initial belt walk becomes a fact-finding mission in addition to being a maintenance inspection. The collection of all pertinent information can make this walk a lengthy one, which often leads to a supplier, contractor, or consultant completing the survey. This “belt walker” is undertaking a census of the system.

Special equipment may be required to properly complete a site survey. Having all the tools necessary to capture key data allows the survey to be completed without repeat trips to the site, looking for “just one more” dimension or serial number.

Tools for the Site Survey
Tool Function
Personal Protective Equipment (PPE) Provide for personal safety, as appropriate for locations to be surveyed. ALWAYS USE.
Anemometer Capture air velocities used in dust suppression
Angle Finder Document the incline of structures
Decibel Meter Measure noise levels
Durometer Reader Determine the surface hardness of conveyor belt and skirtboard seal
Infrared Thermometer Find temperature of components
Level Determine if components are installed level
Soap Stone Temporarily mark steel components
Tachometer Measure belt speed
Tape Measure Measure distances
Flashlight Allow inspection of dark or enclosed areas
Camera Capture still and/or video images of conditions
Pencil & Paper Record data
Tool Belt/Harness Carry tools safely

Recording the Information

During a conveyor system census, a variety of manufacturer, model, and system specification information is collected and recorded. Once this information is collected, it should be archived in a single, central location in the plant maintenance file.

Conveyor System Census
Performed By: Date:
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  

It makes sense to locate this information, complete with the various documents, in one central library of material related to the belt conveyor system. This would include maintenance manuals, service procedures, parts lists, operating instructions, supplier information, and drawings. This captured information can be transferred into a plant’s computerized maintenance management system (CMMS).

Some specialized computerized systems allow the incorporation of materials such as engineering drawings, schematics, parts lists, operator manuals, and other documents into a digital asset library. This system becomes a centralized library for personnel, both plant and contractor, to quickly access information and shorten the time required performing maintenance tasks.

Some maintenance contractors and suppliers offer data collection as a specialized service. This service can be performed as part of a regular assessment of a plant’s materials-handling system, as part of a contract maintenance service, as a stand-alone service, or as part of a CMMS selection and implementation process.

It is important to keep the data updated; it is also a good practice to retain original design information and any change records. Best practice is to regularly update the data with changes as part of a regular inspection cycle.

Topics: Belt Conveyor System Maintenance

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