appenvixp — Conveyor Installation Standards For Belt Conveyors Handling Bulk Materials Introduction Reducer/motor base installation tolerances exible coupling alignment Idler alignment Belt alignment Skirtboard adjustment Idler lubricationIntroduction ‘A trouble-free belt conveyor operation is the product of three properly executed stages of development: 1. Design 2. Manufacturing 3. Installation followed by an effective maintenance program. Less than satisfactory performance in any of these developmental stages will negatively impact all others, resulting in unan- ticipated operating problems. CEMA has already addressed many of the design and maintenance consider- ations critical to proper operation. It is not our intent to specify minimum levels of manufacturing quality. Indeed, it is the responsibility of each manufacturer to pro duce a product of which he and the user can be proud. This document will specify minimum standards for installation of belt conveyors, i.e. acceptable tolerances for structural and mechanical erection in addition to dynamic operating tolerances. In addition, it will provide helpful suggestions that can be utilized to meet or exceed these standards. Each item will be addressed in the sequence in which it is encountered in the field, NOTES: It is important that ANSI lockout procedures be followed when making adjust- ‘ments to bring conveyor machinery into tolerance (ref: ASME B15.1, B20.1, and ANSI 2244.1). 2 All mechanical tolerances should be documented by millwrights,Conveyor Stringer Alignment Conveyor Stringer Alignment “Trusses and channel frame conveyor stringers must be installed parallel, straight, square, and level to allow proper belt training. During installation, dimensional checks shall be made to insure that the following tolerances in the idler carrying chords are not exceeded:* Parallel ‘A maximum tolerance of #4” shall be allowed for the “back to back” dimension in channel frame or angle stringers. Similarly, #34" shall be allowed between webs of beams, wide flange beams, or tees when used as truss chords (Figure D. 1). mao rt es Figure D.1 Maximum tolerances for channel frame of angle stringers, Straightness ‘The maximum allowable lateral offset in conveyor stringers shall be 44" in 40" of length (Figure D.2), Figure D.2 Maximum allowable lateral offset in conveyor stringers. * NOTE: These tolerances are guidelines for design/manufacture to facilitate proper idler and belt alignment in accordance with the Idler Alignment section of this standard. The overriding issue is idler and belt alignment a: opposed to siructural alignment. 409Squareness ‘A check on squareness can be made by comparing diagonal measurements between idlers, as shown in Figure D.3. Figure D.3 Conveyor frame and idler alignment. Lines A and B must be within 4” to assure conveyor frame squareness. Return idlers should, likewise, be installed level and parallel to the head and tail pulleys. Level The two idler support members shall be level within \4" regardless of belt width, In addition, the elevation of stringer above support structure shall be held within £44" (Figure D.4). peers f 1 18 a0" ia a ee 7IN\N Figure DA Level requirements, NOTE: Designers and fabricators must compensate for mill tolerance of members ] to satisfy this level requirement. 410Pulley and Shaft Alignment Pulley and Shaft Alignment Except for special purpose applications (such as turnover exit), all belt conveyor pulleys should be set level, and the shaft centerline should be perpendicular to the Centerline of the belt, Significant departure in alignment will result in unnecessary thrust load on bearings, accelerated and uneven pulley lagging wear, and belt training problems. It is most convenient to field align pulleys after supporting steel is secured and. before belting is installed. After alignment, itis good practice to matchmark bearing, housingand supporting steel to enable realignment if disturbed for any reason. Inten- tional misalignment should not be used as a means to counteract other misaligament forces for training the belt, Because of pulley manufacturing tolerances, alignment measurements should be taken on the shaft and not on pulley elements. By use of adjustable bearing stops (commonly supplied by the conveyor manufacturer) and full bearing surface shim packs (commonly supplied by the erector), the following alignment tolerances cai be reasonably achieved: Using a level and checking both sides of the pulley, shaft elevations at the bearings should be set within 1/32 of an inch (Figure D.5). FigureD.5 Shaftelevation settings. Measuring from a line constructed perpendicular to the conveyor centerline, the shaft centerline should not deviate greater than +1/32 of an inch at the bearings (Fig- ture D6). Because of pulley locations and access thereto, itis common practice to uti- lize offset lines and plumb bobs to make these measurements. oncom alte sf peobreSbeeeg OOR OFFSET LINE Figure D.6 Shaft elevation settings. NOTE: See Figure D.3 for squareness check auWhen pulleys are mounted on shafts by the equipment supplier, they shall be secured to the shaft in accordance with the recommended practice of the locking cle- ment manufacturer. When supplied separately, they should be located on the shaft £46 of an inch of the position shown on the drawings. If pulleys and shafts are field assembled or repositioned, pulley manufacturer rec- ‘ommendations must be followed to avoid dishing of end discs and residual end disc prestress. With some locking elements, it may be necessary to check and tighten clamping bolts several times to insure security of hub and shaft assembly. Manufacturers’ rec- ‘ommendations should be followed with regard to checks and bolt torques. Pulleys, shafts, bearings, and supporting steel may be shipped in various degrees of preassembly. Due to manufacturing and erection tolerances, final bearing setting should be done in the field after supporting steel has been secured, Procedures and tolerances for bearing settings should be obtained from the bear- ing manufacturer's catalogs. Improper setting of both fixed and expansion type bear- ings may result in thrust pre-load, causing premature bearing failure. Reducer/Motor Base Installation Tolerances Fabricated Structural Bases Concrete Supports a2 Characteristic ofall operating mechanical apparatus, correct manufacturing and installation alignment tolerances are necessary to prolong operating life and prevent unnecessary breakdowns, Also, since many reducer manufacturers do not factory oil their reducers, itis imperative that oil levels be checked and maintained by field per- sonnel. Reducer/motor base installation guidelines generally fall into two categories, concrete or structural steel. Either should be sufficiently rigid to minimize vibration and to maintain alignment between the motor and the driven equipment within the manufacturer's recommended tolerances. Base application information may apply to cither motors or reducers, or to bth in combination. Structural bases require a surface which, if not flat, can be shimmed to proper position in the structure, using .003 inch to .005 inch shim packs. After the base plate is secured, flatness should be verified and shims added, if necessary. Concrete foundation-type supports are normally the most rigid and secure, However, the installation must be correct within certain limitations to provide acceptable tolerances in the final arrangement with a minimum of shimming, “Sole plates” can provide a means of adjusting and aligning the motors and reducers or common bedplate to an acceptable tolerance prior to final grouting. Reducer and motor mounting plate surface should be flat to tolerances acceptable 10 the manufacturer, The bottom of the sole plate needs no tolerance requirement inas- much as the grout provides a fulling bearing surface. Ifthe output from the reducer is direct-coupled to a driven unit, the reducer shaft centerline should be held to @ minus tolerance only, which would allow shimming by the erector if required. The same is true of the motor shaft in relation to the reducer input shaft. Itis mandatory that alignment checks be made after the installation is complete, but before operation. Misalignment should be no more than 50 percent of the mis- alignment tolerance allowed by the manufacturer of the coupling being aligned.Flexible Coupling Alignment ‘Structural Steel Although combination fabricated structural bases are normally built as a unit, it Supports is not always necessary to provide continuous support in the structural stee! below the units; however, itis necessary to provide an integrated and sufliciently rigid connee- tion between reducer base and support stec! to accommodate every bolt hole ‘The supporting structure must minimize deflection and distortion under load, preventing warping of the motor/reducer base and subsequent unacceptable mis- alignment. Heme Cap higeunt a. Flexible couplings are used in conveyor drive trains to transmit torque from one rotating element to another. In doing so, they protect expensive driving and driven machinery from misalignment, shock loads, vibration, and thrust loads. Iris true that most couplings will operate under severe misalignment for a given period of time; however, the penalty is reduction in useful life, For this reason, manu- facturers of couplings have established misalignment tolerances that should be strictly adhered to during field assembly. 'A pretequisite to proper alignment isa rigid and level base on which the drive and driven elements ate to be set. If they are to be mounted on a steel frame, a common base plate is necessary to prevent movement between independently supported steel members. Prior to coupling installation, the installer must thoroughly familiarize himself with all of the manufacturer's published requirements of the motor, speed reducer, and couplings. Field breakdown and checking of alignment during assembly to the support structure shall be accomplished using dial indicators, machine test levels, or ‘other means, with only commercial shim stock used for final alignment. “Three types of alignment must be checked: (1) Angular; (2) Parallels (3) Axial. Angular Alignment “Angular alignment” is defined as the movement of the input and output halves of the coupling in such a manner as to permit a rocking and/or sliding action of the clement that connects the coupling halves. See Figure D7. = (ce ig 4 4 Figure D7 Angular alignment. ‘After the coupling halves have been mounted to the driver and driven shafts, the two units should be positioned so that the distance between the coupling faces is equal to the “normal” coupling g 413Parallel Alignment Axial Alignment a4 ‘The coupling halves are then aligned by positioning a spacer block of thickness equal to the required gap between the faces. The spacer block should check gap at a ‘minimum of 90-degree intervals. Once this is accomplished, the gap should be mea: sured with a feeler gauge. “Parallel Alignment” is defined as the movement of the input and output halves ofthe coupling in a way that maintains parallelism between the faces of each coupling half but allows the shafts to occupy separate center lines. The driving and driven ‘equipment should be aligned so that a straight edge can be placed on both coupling flanges at 90-degree intervals and remain parallel to the equipment shafts. Care should be taken when tightening set screws and bolts to insure the proper torque is a} [5 Figure D8 Parallel alignment. End float for both the driving and driven shafts is sometimes required for expan- sion and various other reasons, End float on most couplings can be limited to any. required distance by the use of limited end float kits; however, these kits should only be used as recommended by the manufacturer. Figure D9 Awal alignment, ‘After the couplings have been aligned (cold) and the drive run in to obtain nor- smal operating temperature, it shall be shut down and alignment re-checked using the following procedure: Break all couplings and re-check “hot” alignment. These readings shall not exceed 75 percent of the manufacturer’ s maximum allowable tolerances. If they are not within these limits, the procedure should be repeated as often as needed to achieve necessary *hot” readings.Idler Alignment idler Alignment ‘The objective in aligning idlers is to achieve settings which are square and in line to the conveyor centerline and parallel to each other, as shown in Figure D.5. Idlers shall be set from a previously squared and leveled terminal pulley (prefera- bly the discharge pulley, although this is not essential). A suggested method is to use a tight wire on the conveyor centerline or offset to it, stretched to form a true centerline reference. This line should be at least 100 feet long and referenced to the “squared” starting pulley. Idlers shall be placed at design spacing and square to the tight wire, After a span of about 50 feet has been filled with idlers, the 100-foot line shall be relocated so that there is a 50-foot overlap on the first position. Repositioning of the tight wire should continue until the entire conveyor length is filled with idlers. Belt Alignment Bel training is usually minimized if; + Conveyor has been installed straight and level with tolerances stated | herein + All pulleys and idlers are square with the conveyor centerline + Bet splices are correct and square + There are no defects in the conveyor belting + All idler rolls turn freely However, all these conditions are rarely present concurrently, and some tra oftthe belt is usually required. NOTE: Belt training should be supervised by one person. “Training the belt is a process of adjusting idlers and the method of leading in a ‘manner that will correct any tendency of the belt to run off to one side or the other. ‘When the belt continues to run off consistently over a fixed length of conveyor, the cause is probably in the alignment or leveling of the conveyor structures, idlers, or pulleys in that area. If ove or more segments of the belt run off at all points along the conveyor, the cause is more likely the belt itself, a splice, or the method of loading. When a belt is loaded off center, the lightly loaded edge will rise on the inclined idler roll that it con- tacts. {All pulleys should be level and at 90 degrees to the centerline of the conveyor. ‘They should be maintained this way and never shifted to train the belt. ‘Training the belt with the troughing idlers is accomplished by shifting the idler axis with respect to the path of the belt, commonly known as “knocking idlers.” ‘This method is effective when the entire belt runs to one side along a fixed length of the conveyor. The belt can be centered by “knocking” ahead (in the direction of belt travel) the end of the idler to which the belt runs (See Figure D.10). 415Empty Run-in 46 Figure D.10 Correcting bet alignment. Shifting idlers in this manner should be spread over a length of conveyor preced- ing the region of trouble. In no event shall any idler be shifted more than % inch in any direction from its squared position, NOTE: Compensation by idler “knocking” may have adverse effects on reversible belts; therefore, avoid “knocking” on reversible belts. Instead, use extreme care in initial alignment, A belt might be made to run straight with half the idlers “knocked” one way and half the other, but this would increase rolling friction between the belt and idlers. For this reason, all idlers must be initially squared with the path of the belt in accordance with the Idler Alignment section of this standard, and minimum shifting should be used for training. Ifthe belt is over-corrected by shifting idlers, it should be restored by moving the “knocked” idlers, not by shifting additional idlers in the other direc- tion, ‘The conveyor belt should first be aligned (trained) without material load, Most alignment problems, with the exception of off-center loading, will be detected during this empty run-in period. After ensuring that all elements have been aligned true as stipulated in the Idler Alignment section of this standard, the belt should be slowly “inched” along to pro: vide indication of where corrections of the types described may be required. The first corrections must be those at points where the belt is in danger of being damaged. ‘Once the belt is clear of all danger points, a sequence of training operations can be followed. ‘The best procedure to use in the training sequence is to start with the return run and work toward the tail pulley. This ensures early centering of the belt on the tal pulley so that it can be centrally loaded. Normally the belt can be trained properly onto the tal pulley by manipulation of the return idlets, With the empty belt trained satisfactorily, good operation with load is uswally assured. Disturbances that appear with load are then usually due to off-center loading or to accumulation of material on snub pulleys and return idlers.Skirtboard Adjustment fall corrective measures have been applied, and a particular section of belt con- tinues to run to one side along the entire conveyor length, it can be concluded that the belt may be cambered at that point or may have a splice that is not properly squared. ‘The only corrective measure for a “non-squared” splice is to re-splice. On the other ‘hand, slight camber in a belt may remove itself after an adequate run-in period under load. Full Load Run-in. —_A.belt may be considered properly aligned if after eight hours of continuous oper- ation under full design load, the belt edges remain within the width of the pulley face, Also, when extra wide face pulleys are used, a further criterion that the belt runs ‘within the confines of the normal troughing, or return, idler should be followed. NOTE: Disc return idlers shall be exempt from the above as the standard roll faces supplied are approximately equal to the belt width, In this case, the belt shall be ‘made to track within 14 inches of the conveyor centerline. Idler brackets shall not restrict this movement, ‘To obtain the above alignment under load, it will be necessary to ensure that the load is centered and that all belt scrapers, plows, and skirt seals exert uniform pres~ sure on the belt, Minor adjustments can be made to these devices to improve track- ing. Carrying and return training idlers should be considered in correcting belt align ment problems before rejecting the belting or splice. Helpful Hints: a, One person should be responsible for training belts. ‘This person should super- vise all adjustments. b, Periodically check the conveyor to be sure it is level. This requirement is appar- cent if the conveyor becomes misaligned with no apparent change in loading. «¢.After the belt is run in, an electrician should take readings on voltage, amperes, ‘or wattage. This information can be used for future comparison and a quick trouble check. (Higher readings in the future may indicate excessive drag due to belt mis- alignment or frozen belt idler rolls.) . Do not overtrain the belt. Overtraining will result in increased belt cover wear and increased power consumption. Skirtboard Adjustment Skirthoards are an important element of a well designed belt conveyor. They help centralize and shape the Joad while minimizing spillage over the belt edges and help- ing to contain dust. ‘The steel plates that form the skirting (and any chute lining) should be installed high enough to avoid the risk of contact with the belt, yet low enough to protect the rubber or urethane sealing strips from excessive load pressure and material wear. The cross-sectional area of the chute should be checked carefully to make certain that the skirting and liner do not interfere with flow, It is critical that these steel plates be installed as a smooth, seamless layer that opens in the direction of belt travel, to min- mize material entrapment and the risk of belt damage. Typical dimensions for clear- ance above the belt start at ¥ inch above the belt at the tail and open to 1 inch at the exit of the load zone, 47Affixed to the bottom of the steel is the skirtboard sealing system, which pro- vides a light, flexible contact with the conveyor belt. This low sealing pressure will minimize friction while retaining all material within its boundaries. Excessive pressure will burn grooves in the belt rubber cover and, therefore, must be avoided. Excessive adjustment or downward pressure of the skirtboard seal can lead to accelerated wear of the sealing strip, and/or belt. ‘The maintenance of a flat and stable belt line in the loading zone is a key to | effective sealing. Efforts taken to avoid fluctuations in the belt lin, including closely spaced idlers, belt support cradles, and spiral-wrapping of wing pulleys have generally proven helpful in controlling fugitive material. Idler Lubrication Modern conveyor idlers have evolved through better bearings, improved lubri- cants, and more effective seals. Likewise, the lubrication requirements have changed to accommodate current designs. The following considerations should be reviewed ‘when establishing a lubrication program tailored to a particular installation: Manufacturer's ‘The manufacturer's data can provide a solid basis for designing the lubrication Recommenda- program, tion Type of ‘The proper lubricant will be heavily influenced by operating conditions, the Lubricant operating environment, and the quality of maintenance program desired, Operating conditions such as operating speed, idler loading, type and size of material being handled, and number of operating hours per year should be considered, ‘The operating environment is one of the greatest contributors in determining the lubrication program, Temperature, dust, material abrasiveness, washdown tech- niques, and washdown frequency all affect the lubrication that flushes contaminants, from the bearings. Special synthetic lubricants are available for subzero operating temperatures, Idler ‘The type and efficiency of the seals directly reflect on the lubrication schedule. Construction _Followingare several recommendations that will contribute to establishing a success- ful lubrication program: A. Remove several idlers from service every six months, disassemble them, and inspect to determine if adequate lubrication has been attained, if migratory contarmi- nation and wear have occurred, or if pressure relief plugs are fouled. If these idlers demonstrate that adequate lubrication has been attained, they could be put back into service and the conveyor operated as normal. If contamination was found in this sampling, all idlers on the conveyor should be lubricated. Also, fouling of pressure relief plugs in sampling should encourage cleaning of all plugs. B. Thoroughly clean all grease fittings prior to lubricating the idlers to eliminate the possibility of contamination introduced during maintenance.Idler Lubrication . Establish a good maintenance recordkeeping system. Record the date on which samples were taken and the condition of the samples taken and verify trends that may ‘be occurring within the system. Also record idler failures, including location, to estab- lish system trends and effectiveness of the lubrication program. ‘The establishment of a formal Lubrication program as described above will inerease the likelihood of many years of successful, trouble-free operation. a9,