Turnkey project

A turnkey or a turnkey project (also spelled turn-key) is a type of project that is

constructed so that it could be sold to any buyer as a completed product. This is
contrasted with build to order, where the constructor builds an item to the buyer's
exact specifications, or when an incomplete product is sold with the assumption
that the buyer would complete it.
Types of turnkey projects are
Airport conveyors
Baggage conveyors
Belt conveyors
Bucket conveyors
Dispatch conveyors
Drag conveyors
Pivoted conveyors
Screw conveyors
Others
Examples for turnkey projects
Bucket conveyors

Bucket conveyors are used in carrying mineral or material from deep

excavations
Baggage conveyor

Baggage conveyors are used to carry luggage from one place to another

place
A turnkey project incorporates the following:
Conveyor belt
Idlers
Pulleys
Others

Conveyor belt
A conveyor belt is the carrying medium of a belt conveyor system (often
shortened to belt conveyor). A belt conveyor system is one of many types of
conveyor systems. A belt conveyor system consists of two or more pulleys
(sometimes referred to as drums), with an endless loop of carrying medium
the conveyor beltthat rotates about them. One or both of the pulleys are
powered, moving the belt and the material on the belt forward. The powered
pulley is called the drive pulley while the unpowered pulley is called the idler
pulley. There are two main industrial classes of belt conveyors; Those in
general material handling such as those moving boxes along inside a factory
and bulk material handling such as those used to transport large volumes of
resources and agricultural materials, such as grain, salt, coal, ore, sand,
overburden and more.
Today there are different types of conveyor belts that have been created for
conveying different kinds of material available in PVC and rubber materials.
The belt consists of one or more layers of material. Many belts in general material
handling have two layers. An under layer of material to provide linear strength and
shape called a carcass and an over layer called the cover. The carcass is often a
woven fabric having a warp & weft. The most common carcass materials are
polyester, nylon and cotton. The cover is often various rubber or plastic compounds
specified by use of the belt. Covers can be made from more exotic materials for
unusual applications such as silicone for heat or gum rubber when traction is
essential.
Material flowing over the belt may be weighed in transit using a beltweigher. Belts
with regularly spaced partitions, known as elevator belts, are used for transporting
loose materials up steep inclines. Belt Conveyors are used in self-unloading bulk
freighters and in live bottom trucks. Belt conveyor technology is also used in
conveyor transport such as moving sidewalks or escalators, as well as on many
manufacturing assembly lines. Stores often have conveyor belts at the check-out
counter to move shopping items. Ski areas also use conveyor belts to transport
skiers up the hill.

Belt conveyor systems

Conveyors are durable and reliable components used in automated distribution and
warehousing.[2] In combination with computer controlled pallet handling equipment
this allows for more efficient retail, wholesale, and manufacturing distribution. It is
considered a labor saving system that allows large volumes to move rapidly through
a process, allowing companies to ship or receive higher volumes with smaller
storage space and with less labor expense.
Rubber conveyor belts are commonly used to convey items with irregular bottom
surfaces, small items that would fall in between rollers (e.g. a sushi conveyor bar),
or bags of product that would sag between rollers. Belt conveyors are generally
fairly similar in construction consisting of a metal frame with rollers at either end of
a flat metal bed. The belt is looped around each of the rollers and when one of the
rollers is powered (by an electrical motor) the belting slides across the solid metal
frame bed, moving the product. In heavy use applications the beds which the
belting is pulled over are replaced with rollers. The rollers allow weight to be
conveyed as they reduce the amount of friction generated from the heavier loading
on the belting. Belt conveyors can now be manufactured with curved sections which
use tapered rollers and curved belting to convey products around a corner. These
conveyor systems are commonly used in postal sorting offices and airport baggage
handling systems. A sandwich belt conveyor uses two conveyor belts, face-to-face,
to firmly contain the item being carried, making steep incline and even vertical-lift
runs achievable.
Belt conveyors are the most commonly used powered conveyors because they are
the most versatile and the least expensive. Product is conveyed directly on the belt
so both regular and irregular shaped objects, large or small, light and heavy, can be
transported successfully. These conveyors should use only the highest quality

premium belting products, which reduces belt stretch and results in less
maintenance for tension adjustments. Belt conveyors can be used to transport
product in a straight line or through changes in elevation or direction. In certain
applications they can also be used for static accumulation or cartons.
Long belt conveyors

The longest belt conveyor system in the world is in Western Sahara. It is 98 km

(61 mi) long, from the phosphate mines of Bu Craa to the coast south of ElAaiun.[3]
The longest conveyor system in an airport is the Dubai International Airport
baggage handling system at 63 km (39 mi). It was installed by Siemens and
commissioned in 2008, and has a combination of traditional belt conveyors
and tray conveyors.[4]
Boddington Bauxite Mine in Western Australia is officially recognised as
having the world's longest and second-longest single belts with a 31kilometre-long (19 mi) belt feeding a 20 km (12.5 miles) long belt. This
system feeds bauxite through the difficult terrain of the Darling Ranges to
the alumina refinery at Worsley. The longest single-belt international
conveyor runs from Meghalaya in India to a cement factory at Chhatak
Bangladesh.[5][6][7] It is about 17 km long and conveys limestone and shale at
960 tons/hour, from the quarry in India to the cement factory (7 km long in
India and 10 km long in Bangladesh). The conveyor was engineered by
AUMUND France and Larsen & Toubro. The conveyor is actuated by three
synchronized drive units for a total power of about 1.8 MW supplied by ABB
(two drives at the head end in Bangladesh and one drive at the tail end in
India). The conveyor belt was manufactured in 300-meter lengths on the
Indian side and 500-meter lengths on the Bangladesh side, and was installed
on-site by NILOS India. The idlers, or rollers, of the system are unique[citation needed]
in that they are designed to accommodate both horizontal and vertical
curves along the terrain. Dedicated vehicles were designed for the
maintenance of the conveyor, which is always at a minimum height of 5
metres (16 ft) above the ground
What is a conveyor belt?
The belt conveyor is an endless belt moving over two end pulleys at fixed positions
and used for transporting material horizontally or at an incline up or down. The main
components of a belt conveyor are:
The belt that forms the moving and supporting surface on which the conveyed

material rides. It is the tractive element. The belt should be selected considering
the material to be transported.
The idlers, which form the supports for the carrying and return stands of the belt.
The pulleys that support and move the belt and controls its tension.
The drive that imparts power to one or more pulleys to move the belt and its loads.
The structure that supports and maintains the alignments of the idlers and pulleys
and support the driving machinery.
Other components include:
Loading chute or feeder chute that organizes the flow of material and directs it on
the belt conveyor.
Take-up-device which is used to maintain the proper tension of the belt for
effective power transmission.
Belt cleaner that keeps the belt free from materials sticking to the belt.
Tramp removal device, which is optionally used in case the conveyed material
bears the chance of having tramp iron mixed with it and subsequent handling of the
material, demands its removal.
Continuous weighing device for constantly measuring the load being carried by
the conveyor belt.
Discharge chutes to guide the discharged projectile to subsequent conveyor or
other receiving point.
Surge hopper and feeder, which is essential for supplying material to the
conveyor at uniform rate when the supply of material is intermittent.
Tripper arrangement to discharge material at different point or to other device.

Application
Conveyor belts are widely used in mineral industry. Underground mine transport,
opencast mine transport and processing plants deploy conveyor belts of different
kinds to adopt the specific job requirements. The main advantages of conveyor belt
system are:
A wider range of material can be handled which pause problems in other
transportation means. Belt conveyor can be used for abrasive, wet, dry, sticky or
dirty material. The lump size of the transported material is limited by the width of

the belt. Belts up to 2500 mm wide are used in mining industry.

Higher capacity can be handled than any other form of conveyor at a considerably
lower cost per tonne kilometre. Conveyor belts with capacity of 11000t/h and even
higher can be deployed to match with higher capacity mining machinery.
Longer distances can be covered more economically than any other transportation
system. A single belt conveyor or a series of belt conveyors can do this. Belt
conveyors can be adopted for cross-country laying.
By the use of many forms of ancillary equipment such as mobile trippers or
spreaders bulk material can be distributed and deposited whenever required.
Many other functions can be performed with the basic conveying like weighing,
sorting, picking, sampling, blending, spraying, cooling, drying etc.
Structurally it is one of the lightest forms of conveying machine. It is comparatively
cheaper and supporting structures can be used for many otherwise impossible
structures such as crossing rivers, streets and valleys.
The belt conveyor can be adopted for special purposes (fire resistant, wear
resistant, corrosion resistant, high angle negotiation etc.) and can be integrated
with other equipment.
It can be horizontal, incline or decline or combination of all.
Minimum labour is required for the operation and maintenance of belt conveyor
system.
In underground mine transport, belt conveyor can be used in thin seams as it
eliminates the rock works that might otherwise be required to gain haulage height.
Moreover, belt conveyor can provide continuous haulage service from pit bottom to
the surface.

Idlers
Idlers Introduction
Idlers are an important component in any conveyor system as they are used
to support the conveyor belt and the load carried on the belt.
In a conveyor belt installation different types of idlers or roller supports are used.
The idlers are required for proper support and protection of the belt and proper
support of the load being conveyed.Idlers are designed with different diameters and
are provided with antifriction bearings and seals, and are mounted on shafts.
Frictional resistance of idlers influences the belt tension and consequently the
power requirement.

Idlers are mounted on a support frame, which can be shiftable or permanent. The
carrying side of the belt is supported on the carrier rollers sets. A set of three rollers
are arranged to form a trough for the troughed belt conveyor. The return side of the
belt is supported on straight return idlers. The spacing of the idlers is determined
based on the belt sag between the idlers. The sag depends on the belt tension, belt
width, belt properties and the pay-load per meter of the belt. The idlers are
specified by its length and diameter. These parameters are selected based on the
required belt speed for the particular width of the belt.

There are a significant number of idlers on a conveyor and if the incorrect

idlers are selected, the subsequent problem manifests itself along the entire
conveyor length !
Idlers are the 'low friction sliding surface' over which an endless conveyor
belt is 'dragged' by the drive pulley(s), enabling a conveyor to operate for
many thousands of hours without wearing out the belting.

The selection of the correct type of idlers is very important with respect to
the optimum load-carrying capacity of a conveyor and the environment in
which the conveyor is to operate. Similarly, understanding the design of
idlers, their limitations and the factors which affect their performance, is
important in ensuring that the conveyor operates reliably and cost-effectively.
Idler spacing will depend on a number of factors, i.e. layout, loads, rates of
feed, belt tension. etc. Average troughing idler spacing for run of mine ore is
in the vicinity of 1,2 meter. Return idler spacing is two to three times the
troughing spacing

It has been stated above that there are basically two types of idlers namely,
carrying and return idlers.
Within these categories however, there are a number of different designs of
idler sets which have developed as a result of particular applications, the
need to minimise the stress imposed onto the belt and the environment in
which the conveyor operates.

These different types of idlers are described below, together with a different
application for each.

Classification of idlers
Idler Type

CEMA Class
Roll Diameter
inches (mm)

Light-duty

Classic Idlers
Bearing Type

RexDura Idlers

Belt Width

Bearing Type

inches (mm)

Roller

Ball

18 to 48 (457 to 1,219)

Roller
Roller

Ball
Ball

18 to 60 (457 to 1,524)
18 to 72 (457 to 1,829)

Ball
Ball

36 to 96 (914 to 2,438)
60 to 120 (1,524 to 3,048)

4 (102)
5 (127)
Medium-duty

C
D

5 (127)
6 (152)

5 (127)
6 (152
Heavy-duty

E
F

6 (152)
7 (178)

7 (178)
8 (203)

Classification

Diameter
(inches)

Belt Width (Inch)

Description

B4

18 48

Light duty

B5

18 48

Light Duty

C4

18 60

Medium Duty

C5

18 60

Medium Duty

C6

24 60

Medium Duty

D5

24 72

Medium Duty

D6

24 72

Medium Duty

E6

36 96

Heavy Duty

E7

36 96

Heavy Duty

TYPES OF IDLERS
Carrying Idlers (Troughing or Flat)
Support the belt in the section of the conveyor that transports the material. These idlers
may be flat or troughed to shape the belt to prevent spillage and are available in 20, 35
and 45 trough angles with equal or unequal roll lengths. Normal spacing is 3 to 5 feet.

Impact Idlers (Troughing or Flat)

Prevent damage to the belt at the loading point. These idlers may be troughing or flat
types with grooved, molded rubber rolls. It is standard practice to use impact idlers at all
loading and transfer points when the impact force exceeds 40 foot-pounds.
To ensure maximum belt protection for optimum life and to reduce skirtboard leakage, the
impact idlers should be at least six-inch diameter and spaced at one-foot intervals

Return Idlers
Support the empty belt between the discharge point and the tail pulley. Normal spacing
is 10 feet.

a.

Steel Used where materials are not sticky, corrosive or abrasive. Available

with urethane covering. Six-inch diameter also available in 1/4" wall thickness.

b.

Spiral Used where sticky materials adhere to the belt, where a corrosive

environment is present or abrasive wear is a problem. Unique construction

minimizes belt fleet and damage to the return belt due to material buildup on
the idler rolls. Spiral roll idlers can be used for belt travel in one direction only.

c.

Disc Used under the same conditions as the spiral idler. These idlers

can be used for belt travel in either direction. Massed end discs are standard.
Ceramic, urethane and rubber disc rolls available

Carrying Belt Training Idlers (Troughing or Flat)

Assist in keeping the belt centered on the conveyor. Actuating shoe type is used on belt
traveling in either direction. Positive type is used on belt traveling in one direction only
and is illustrated. Normal spacing is 100 feet and not within 50 feet of the head or tail
pulley.
(Urethane rolls enhance trainer effectiveness.)

Return Belt Training Idlers

Used for the same purposes as are carrying training idlers. They are of the actuating shoe
type, belt travel either direction, and the positive belt travel one direction only. The
positive type is illustrated. Normal spacing is 100 feet and not within 50 feet of the head
or tail pulley.
(Urethane rolls enhance trainer effectiveness.)
Can also be furnished with spiral or disc rolls.

DISCHARGE HOOD

TRIPPER

SKIRT BOARD
SCRAPER

END PULLEY

END PULLEY

IMPACT IDLERS
BEND PULLEY
SNUB PULLEY

CARRYING IDLERS

RETURN IDLERS

GRAVITY TAKE-UP

Figure 7 Components of belt conveyor

BELT CLEANER

Fixed carrying idler

Fixed impact idler

Idler spacing

Belt
Width
(inche
s)

Troughed Idler Spacing

Return
Idler

Weigh of Material Handled (lbs/cu ft)

30

50

75

100

150

200

18

5.5

5.0

5.0

5.0

4.5

4.5

10.0

24

5.0

4.5

4.5

4.0

4.0

4.0

10.0

30

5.0

4.5

4.5

4.0

4.0

4.0

10.0

36

5.0

4.5

4.0

4.0

3.5

3.5

10.0

42

4.5

4.5

4.0

3.5

3.0

3.0

10.0

48

4.5

4.0

4.0

3.5

3.0

3.0

10.0

54

4.5

4.0

3.5

3.5

3.0

3.0

10.0

60

4.0

4.0

3.5

3.0

3.0

3.0

10.0

72

4.0

3.5

3.5

3.0

2.5

2.5

8.0

84

3.5

3.5

3.0

2.5

2.5

2.0

8.0

96

3.5

3.5

3.0

2.5

2.0

2.0

8.0

Pulley
A conveyor belt system uses different types of pulleys like end pulley, snub pulley,
bend pulley etc. as shown in the Figure 3. The end pulleys are used for driving and
sometimes for making tensioning arrangements. Snub pulleys increase the angle of
wrap thereby increasing the effective tension in the belt. The pulley diameter
depends on the belt width and belt speed.
Pulleys are used for providing the drive to the belt as well as for maintaining the
proper tension to the belt.
Minimum transition distance as shown in Table 4 should be followed while placing
idlers in front of pulleys.
Power is given to the pulleys in a conveyor belt.

There are two types of pulleys 1> head pulley, which is adjusted at top of a inclined
belt
2>tail pulley, which is adjusted at bottom of a belt

Conveyor belts used in coal mines:

Coal occupies a central position in modern human endeavors. Last year over 7000
megatons were mined worldwide. Powerful, yet dirty and dangerous, use of coal is
expanding every year, with 2010 witnessing a production increase of 6.8%. Around
70 countries have recoverable reserves, which some estimates claim will last for
over a hundred years at current production levels. Mining for coal is one of the
world's most dangerous jobs. While deadliest in China, where thousands of miners
die annually, the profession is still hazardous in the West and other regions as well.
Our mining and use of coal accounts for a variety of environmental hazards,
including the production of more CO2 than any other source. Other concerns include
acid rain, groundwater contamination, respiratory issues, and the waste products
which contain heavy metals. But our lives as lived today rely heavily on the
combustible sedimentary rock. Over 40% of the world's electricity is generated by
burning coal, more than from any other source. Chances are that a significant
percentage of the electricity you're using to read this blog was generated by
burning coal. Gathered here are images of coal extraction, transportation, and the
impact on environment and society.
By incorporating a conveyor belt in coal mines, there is a drastically reduction in
man power and time consumption.

Manufacturing of idlers for conveyors belts

Manufacturing of idlers involves different process
There is a company called hi-tec hydraulic engineers at cherlapally phase-5, which
manufacture idlers
Different types of idlers manufactured by this company are:

Carriage idlers

Return idlers

Impact idlers

Guide returns

The processes involving in manufacturing are

CUTTING
In this process M.I (mild steel) pipe of required diameter is selected and it is placed
against the cnc cutting machine, which cuts mild steel pipe with required
dimensions.
Required dimensions are to be included in the programme of the cnc cutting
machine.

Mild steel pipe

cnc cutting machine consists of the circular saw blade , which rotates inside the
machine with the help of a motor
HSS Metal cutting circular saw blades are offered in 4 different quality levels:

HSS-DMo5 for cutting mild steel up to 500 N/mm2.

HSS-DMo5 KX-COATED for cutting mild steel up to 800N/mm2 and for

stainless steel.

HSS-Co Cobalt for cutting stainless steel.

HSS-DMo5 KX-COATED + CHIP BREAKER for cutting mild steel up to

800/N/mm2

Length of the roller should be entered in the cnc cutting machine, then machine
automatically adjust the long pipe after each cutting.

After cutting M.S pipes of different sizes

Similarly shafts are also cutted with required lengths in a cnc cutting machine
Material of shafts is mild steel bright bar.

BORING
Boring is the process of enlarging a hole that has already been drilled (or cast), by
means of a single-point cutting tool (or of a boring head containing several such
tools), for example as in boring a gun barrel or an engine cylinder. Boring is used to
achieve greater accuracy of the diameter of a hole, and can be used to cut a
tapered hole. Boring can be viewed as the internal-diameter counterpart to turning,
which cuts external diameters.
After cutting, boring has to be done so that iron housings at both ends can be
incorporated to the roller.
For any idlers , boring machine can bore upto 9mm,so that housing can be fitted
properly

WELDING

After boring, MIG welding has to be done to the housing cap and to the roller.
MIG welding consumes a mild steel copper coated wire and co2 gas to produce a
permanent joint.
Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert
gas (MIG) welding or metal active gas (MAG) welding, is a welding process in which
an electric arc forms between a consumable wire electrode and the workpiece
metal(s), which heats the workpiece metal(s), causing them to melt, and join.
Along with the wire electrode, a shielding gas feeds through the welding gun, which
shields the process from contaminants in the air. The process can be semiautomatic or automatic. A constant voltage, direct current power source is most
commonly used with GMAW, but constant current systems, as well as alternating
current, can be used. There are four primary methods of metal transfer in GMAW,
called globular, short-circuiting, spray, and pulsed-spray, each of which has distinct
properties and corresponding advantages and limitations.
Originally developed for welding aluminum and other non-ferrous materials in the
1940s, GMAW was soon applied to steels because it provided faster welding time
compared to other welding processes. The cost of inert gas limited its use in steels
until several years later, when the use of semi-inert gases such as carbon dioxide
became common. Further developments during the 1950s and 1960s gave the
process more versatility and as a result, it became a highly used industrial process.
Today, GMAW is the most common industrial welding process, preferred for its
versatility, speed and the relative ease of adapting the process to robotic
automation. Unlike welding processes that do not employ a shielding gas, such as
shielded metal arc welding, it is rarely used outdoors or in other areas of air
volatility. A related process, flux cored arc welding, often does not use a shielding
gas, but instead employs an electrode wire that is hollow and filled with flux.

Milling, turning and sloting

Shaft is moved for milling process, turning process and two slots are made on the
shaft.
Milling is the machining process of using rotary cutters to remove material[1] from a
workpiece advancing (or feeding) in a direction at an angle with the axis of the tool.
[2][3]
It covers a wide variety of different operations and machines, on scales from
small individual parts to large, heavy-duty gang milling operations. It is one of the
most commonly used processes in industry and machine shops today for machining
parts to precise sizes and shapes.

Turning is an engineering machining process in which a cutting tool, typically a nonrotary tool bit, describes a helical toolpath by moving more or less linearly while the
workpiece rotates. The tool's axes of movement may be literally a straight line, or
they may be along some set of curves or angles, but they are essentially linear (in
the nonmathematical sense). Usually the term "turning" is reserved for the
generation of external surfaces by this cutting action, whereas this same essential
cutting action when applied to internal surfaces (that is, holes, of one kind or
another) is called "boring". Thus the phrase "turning and boring" categorizes the
larger family of (essentially similar) processes.
Slotting is a machining process used to cut short, straight features into a work
piece. Slotters can be a dedicated machine or an attachment to a conventional
milling machine. A slotting machine will usually use some sort of form tool to cut
features such as internal keyways, splines and internal gear teeth.
Here capstan and turret lathe is used to perform both turning and slotting, so that
work piece is in stationary position and cutting tool is in rotary position.
This lathe is provided with 3 servo motors and a D.C motor.
Cutting of edges of the shaft are done by cnc milling machine, in milling machine
both work piece and cutting tool rotates at a time so that two cuttings takes place
at a time at each end.
It is also provided with servo motors.

ASSEMBLING
In this process, assembling of roller and shaft takes place by attaching some others
products in between roller and shaft.
Others products include

Nylon cap

Cyr clip

Ball bearing

Labyrinth seal female

Labyrinth seal-male

Cyr clip

Nylon cap

Dust cap

Grease is to be placed in between labyrinth seal female and labyrinth seal male.

PAINTING
In painting first roller is coated with premier and it is allowed to dry for some time.
After the premier is dried it is coated with final coating with a paint of companys
preference.

Carriage idler
Idler after manufacturing is placed in frame for the proper arrangement of belt
conveyor.

Frame for idlers

Carriage idlers

Impact idlers
A special rubber ring is arranged on the roller to sustain the impacts due to sudden
loads.

Impact idlers