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CONVEYOR 101JEFF JURASITS VICE PRESIDENT OF BUSINESS DEVELOPMENT & TRAINING

Jeff Jurasits

Jeff Jurasits is ASGCO’s Vice president of Business Development & Training with 34 years of experience working in various capacities. Since joining ASGCO Jeff has held several positions over the years, including field service crew leader for five years, performing numerous field installations and maintenance of many ASGCO products, followed by 15 years as Operation Manager of ASGCO’s Manufactured Products Division where he continues to be involved in the overall daily operations.

In his current position as VP of Business Development & Training ,for the past 16 years, Jeff has travelled globally attending industry events and conferences, providing feedback and information on market and creative trends, while also

performing conveyor site inspections and ASGCO Conveyor Training (ACT™) sessions created to provide the highest quality training to solve conveyor problems. His work has included using his knowledge of the market and competitors to identify and develop unique selling propositions and differentiators, while working with the technical and other internal colleagues to meet customer’s needs.

Speaker Biography

Typical Conveyor Layout

Belt

Troughing Idler

Troughing Idler

Troughing Idler

Troughing Idler

Troughing Training Idler

Return-Side Training IdlerReturn Idler

Gravity Take-Up Pulley

Return Idler

Return-Side Training Idler

Return Idler

V-Plow

Slider Bed with Center Rolls

Tail Pulley(Wing Pulley)

Tail Box

Loading Spoon

Load Chute

Impact Bed

Skirting Dust Seal

Dust Curtain

Snub Pulley

Secondary Cleaner

Dribble Chute

Primary Cleaner Deflector

High TensionBend Pulley

Low TensionBend Pulley

CONVEYOR SAFETY

Lock out/Tag out and Hazard Avoidance

Since 2005, 28 metal and nonmetal miners have died in electrical and machinery accidents in which power was not disconnected and locked out before work was begun on power circuits or equipment.

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Lock out/Tag out and Hazard Avoidance

(LOTO) ensure that all energy sources are isolated before electrical or mechanical work is performed. LOTO protects miners from the dangers of uncontrolled, unplanned release of energy (movement of equipment or materials; electrical, hydraulic or pneumatic), or toxic materials.

1. Stop the equipment, disconnect power and lock the switch.

2. Attach your identifying tag.

3. With miners in the clear, try to start the equipment or test for power.

LOTOTO - IT’S NOT LOCKED OUT UNTIL YOU’VE TRIED IT OUT!

Conveyor Safety2017 Comparison of Year-to-Date and Total Fatalities for M/NM & Coal

Fata

litie

sMSHA Safety Guidelines

• This guide is provided to assist the mining community with designing, installing, and maintaining equipment guards to ensure that miners are not exposed to hazardous moving machine parts.

• Contact with machine parts may result in serious accidents or death.

• Proper equipment guarding is essential to reduce the risk of injury.

MSHA’s Guide to Equipment Guarding

Moving Machine Parts

• Moving machine parts shall be guarded to protect persons from contacting gears, sprockets, chains, drive, head, tail and take-up pulleys, flywheels, couplings, shafts, fan blades and similar moving parts that can cause injury.

• Guards shall not be required where the exposed moving parts are at least seven feet away from walking or working surfaces.

Belt Conveyor Components to Guard

• Head & tail pulleys

• Take-up & bend pulleys

• Return rollers (Subject to miner’s exposure)

• Drive & power transmission components

MSHA’s Guide to Equipment Guarding

• Return roller is 6 feet above a walkway, and the area is 50 feet above the ground, guards are needed

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• Above 7ft from the ground or walking and working surfaces.

MSHA’s Guide to Equipment Guarding

Guards are meant to protect persons from:

• “Inadvertent, careless, or accidental contact”

• “Deliberate or purposeful work-related actions…” (inspection, testing, cleaning, maintenance, troubleshooting, lubrication, adjustment, servicing, etc…)

• Standard does not address deliberate or purposeful, NON-work-related actions

MSHA’s Guide to Equipment Guarding

Uprights or Obstructions which could trap

Guard Mounting DistancesThe Safety Gauge was developed to determine guard mounting distances based on the maximum opening sizes in the guarding. The standard ensures that any body part which can fit through the mesh won’t be able to contact the pinch point inside.

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Safety Inspection and Access Doors• Doors should be designed for easy

inspection or maintenance of components inside of the chute or load zone area.

• Safety - inspection screen guard standard on every door for the ability to safely inspect equipment while it is running.

Conveyor Belt Fundamentals

What is a conveyor belt?

• Operates over suitable idlers and pulleys

• An “endless” mechanism

• Often … the single most expensive purchase of any conveyor component

Conveyor BeltHandling of Conveyor Belt Rolls

The correct wat to lift rolls of belting is with a bar passed through the center core, then depending on the width and weight, the roll may be lifted by a fork lift truck or crane. If chains or slings are used on the bar at each side of the roll, a spreader bar should be used to prevent damage to the edges of the belt.

If a spreader bar is not available use off-cuts of belting between the sling and the belt edge to help prevent damage.

Conveyor BeltHandling of Conveyor Belt Rolls

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Conveyor Belt FundamentalsThe “Carcass”…• Provides the STRUCTURAL strength in moving

the belt … receiving /supporting the load

• Is the PRIMARY reinforcement for abuse (impact, etc.)

• Can be a SINGLE ply or SEVERAL plies

• Can be TEXTILE, or STEEL … or, combinations of both

• Dictates the ELONGATION and SPLICING attributes of the belt

BONDING LAYER RUBBER

Conveyor Belt Fundamentals

CARCASS

TOP COVER

CARCASS

TOP COVER RUBBER

The standard of Rubber Conveyor Belt consists of cover rubber, carcass and rubber skim coat. And the reinforced fabric is used for extra protection.

BOTTOM COVER

BOTTOM COVER

Cover SelectionSelecting Rubber Covers

RMA Grade 1Referred as Cut/Gouge Resistant rubber with good abrasion resistance. Minimum rubber tensile strength of 2500 psi and Din greater than 150

RMA Grade 2 Referred as the abrasion and wear resistant rubber. Minimum rubber tensile strength of 2000 psi and a DIN less than 150.

Properly Squared BeltSquaring Ends Using the Center Line Method

Double Intersecting Arc

Splicing of the Conveyor BeltStep splice, Finger splice or Steel cable splice

Splicing of the Conveyor BeltVulcanized Splice

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Splicing of the Conveyor Belt

IDLERS AND PULLEYS

CEMA• Classes: CEMA B, C, D, E, and F • Roll Diameter: 4”- 8” • Belt Widths: 18”- 120”

TYPE CEMA CLASS Roll Diameter Belt Width

Light Duty B 4,5 18” – 48”

Medium Duty C 5,6 18” – 60”

Medium Duty D 5,6 18” – 72”

Heavy Duty E 6, 7 36” – 96”

Heavy Duty F 7, 8 60” – 120”

Idler Application

Idler Types & Specification

TYPES

Flat Return Rolls

Impact Idlers

Live Shaft Idlers

Offset idlers

Rubber Disc Idlers

Self-Aligning Idlers

Troughing Idlers

V-Return

Drum Pulleys

Drum pulleys are manufactured from thick wall pipe or tubing, with a crowned face or flat face.

Types

• Machined

• Standard Duty

• Mine Duty

• Quarry Duty

Additional Options

• Lagged

• Shafting

• Bearing Assemblies

• Take-Up Systems

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Drum Pulleys Wing Pulleys

Wing Pulleys are constructed from extremely heavy materials and are recognized in the industry as the most aggressive CEMA grade stock pulley on the shelf.

Types

• Standard Duty

• Mine Duty

• Quarry Duty

• Quarry Duty AR

Additional Options

• Wing Lagging

• Shafting

• Bearing Assemblies

• Take-Up Systems

Wing Pulleys Typical Problems

When it comes to material handling, the conveyor that the materials are transported on is just as important as the materials themselves. While the primary goal of most conveyor systems is to provide an opportunity to inspect products and transport them throughout your facility, this is not possible without the implementation of a proper handling system.

The 3 Most Common Conveyor Belt Problems Faced By the Material Handling Industry:

1. Mistracking

2. Spillage and Carryback

3. Transfer Design Problems

Conveyor Belt MistrackingAffect of Material Buildup on Pulleys

Conveyor Belt Mistracking

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Conveyor Belt Mistracking

Pulley AdjustmentImproper Pulley Adjustment

Adjustment to the tail pulley can have some effect on belt tracking. Be sure not to under or over tension belt when making tail pulley adjustments for belt tracking.

Bad SpliceChances are if a belt was recently changed and a mistracking problem becomes apparent then the splice could be not square to the belt. The company responsible for the splice should be brought in to correct it.

Defects in Belt Construction

There could be defects in the ply's or cords. The belt could be bowed like a banana. This belt defect is almost impossible to correct with structural adjustments and is more common than you might realize due to the way some low cost belts are manufactured.

Poor Conveyor Belt Tracking

• Edge damage to the conveyor belt

• Cut and or worn return idler brackets

• Hot marks on the sides of the head chute were the belt has been riding

• Spillage in the load zone

• Belt running off at the counter weight and tail pulleys

Conveyor Belt Mistracking

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Training Idlers Spillage and Carryback

FACT:The most expensive material at a plant is the material that has become fugitive through spillage and carry-back

Reduced Operating Efficiency

FACT:Fugitive material is one of the largest contributors to increased maintenance expenses and premature component wear and replacement.

Increase Maintenance CostsIncludes cost of personnel shoveling or vacuuming up the material and returning it to the belt or worse, discarding it as waste.

Most Obvious Added Expense is Cleanup.

Measuring Carry-backBased on a conservative 1% factorA conveyor conveying at 350TPH will carry-back material at a rate of 3.5 TPH. At 8 hours a day 5 days a week that's 140 Tons per week.

Effects of Carry-back on Conveyor Belt Tracking

• Material buildup on conveyor rollers, primarily on the return rollers which contact the dirty carrying side of the conveyor belt, account for an ever changing tracking problem.

• As the buildup changes on the rollers, the conveyor belt will also change to follow the buildup which is a false crown.

• Carry back which is deposited under the conveyors and has to be constantly shoveled and hosed down, requiring extensive labor cost.

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Spillage and Carry-back Costs

Much of the carry-back is deposited on the return components. What is dislodged by the return components is spilled under the conveyor. Tremendous costs are associated with this fugitive material.

• Premature component replacement• Belt mistracking• Belt damage!• Rehandling of material• Cleanup costs• Wasted material

Belt Cleaning

The Focus on Belt Cleaning

• Belt Cleaning is an important component of comprehensive Conveyor Maintenance Contracts.

• Clean Belts are an important cost consideration of the Customer

• Bad and/or Damaged belt cleaners destroy belts

• Belt Cleaners value add to the - Conveyor Belt

Importance of Belt Cleaners• Belt cleaners are an essential part of any conveyor system. Belt cleaners

help remove product carry back and prevent it from falling off at various points along the return side of the belt causing various housekeeping and maintenance problems. Carry back can lead to:

• Excessive buildup and wear on belt idlers and pulleys

• Conveyor belt misalignment due to the artificial crown created by the carry- back

• Accumulation of material falling off idlers and structure to the ground or on buildings, vehicles or even people

• Negative and unsafe work environment

Variables for Selecting the Proper Belt Cleaner

• Vulcanized or mechanical laced belt

• Diameter of the head pulley

• Material being conveyed

• Belt speed

• Location available for proper installation

• Location of/if any dribble chute

Primary Cleaner Secondary Cleaner

Positive Rake Angle

ZeroRake Angle

NegativeRake Angle

Secondary Cleaner

Types Belt Cleaners

Primary Belt Cleaners keep conveyor systems cleaner, safer and more productive by eliminating carry-back that can cause housekeeping and maintenance issues.

Types Belt CleanersSecondary Belt Cleaners are installed after the point where the belt leaves the head (discharge) pulley and or anywhere on the return side of the belt where it can be cleaned and maintained effectively.

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Belt Cleaners Location Importance of Belt Cleaners

Importance of Belt Cleaners Seized Rollers

Transfer Point Areas

• Entry Chute

• Load Zone

• Chute walls and edge sealing

• Exit Sealing

• Box design for dust control

The transfer point areas controls the dust by keeping the column of material together so that air does not become entrapped in the material flow, then forced back out of the flow carrying dust when the material is loaded on the receiving belt.

Transfer Point Areas

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Transfer Point Areas

Transfer Point Spillage Transfer Point Spillage

Transfer Point SpillageOff-Center Loading Problems

Ideal Transfer PointShould be designed to load material on the belt:

• Centrally with minimum impact

• At a uniform rate

• At the same speed and direction belt is

AND provide adequate space andsystems for:

• Entry and edge sealing

• Carry-back removal

• Dust management

• Inspection and service activities

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A popular way is to confine the impact forces to the material itself. "Material to material" Rock boxes are a good method. They are a "ledge" that is installed partially across a chute to create a "cascade transfer" of material. This will dissipate loading forces minimizing impact. These are very important in very long transfers.

Minimizing ImpactIdler Transition Distances

Transition idlers are used to support the belt between a terminal pulley and the first standard idler.

Idler Junction Fatigue…

“Transition” distances“Short” transitions can lead to:

• Conveyor belt carcass and overall belt failure

• Conveyor belt splice failures

• Idler failures

• high edge overstress

• Compression at idler junction regions

• Rapid belt & splice failures

Belt Support

The belts travel line must be kept consistently steady and straight (flat as possible) Similar to a table top. This is the best way to maintain a constant material seal by the chute walls and liner and dust seal by the skirting

Belt Support Devices

• Impact idlers

• Impact beds

• Slider beds

• Edge support beds (slide and roll)

• Roller cassettes

Belt Support Standard Design Criteria

Skirtboard width - 35degree

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Chute Walls and Edge Sealing

• Once the proper foundation has been selected the chute walls and edge sealing systems are crucial.

• Even with the best belt support system a poorly designed chute wall and dust sealing system can result in spillage and vice versa.

• They go hand in hand in the prevention of spillage!

Chute Wall Design

Side Skirt Wall Design

It is imperative that the chute wall, as it is the proper component to resist the forces of the material loading, be positioned correctly above the belt.

The entry edge of the wall should be closer to the belt than the exit edge. This will provide relief for any material that gets between the wall and the belt.

Chute Wall Design

Important point: The chute wall and its lining, if necessary, are the first line of defense against the forces of material during loading. The Skirting is flexible and is to be used as a dust seal ONLY! Not a defense against the forces of the material during loading.

This technique combined with a

properly designed belt support will

provide the best solution to spillage

problems.

FACT

Chute Lining

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Always design for the "worse case".

It is important to consider the material's various conditions when designing these devices. You do not want to create opportunities for chute pluggages. Dry material and wet material act dramatically different.

INSPECTION AND MAINTENANCE PROGRAM

Conveyor Maintenance

• Includes proper not only care of the belt itself but includes care and maintenance of the frame and conveyor hardware.

• More importantly it includes eliminating the risk of injury and death to personnel operating in the vicinity of the “live” conveyor.

Belt Conveyor Inspection

• Good Housekeeping - Critical

• Structural Damage.

• Missing or Loose or Damaged Rollers.

• Belt Damage / Splice Damage.

• Belt Mistracking.

Conveyors 101

Jeff JurasitsVice President

Business Development and Training

Thank You!

Questions?

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