Belt Conveyors: Learner Guide

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 2/10/2017 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 2/10/2017 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 conveyors 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 conveyors 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
conveyors 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 Belts 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 drives 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 Conveyors 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 Conveyors 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 drives 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 Conveyors 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 Conveyors 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
inverted V decking
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
inverted V decking
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
inverted V decking
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
inverted V decking
Improve maintenance
Belt slips on starting Insufficient traction between belt and pulley Increase wrap with snub pulleys
Lag drive pulley
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
inverted V decking
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 new
loose splice.
Pulleys too small Use larger diameter pulleys
Excessive tension Recalculate and adjust tension

Material between belt and pulley Use skirtboards properly
Remove accumulation
Improve maintenance
with transfer point
Vulcanized splice Excessive tension Recalculate and adjust tension
separation Use vulcanized splice within recommended limits
with transfer point
Remove accumulation
Improve maintenance
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
inverted V decking
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
Improve maintenance
Insufficient traction between belt and pulley Increase wrap with snub pulleys

Lag drive pulley
Remove accumulation
Improve maintenance
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
inverted V decking


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

Improve maintenance
inverted V decking
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
inverted V decking
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
Remove accumulation
Improve maintenance


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
Dont 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 Conveyors: Learner Guide

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Belt Conveyors: Learner Guide

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Field Operator Certification

Self-Directed/In-Class Learning Objectives

On-the-job Learning Objectives

Field Operator Certification 2/10/2017 1

2 2/10/2017 Field Operator Certification

Field Operator Certification 2/10/2017 3

Belt Conveyors Learning Content

4 2/10/2017 Field Operator Certification

Field Operator Certification 2/10/2017 5

Top and Bottom Covers

6 2/10/2017 Field Operator Certification

Selection Criteria for Covers and Carcass

Field Operator Certification 2/10/2017 7

8 2/10/2017 Field Operator Certification

Field Operator Certification 2/10/2017 9

10 2/10/2017 Field Operator Certification

Negative Crown Pulley

Field Operator Certification 2/10/2017 11

Curved or Crown Pulley

12 2/10/2017 Field Operator Certification

Field Operator Certification 2/10/2017 13

14 2/10/2017 Field Operator Certification

T ROUGHING AND R ETURN I DLER

Impact Troughing Idler

Field Operator Certification 2/10/2017 15

Belt Training Idlers, Carrying

Helps to maintain Belt alignment

16 2/10/2017 Field Operator Certification

Flat Return Idlers

Self-Cleaning Return Idler

Field Operator Certification 2/10/2017 17

S ELF C LEANING R ETURN I DLER

18 2/10/2017 Field Operator Certification

Field Operator Certification 2/10/2017 19

Feeding receiving conveyor in its direction of travel

To shape and settle the load after transfer

20 2/10/2017 Field Operator Certification

S KIRTBOARD AND S EAL

Field Operator Certification 2/10/2017 21

22 2/10/2017 Field Operator Certification

Field Operator Certification 2/10/2017 23

24 2/10/2017 Field Operator Certification

Automatic Belt Protection

Types of Belt Protection

Automatic Belt Protection Electrical

Field Operator Certification 2/10/2017 25

Side Travel / Drift Switch

Zero Speed / Motion Switch

Z ERO S PEED / M OTION S WITCH

26 2/10/2017 Field Operator Certification

Automatic Belt Protection Mechanical

Field Operator Certification 2/10/2017 27

Deck Plates and Return Belt Scrapers

28 2/10/2017 Field Operator Certification

R ETURN B ELT S CRAPERS

Belt Cleaner location

Belt Turnover Scheme

To eliminate problems caused by dirty Belts in

Field Operator Certification 2/10/2017 29

Backstops and Holdbacks

30 2/10/2017 Field Operator Certification

R ATCHET & P AWL B ACKSTOP