BHM FLAT BELT CONVEYOR by nunthiya

VIEWS: 88 PAGES: 16

									Writer                     Date               Doc 29340-
VilSa                      30.12.2008
Checked/date               Approved/date
TasTe/30.12.2008           HuhAr/18.09.2009




               OPERATING INSTRUCTION
                   FLAT BELT CONVEYOR
                           REV 0
                                                                        OPERATING INSTRUCTION
                                                                        Flat belt conveyor

S. Vilponen                                                             30/12/2008                                                                2 (16)

TABLE OF CONTENTS


1     SAFETY PRECAUTIONS RELATED TO USE ....................................................................................... 3
      1.1 Fixed flat belt conveyor safety systems ......................................................................................... 3
           1.1.1     Mechanical safety systems ............................................................................................. 3
           1.1.2     Electric safety systems ................................................................................................... 3
      1.2 Start-up ........................................................................................................................................... 4
      1.3 Operation supervision .................................................................................................................... 5
      1.4 Stopping the flat belt conveyor ....................................................................................................... 5
      1.5 Flat belt conveyor emergency stop ................................................................................................ 6
      1.6 Working near the flat belt conveyor................................................................................................ 7
2     FLAT BELT CONVEYOR ........................................................................................................................ 8
      2.1 Flat belt conveyor structure ............................................................................................................ 8
      2.2 Purpose of a flat belt conveyor....................................................................................................... 9
3     INSPECTIONS BEFORE A FLAT BELT CONVEYOR START-UP ......................................................10
      3.1 Motor ............................................................................................................................................10
      3.2 Gear .............................................................................................................................................10
      3.3 Bearings .......................................................................................................................................10
      3.4 Attachment of the actuator and torque support............................................................................11
      3.5 Shields ..........................................................................................................................................11
      3.6 Foreign objects .............................................................................................................................11
      3.7 Safety equipment .........................................................................................................................11
4     FLAT BELT CONVEYOR OPERATION ................................................................................................12
      4.1 Test operation procedure .............................................................................................................12
      4.2 Operating procedure ....................................................................................................................12
           4.2.1     Automatic operation ......................................................................................................13
           4.2.2     Manual operation ..........................................................................................................13
      4.3 Inspections related to operation ...................................................................................................13
      4.4 Preventing clogs ...........................................................................................................................13
5     DISTURBANCES OCCURRING IN A FLAT BELT CONVEYOR .........................................................14
      5.1 Automation/control system disturbances .....................................................................................14
      5.2 Triggering of overload protection .................................................................................................14
      5.3 Actuator damage ..........................................................................................................................15
      5.4 Safety equipment damage ...........................................................................................................15
      5.5 Bearing damage ...........................................................................................................................15
      5.6 Tail drum wiper malfunction .........................................................................................................15
      5.7 Belt damage .................................................................................................................................16
      5.8 Oversize detector damage ...........................................................................................................16
      5.9 Disturbances due to exceptional circumstances ..........................................................................16




BMH Technology Oy                   Tel. +358 20 486 6800                         BMH Technology AB                        Tel. +46 171 24 370
Kaivopuistontie 31                  Fax. +358 20 486 6990                         Kaptensgatan 23                          Fax. +46 171 24 371
BOX 32                              e-mail: service@bmh.fi                        BOX 12                                   e-mail: service@bmh.se
FI-26101 RAUMA                      http://www.bmh.fi/                            SE-749 35 ENKÖPING                       http://www.bmh.se/
FINLAND                                                                           SWEDEN
                                             OPERATING INSTRUCTION
                                             Flat belt conveyor

S. Vilponen                                  30/12/2008                                3 (16)

1       SAFETY PRECAUTIONS RELATED TO USE

Any persons working with the flat belt conveyor must familiarise themselves with the
essential parts of the operating and maintenance instructions that are supplied with the flat
belt conveyor.


                   The flat belt conveyor must only be operated and serviced by those
                   individuals who have been initiated in flat belt conveyor operation.


                   The flat belt conveyor has been designed and manufactured
                   following the safety regulations and instructions. However, special
                   care must be taken when using the conveyor and when moving in the
                   passage and maintenance platforms, as hazardous situations may
                   occur despite good protection.

In addition to what has been stated in the operating and maintenance instructions, all of
the appropriate regulations and instructions as well as local occupational safety legislation
must be followed when operating and servicing the equipment. In addition to these general
safety regulations for BMH Technology Oy equipment, the employer must bring the
following instructions and regulations to the attention of their employees and, where
necessary, attach them to this folder:

-       All local and company-internal occupational safety regulations and standards
-       All standards and guide magazines concerning the applicable equipment,
        occupational safety, and general instructions and principles.


1.1       Fixed flat belt conveyor safety systems

1.1.1     Mechanical safety systems

The flat belt conveyor typically has the following fixed mechanical safety systems:

-       Shields for the speed limit switch


1.1.2     Electric safety systems

The flat belt conveyor typically has the following fixed electric safety systems:
                                             OPERATING INSTRUCTION
                                             Flat belt conveyor

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-     Lockable safety switch for the actuator
-     Regional emergency/stop button
-     Control system electric locks and protections
-     Speed limit switch (Figure 1)
-     Oversize detector




                                  Figure 1. Speed limit switch.

                 The flat belt conveyor must absolutely not be used if the safety
                 systems do not operate properly or any deficiencies are discovered
                 in them!


1.2   Start-up

Normal start-up is usually carried out by remote control, and when working in the conveyor
space, it must be noted that the start-up may not always be preceded, for one reason or
another, by a start-up warning.

If the flat belt conveyor is in manual control, danger-free start-up must be ensured by
having the conveyor in plain sight or ensuring a lack of danger otherwise.

The conveyor system commissioning requires that all the safety-related shields and safety
devices are attached to the roll and that the electric safety systems are operational. The
person responsible for conveyor system operation is in charge.
                                           OPERATING INSTRUCTION
                                           Flat belt conveyor

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                 Beware, the system has remote actuation



1.3     Operation supervision

Although the conveyor system is usually centrally controlled from the plant central control
room, the occurrence of disturbances increasing safety risks must also be prevented.

The functionality of the conveyor must be regularly inspected. The functionality of the
safety and protective equipment must especially be inspected.

Typical inspection locations during operation include:

-     Preventing clogs (crossings)
-     Shields kept in their places
-     Service spaces are clear and clean
-     Free passage to emergency stops
-     Alarm and warning equipment functional


                 Any deficiencies and abnormalities must immediately be brought to
                 the attention of the person responsible for operating the system.



1.4     Stopping the flat belt conveyor

The conveyor line must be stopped so that it does not cause clogs in the feed and
discharge ends. Stopping, just as in the start-up, must take into account the operation of
the automatic conveyor control system.

The stop and operation periods vary greatly by location, and from a safety point of view, it
must be remembered that the unnecessary stopping of the conveyor introduces the
possibility of a disturbance. A continuously operating system is safer.

If possible, the flat belt conveyor should be run empty before stopping.

Other special limitations or requirements may also be related to the conveyor. These must
be studied from the conveyor operating and maintenance instructions.
                                             OPERATING INSTRUCTION
                                             Flat belt conveyor

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1.5       Flat belt conveyor emergency stop

                 The emergency stop switches are only used to stop the system
                 during emergencies or hazardous situations. The use of emergency
                 stop switches for stopping the system in other cases, e.g. at the end
                 of a shift, is forbidden.

The flat belt conveyor is a closed construction and as such, it is well protected against
accidents, which is why an emergency stop is carried out by using a local emergency stop
switch.

Easy access to the emergency stop switches of the conveyors and other equipment must
be constantly maintained.

The emergency stop switch locks itself in the open position. Restoring the switch does not
restart the conveyor, but instead, start-up is only possible according to the normal locking
sequence and after the emergency stop relay has been acknowledged from the
pushbutton and the cause of the stop/fault has been defined and corrected. The
emergency stop does not separate the circuits that are relevant to safety, such as lighting
or brakes.

The person responsible for operating the conveyor system must be informed of each
emergency stop and its respective reasons.



                 Keep service platforms and pathways clear and clean.




                 Ensure easy access to the emergency stop switches.



                 No attempts must be made to restart the flat belt conveyor, after a
                 stop is caused by a disturbance, before the cause of the stop has
                 been analysed and removed/repaired.
                                          OPERATING INSTRUCTION
                                          Flat belt conveyor

S. Vilponen                               30/12/2008                              7 (16)

1.6     Working near the flat belt conveyor

The case-like closed structure of the flat belt conveyor makes the conveyor type safe, if
the instructions are followed during service and repair. The conveyor itself has no moving
parts outside the casing.

Cleaning must not cause hazardous situations. During cleaning, safety is increased by
using good and suitable tools as well as having clear and clean service and passageways.

Dedicated service platforms and stairs must be used for service and cleaning. The
conveyors may only be crossed when using purpose-built crossing platforms with rails.

If e.g. cleaning residue is loaded onto the conveyor during operation, the limits and
dangers of loading must be well communicated (e.g. danger of dust explosion).


                The flat belt conveyor must only be operated and serviced by those
                individuals who have been initiated in flat belt conveyor operation.




                            Use protective glasses and a hard hat!




                Use hearing protection when working at sites with noise in excess of
                85 dB(A)!
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                                              Flat belt conveyor

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2     FLAT BELT CONVEYOR

2.1       Flat belt conveyor structure

The actual structure of the flat belt conveyor can be found in the documents and blueprints
that are supplied with the equipment. The operating and maintenance instructions show a
general flat belt conveyor structure.

            i                  h     k           f


                                                                       b




      c     j     g            d                                   a

                                   Figure 2. Flat belt conveyor.

Flat belt conveyor parts (Figures 2 and 3):

a.    Actuator
      -     The manufacturer operating and maintenance instructions for the motor and
            gear are supplied with these equipment-specific instructions.
b.    Drive drum
      -     See the separate lubrication procedure for the bearing lubrication points.
c.    Tail drum
      -     See the separate lubrication procedure for the bearing lubrication points.
d.    Conveyor belt
e.    Guide plate
f.    Drum wiper
g.    Inspection hatch
h.    Cover
i.    Speed limit switch
j.    Oversize detector
                                              OPERATING INSTRUCTION
                                              Flat belt conveyor

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                  The original structure of the flat belt conveyor must never be altered
                  without permission from the manufacturer.




                    Figure 3. Flat belt conveyor installed in a conveyor system.


2.2        Purpose of a flat belt conveyor

Transferring large amounts of material quickly, reliably, and cost-efficiently from point A to
point B.


                  The flat belt conveyor must only be used for the purpose and
                  material that it is originally intended.


                  The flat belt conveyor must not be operated at a higher load than it
                  was designed for. The structures must not be loaded more than they
                  have been designed for.
                                            OPERATING INSTRUCTION
                                            Flat belt conveyor

S. Vilponen                                 30/12/2008                                10 (16)

3     INSPECTIONS BEFORE A FLAT BELT CONVEYOR START-UP

The following lists the items to be inspected before a flat belt conveyor start-up. Any
deficiencies that are discovered must be removed before the flat belt conveyor can be
started. Neglecting these procedures may damage the flat belt conveyor and/or cause
danger to the operating personnel. The warranty of the flat belt conveyor is only valid if the
service, inspection, and operation procedures in the operating instruction are followed.


                Before inspecting, the flat belt conveyor must be disconnected from
                the circuit with the safety switches and the switches locked in the 0
                position.


                When carrying out inspections or service or removing clogs etc., it is
                recommended that at least 2 people at a time are present.



                Always verify that no persons are in the danger area before starting
                the flat belt conveyor.


The inspections must always be carried out if e.g. the actuator has been removed,
loosened, or replaced during service and repair.


3.1     Motor

The direction of the rotation is to be checked with a short start-up.


3.2     Gear

Verify that the gear is filled with oil. The correct amount and quality of the oil must be
checked from the manufacturer’s oil recommendations.


3.3     Bearings

Check that all the bearings are lubricated. If necessary, the bearings are lubricated
according to the lubrication procedure.
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                                            Flat belt conveyor

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3.4   Attachment of the actuator and torque support

Check that the attachments are proper and the screw attachments and stopper screws are
appropriately tightened.


3.5     Shields

Check that all the shields are installed.


3.6     Foreign objects

Check that all the service and repair tools etc. have been removed from inside the
equipment and the immediate vicinity.


3.7     Safety equipment

Check that all the safety equipment is connected and functional.
                                            OPERATING INSTRUCTION
                                            Flat belt conveyor

S. Vilponen                                 30/12/2008                                12 (16)

4     FLAT BELT CONVEYOR OPERATION



                Study the safety instructions before operating.



4.1     Test operation procedure

It is important for the flat belt conveyor to be tested without material prior to starting the
actual process use. The test run must also be carried out if service and repair has been
carried out on the flat belt conveyor.

Start the equipment and monitor its functionality for approx. 5 minutes. Ensure that no
abnormal behaviour (e.g. abnormal noises) occurs during operating and that the belt is
properly in place.

After this, if no abnormalities appear, continue the test operation by running the flat belt
conveyor uninterruptedly for 2 to 5 hours. During the test operation, pay attention to the
following issues:

-     Belt behaviour (a new belt will travel laterally during the first weeks before the belt
      properly adapts)
-     No abnormal heating of the motor, gear, or bearings
-     No abnormal sounds from the conveyor
-     No abnormal vibration in the conveyor
-     No oil leaks

After the test operation, verify that the screw connections are tight and the oversize
detector is properly adjusted.


4.2     Operating procedure

Once the flat belt conveyor has been test operated and approved for commissioning, the
material processing may begin. The flat belt conveyor is equipped with a local control
centre that is used to select the desired mode of operation. The choices are automatic or
manual operation. The flat belt conveyor motor safety switches and emergency stop
switches are installed in the immediate vicinity of the local control centre.
                                            OPERATING INSTRUCTION
                                            Flat belt conveyor

S. Vilponen                                 30/12/2008                                 13 (16)

4.2.1   Automatic operation

When the flat belt conveyor is introduced into the material handling process, the local
control centre is set to “automatic operation”, in turn causing the flat belt conveyor to start
as a part of a larger equipment group according to the locking sequence. It is worth
remembering that in automatic operation mode the flat belt conveyor can be started from
the control room.


4.2.2   Manual operation

When choosing “manual operation” from the local control centre, each actuator may be
operated separately or together. This operation mode is recommended for test operation
during service and/or repair procedures.


4.3     Inspections related to operation

During flat belt conveyor operation, the functionality of the flat belt conveyor must be
monitored for the problems that are listed under 4.1 (test operation procedure). Attention
should also be paid to the steady passage of the material in the centre of the belt.

The inspections that are listed in the maintenance instruction need to be carried out while
the flat belt conveyor is not operational. In case of disturbances, the flat belt conveyor is to
be stopped and the necessary procedures are to be taken in order to remove the
disturbance.


4.4     Preventing clogs

Clogs may cause serious accidents, such as fires, so it is important to acknowledge the
danger and try to prevent dangerous circumstances.

Clogs are usually formed in the load, discharge, and crossing locations. They should be
regularly monitored. If e.g. cave-in, or other abnormalities that might cause a clog, is
noticed in the funnel, the conveyor must be stopped and the disturbance removed.


                When removing clogs, the conveyor must be stopped and the
                accidental or load-induced start-up prevented.
                                            OPERATING INSTRUCTION
                                            Flat belt conveyor

S. Vilponen                                 30/12/2008                            14 (16)

5     DISTURBANCES OCCURRING IN A FLAT BELT CONVEYOR

5.1      Automation/control system disturbances

Typical automation/control system disturbances include:

-     Missing lock, sensor, and/or status information affecting the automation system
      software’s functionality
-     Component damage (sensor operation disturbances)
-     Temporary errors
-     Erroneous settings

The disturbances due to automation are often symptomless and, therefore, difficult to
foresee. The weaknesses and deficiencies of the system must be discovered by
monitoring and disturbance logging. Steps must then be taken to eliminate them.

When changing the guidance system or software, the safety aspects must be taken into
account and the complete storing of updates in the system ensured. After a control system
change or sensor replacement, the correct functionality of the device must be locally
ensured.

The sensors must be checked for their attachment and distance from the sensor surfaces.


5.2      Triggering of overload protection

The triggering of the overload protection will cause the flat belt conveyor to stop. The
typical reasons include:

-     A long piece wedged in the feed or discharge hole
-     Electrical fault
-     Overload

The procedure in this case, as well as for other disturbances, is as follows:

-     Lock the safety switch in the 0 position
-     Analyse and repair the cause of the stop
-     Replace any damaged parts
-     Start the equipment/line normally
                                              OPERATING INSTRUCTION
                                              Flat belt conveyor

S. Vilponen                                   30/12/2008                        15 (16)

5.3     Actuator damage

The typical operational disturbances include:

-     Motor damage
-     Bearing damage
-     Breaking of clutch pieces
-     Gear wheel damage
-     Seal damage
-     Low oil surface

The aim must be to prevent actuator damage through condition monitoring, since the
damage may lead to a longer outage. The flat belt conveyor must be separated from the
process for repair work.

When repairing the actuator, as well as other components, care must be taken to use
safety-certified equipment for lifting, transferring, and re-installation.


5.4     Safety equipment damage


                 All safety equipment repairs must be carried out immediately and the
                 line must be stopped. Occupational safety legislation always requires
                 the safety equipment to be operational under all conditions.


5.5     Bearing damage

Bearing damage is usually caused by insufficient lubrication, wear, or dirt entering the
bearing housing. The equipment must be stopped and separated from the system for
bearing damage repair.


5.6     Tail drum wiper malfunction

A worn tail drum wiper may cause the drum to become dirty and affect the belt movement.
Operation can usually be resumed up until the next service, if the conveyor is otherwise
working.

The conveyor must absolutely be separated from the process for the replacement!
                                             OPERATING INSTRUCTION
                                             Flat belt conveyor

S. Vilponen                                  30/12/2008                            16 (16)

5.7     Belt damage

The most common causes for belt damage are temporary overload, a sharp object
wedged between the belt and guide plate, or the belt grinding against the frame.

When the belt grinds against the conveyor frame or some transported material is wedged
or accumulates between the belt and guide plate, a fire risk is imminent.

Belt damage usually requires the immediate stopping and process separation of the
conveyor.


5.8     Oversize detector damage

Damage to and non-functionality of the oversize detector may cause an oversized object
to become wedged between the drive rum and magnet. This may lead to conveyor belt
stopping, belt damage, and motor overheating.

This requires immediate stopping and process separation of the conveyor.


5.9     Disturbances due to exceptional circumstances

Disturbances due to exceptional circumstances include:

-     Material freezing to the surface of the drum or between the belt
-     The belt freezing to the slide rails

Thawing/heating can be carried out by using e.g. an external fan. At the same time, verify
the wiper function, slide rail condition, and belt plough functionality (can drop material
between the belt).

								
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