Mechanical Instructions for Assembly, Operating & Maintenance Pipe conveyors (FLSmidth)
2 thg 11, 2023 | 23:51

Mechanical Instructions for Assembly, Operating & Maintenance Pipe conveyors (FLSmidth)



Tài liệu hướng dẫn lắp ráp, vận hành và bảo trì băng tải ống (FLSmidth)


The present instructions are concerned with the situations which, according to the experience of FLSmidth, are the most likely to occur during manufacture, installation, operation and maintenance of the equipment. An exhaustive enumeration of all conceivable situations, which may occur, cannot be provided.

Consequently, if a situation should arise, the occurrence of which is not foreseen in the instructions, and which the operator is/or feels unable to handle, it is recommended that FLSmidth is contacted without undue delay for advice on appropriate action.

All references to relevant safety standards are given at the EC declaration of conformity if required.

Reference by seller to any international or national standard does not incur an obligation on seller to provide any recipient, reader or user of the documentation with samples or copies of the said standard(s).

Hence, any recipient, reader or user of the documentation is expected – at his own cost – to obtain necessary knowledge of the contents of any of the standards referred to.


CONTENTS:


1 Foreword................................................................................10

1.1 Safety...................................................................................... 10

1.2 Definitions and abbreviations ...................................................... 10

1.3 Safety legend ........................................................................... 11

2 Equipment according to material flow / Flow Sheet...............12

3 Introduction...........................................................................13

4 Technical Parameters.............................................................14

4.1 Environmental conditions ........................................................... 14

4.2 Electrical parameters ................................................................. 15

4.3 Material characteristics .............................................................. 15

4.4 Plant data ................................................................................ 15

4.5 Scope of Supply for Pipe Conveyor .............................................. 16

5 Instructions for Transport......................................................19

5.1 Scope ...................................................................................... 19

5.2 Definitions................................................................................ 19

5.3 General.................................................................................... 19

5.4 Environmental considerations ..................................................... 20

5.5 Instructions for Equipment Transport........................................... 20

6 Instructions for the Storage of the Delivery ...........................22

6.1 General remarks ....................................................................... 22

6.2 Storage and preservation requirements for mechanical equipment .. 22

6.2.1 Preservation on Storage............................................................. 22

6.2.2 Preservation measures............................................................... 23

6.3 Storage and preservation requirements for switch cabinets and other

electrical equipment .................................................................. 25

7 Description of Equipment .......................................................26

7.1 Scope ...................................................................................... 26

7.2 Design ..................................................................................... 26

7.3 Normative references ................................................................ 26

7.4 General description of the process flow ........................................ 27

7.5 Pipe conveyors.......................................................................... 28

7.6 Pipe conveyor´s principle ........................................................... 29

22135_B1_0_Pipe conveyor_EN_2

Page 4 of 246 Original version

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not

be duplicated, disclosed or utilized without written consent from FLSmidth.

7.7 Pipe Conveyor components......................................................... 31

7.8 Drive station............................................................................. 32

7.9 Drive units ............................................................................... 33

7.10 Pulleys ..................................................................................... 34

7.11 Rubber belt .............................................................................. 35

7.12 Belt scraper.............................................................................. 36

7.13 Idler stations including belt forming idlers .................................... 38

7.13.1 Adjustable idler stations ............................................................. 39

7.13.2 Panels with 12 carrying idlers ..................................................... 40

7.13.3 Belt forming idlers ..................................................................... 41

7.13.4 Safety panels............................................................................ 42

7.13.5 Return idler stations .................................................................. 43

7.13.6 Return guiding wheel ................................................................. 43

7.14 Return station........................................................................... 44

7.15 Vertical gravity take-up.............................................................. 45

7.16 Steel construction ..................................................................... 46

7.16.1 Standard belt frames ................................................................. 46

7.16.2 Walkway bottom covering .......................................................... 46

7.16.3 Support, trestle......................................................................... 46

7.16.4 Standard belt frames at feeding and discharging area.................... 47

7.16.5 Material guidance ...................................................................... 47

7.16.6 Discharge chute ........................................................................ 48

7.16.7 Dust sealing equipment.............................................................. 48

7.17 Electrical components ................................................................ 49

7.17.1 Emergency pull cord switch ........................................................ 50

7.17.2 Belt misalignment switch............................................................ 51

7.17.3 Speed Monitoring ...................................................................... 52

7.17.4 Clogged chute sensor ................................................................ 53

7.17.5 Take-up limit switch and sensor .................................................. 54

7.17.6 Over filling switch...................................................................... 55

7.17.7 Twist switch ............................................................................. 55

7.17.8 Belt rip detection....................................................................... 56

7.17.9 Safety panel switch ................................................................... 57

7.18 Description of attached equipments with pipe conveyor ................. 57

8 Scope of works by the construction company ........................58

8.1 Responsibility of the construction company................................... 58

8.2 Quality of work ......................................................................... 60

8.2.1 Scope and documents................................................................ 60

8.2.2 General quality requirements...................................................... 60

8.3 Welding ................................................................................... 60

8.4 Surface treatment inspection ...................................................... 61

8.5 Machinery installations............................................................... 61

22135_B1_0_Pipe conveyor_EN_2

Page 5 of 246 Original version

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not

be duplicated, disclosed or utilized without written consent from FLSmidth.

8.6 Fastening of bolts...................................................................... 61

8.7 Project plan .............................................................................. 62

8.7.1 General.................................................................................... 62

8.7.2 Project plan .............................................................................. 62

8.7.3 Follow-up of the project plan ...................................................... 63

8.7.4 Mounting works ........................................................................ 63

8.7.5 Common requirements mounting alternatives ............................... 64

8.8 Components to be delivered by FLSmidth..................................... 64

8.8.1 Design ..................................................................................... 64

8.8.2 Components and structures ........................................................ 64

8.8.3 Arrival of components and structures........................................... 64

8.9 Preassembly works.................................................................... 65

8.10 Mounting works ........................................................................ 65

8.10.1 Mounting equipment.................................................................. 65

8.10.2 Mounting works ........................................................................ 66

8.11 Testing .................................................................................... 66

8.11.1 Supervision by FLSmidth............................................................ 66

9 assembly and disassembly Instructions .................................67

9.1 Instructions for the installation and mechanical completion ............ 67

9.1.1 General Safety Instructions ........................................................ 67

9.1.2 Using the machine documentation............................................... 70

9.2 Introduction ............................................................................. 71

9.3 Preparatory work ...................................................................... 73

9.3.1 Important mounting equipment and tools..................................... 74

9.3.2 Drawings and documents ........................................................... 74

9.3.3 Reference axes and levels .......................................................... 75

9.3.4 Tightening torque and tensile force.............................................. 76

9.4 Sequence of the mounting of the conveyor................................... 78

9.4.1 Pre-assembly............................................................................ 78

9.4.2 Materialization of the conveyor centreline..................................... 83

9.4.3 Installing the frame of the drive pulley......................................... 83

9.4.4 Installing the substructure.......................................................... 83

9.4.5 Installing the return frame ......................................................... 84

9.4.6 Installing the counterweight ....................................................... 84

9.4.7 Installing the idler supports ........................................................ 85

9.4.8 Adjustable carrying idler station .................................................. 85

9.4.9 Belt forming idler ...................................................................... 86

9.4.10 Safety panel ............................................................................. 86

9.4.11 Carrying idlers – Panel ............................................................... 86

9.4.12 Installation of the belt................................................................ 87

9.4.13 Installing the drive unit .............................................................. 91

9.4.14 Installing the steel plate items and various fittings ........................ 91

9.4.15 Skirt board ............................................................................... 92

9.4.16 Installing the electrical components............................................. 92

9.4.17 Adjusting the belt tension and providing various settings ............... 93

22135_B1_0_Pipe conveyor_EN_2

Page 6 of 246 Original version

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not

be duplicated, disclosed or utilized without written consent from FLSmidth.

9.4.18 Preparing the tests .................................................................... 94

9.4.19 Allowable tolerances .................................................................. 95

9.5 Settings ................................................................................. 101

9.5.1 Materialization of the axes of reference ...................................... 101

9.5.2 Pulleys ................................................................................... 102

9.5.3 Substructure........................................................................... 104

9.5.4 Idler supports ......................................................................... 106

9.5.5 Guides of the counterweight box ............................................... 109

9.5.6 Counterweight variations.......................................................... 111

9.5.7 General description on works in case of belt misalignment ........... 111

9.5.8 Conveyor belt ......................................................................... 112

9.5.9 Conveyor pulleys..................................................................... 112

9.5.10 Take-up stations ..................................................................... 112

9.5.11 Idler stations .......................................................................... 112

9.5.12 Transfer chutes....................................................................... 113

9.5.13 Belt cleaning equipment........................................................... 114

9.5.14 Conveyor structure.................................................................. 115

9.5.15 General belt misalignment........................................................ 115

9.5.16 General inspection of the pipe conveyor prior to aligning the belt

without material...................................................................... 115

9.5.17 Inspection of the take-up station............................................... 116

9.6 Interferences, faults and repair ................................................. 117

9.6.1 Correct fixing of belt forming idler ............................................. 117

9.6.2 Belt twist ............................................................................... 118

9.6.3 Overlapping of the belt ............................................................ 119

9.6.4 Belt correction at twisted belt ................................................... 120

9.6.5 Correction of belt running......................................................... 121

9.6.6 Belt tension ............................................................................ 122

9.7 Installing the attached equipents with conveyor .......................... 123

9.8 Installation of cable trays and cables ......................................... 124

9.9 Final assembly ........................................................................ 126

9.10 Pre-operational verification....................................................... 127

9.11 Test on mechanical completion ................................................. 127

9.12 Commissioning ....................................................................... 127

9.13 General conclusion .................................................................. 127

10 Start-up / Commissioning / Operating Instructions.............128

10.1 Check list ............................................................................... 128

10.2 General remarks ..................................................................... 131

10.3 Procedure............................................................................... 131

10.4 Positioning of personnel ........................................................... 131

10.5 Preparation ............................................................................ 132

10.6 Activation............................................................................... 132

22135_B1_0_Pipe conveyor_EN_2

Page 7 of 246 Original version

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not

be duplicated, disclosed or utilized without written consent from FLSmidth.

10.7 1st Test run............................................................................ 133

10.8 2nd Test run........................................................................... 133

10.9 3rd Test run ........................................................................... 133

10.10 Run-in ................................................................................... 134

10.11 Operation............................................................................... 134

10.12 Pre-operational check .............................................................. 134

10.13 Trial-run with application of material ......................................... 135

10.14 Start...................................................................................... 135

10.15 Shutdown procedures .............................................................. 135

10.16 Operation modes..................................................................... 136

10.17 Emergency shutdown............................................................... 137

10.18 Local control stations ............................................................... 137

11 General Maintenance Instructions........................................138

11.1 Introduction ........................................................................... 138

11.2 Regulations for maintenance works ........................................... 138

11.3 General inspection and maintenance routine instructions.............. 139

11.4 Maintenance & assembly instructions for standard equipment ....... 140

11.5 General maintenance instructions for pipe conveyors................... 140

11.5.1 Cleaning................................................................................. 142

11.5.2 Steel structure ........................................................................ 142

11.5.3 Bolts...................................................................................... 142

11.5.4 Gear, gear motor .................................................................... 142

11.5.5 Motor..................................................................................... 142

11.5.6 Brake .................................................................................... 143

11.5.7 Fluid coupling ......................................................................... 143

11.5.8 Flexible coupling ..................................................................... 143

11.5.9 Shrink disk ............................................................................. 143

11.5.10 Bush at torque arm ............................................................. 143

11.5.11 Roller bearings.................................................................... 143

11.5.12 Sealing ring ........................................................................ 144

11.5.13 Pulleys ............................................................................... 144

11.5.14 Idler stations ...................................................................... 144

11.5.15 Rubber belt ........................................................................ 145

11.5.16 Status check of roller bearings .............................................. 148

11.5.17 Functional test .................................................................... 148

11.5.18 Electrical equipment ............................................................ 149

11.5.19 Maintenance and modification works on and around pipe conveyors

and its secondary structures ..................................................... 150

11.5.20 Commissioning after maintenance and modification works........ 150

11.5.21 General description on maintenance works in case of belt

misalignment.......................................................................... 151

11.5.22 General description on maintenance works in case of fault ....... 151

22135_B1_0_Pipe conveyor_EN_2

Page 8 of 246 Original version

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not

be duplicated, disclosed or utilized without written consent from FLSmidth.

11.6 Dismantling and disposal.......................................................... 152

11.6.1 Dismantling work .................................................................... 152

11.6.2 Disposal ................................................................................. 153

12 Instructions for the Lubrication of the Equipment................154

12.1 General safety instructions ....................................................... 154

12.1.1 Personal safety - Health and safety instructions .......................... 155

12.1.2 Personal protective equipment .................................................. 155

12.1.3 Regulations for the prevention of accidents ................................ 155

12.2 Storage of lubricants ............................................................... 156

12.3 Cleaning of machines............................................................... 156

12.4 Disposal of waste lubricants...................................................... 157

12.5 Types of lubricants .................................................................. 157

12.5.1 General application of oil and grease ......................................... 157

12.5.2 Methods of lubrication.............................................................. 157

12.5.3 Oil......................................................................................... 158

12.5.4 Grease................................................................................... 158

12.5.5 Synthetic lubricants ................................................................. 158

12.6 Lubrication plans..................................................................... 159

12.6.1 Use of lubrication plans ............................................................ 160

12.6.2 Factory filling.......................................................................... 160

12.6.3 General lubrication instructions ................................................. 161

13 Specific Instructions and Information..................................162

13.1 Assembly drawing list .............................................................. 162

13.2 Technical data ........................................................................ 163

13.3 Spare parts ............................................................................ 169

13.3.1 Spare parts catalog for Pipe conveyor 0720-PC-1021................... 170

13.3.2 Spare parts catalog for Pipe conveyor 0320-PC-1012................... 186

13.4 Lubrication plan ...................................................................... 203

13.4.1 Lubrication plan for Pipe conveyor 0720-PC-1021........................ 205

13.4.2 Lubrication plan for Pipe conveyor 0320-PC-1012........................ 212

13.4.3 SEW Lubricant ........................................................................ 221

SEW Lubricant .................................................................................. 223

13.5 Inspection & maintenance schedule guideline ............................. 225

13.6 Troubleshooting chart .............................................................. 232

13.6.1 General.................................................................................. 233

13.6.2 Gear unit................................................................................ 234

13.6.3 Motor..................................................................................... 235

13.6.4 Fluid coupling ......................................................................... 236

13.6.5 Disc brake .............................................................................. 237

13.6.6 Thruster at disc brake.............................................................. 238

13.6.7 Elastic coupling ....................................................................... 238

13.6.8 Shrink disc ............................................................................. 239

22135_B1_0_Pipe conveyor_EN_2

Page 9 of 246 Original version

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not

be duplicated, disclosed or utilized without written consent from FLSmidth.

13.6.9 Silent block ............................................................................ 239

13.6.10 Pulley ................................................................................ 240

13.6.11 Belt ................................................................................... 241

13.6.12 Belt cleaner ........................................................................ 242

13.6.13 Idler .................................................................................. 243

13.6.14 Belt forming idler ................................................................ 243

13.6.15 Tension guidance with take-up station ................................... 244

13.6.16 Skirt board ......................................................................... 244

13.6.17 Dust sealing equipment ....................................................... 245

13.6.18 Discharge hood and chute .................................................... 245

13.6.19 Belt scale ........................................................................... 246

13.6.20 Additional equipments (belt scale, maintenance hoist, etc.)...... 246











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Tài liệu hướng dẫn lắp ráp, vận hành và bảo trì băng tải ống (FLSmidth)


The present instructions are concerned with the situations which, according to the experience of FLSmidth, are the most likely to occur during manufacture, installation, operation and maintenance of the equipment. An exhaustive enumeration of all conceivable situations, which may occur, cannot be provided.

Consequently, if a situation should arise, the occurrence of which is not foreseen in the instructions, and which the operator is/or feels unable to handle, it is recommended that FLSmidth is contacted without undue delay for advice on appropriate action.

All references to relevant safety standards are given at the EC declaration of conformity if required.

Reference by seller to any international or national standard does not incur an obligation on seller to provide any recipient, reader or user of the documentation with samples or copies of the said standard(s).

Hence, any recipient, reader or user of the documentation is expected – at his own cost – to obtain necessary knowledge of the contents of any of the standards referred to.


CONTENTS:


1 Foreword................................................................................10

1.1 Safety...................................................................................... 10

1.2 Definitions and abbreviations ...................................................... 10

1.3 Safety legend ........................................................................... 11

2 Equipment according to material flow / Flow Sheet...............12

3 Introduction...........................................................................13

4 Technical Parameters.............................................................14

4.1 Environmental conditions ........................................................... 14

4.2 Electrical parameters ................................................................. 15

4.3 Material characteristics .............................................................. 15

4.4 Plant data ................................................................................ 15

4.5 Scope of Supply for Pipe Conveyor .............................................. 16

5 Instructions for Transport......................................................19

5.1 Scope ...................................................................................... 19

5.2 Definitions................................................................................ 19

5.3 General.................................................................................... 19

5.4 Environmental considerations ..................................................... 20

5.5 Instructions for Equipment Transport........................................... 20

6 Instructions for the Storage of the Delivery ...........................22

6.1 General remarks ....................................................................... 22

6.2 Storage and preservation requirements for mechanical equipment .. 22

6.2.1 Preservation on Storage............................................................. 22

6.2.2 Preservation measures............................................................... 23

6.3 Storage and preservation requirements for switch cabinets and other

electrical equipment .................................................................. 25

7 Description of Equipment .......................................................26

7.1 Scope ...................................................................................... 26

7.2 Design ..................................................................................... 26

7.3 Normative references ................................................................ 26

7.4 General description of the process flow ........................................ 27

7.5 Pipe conveyors.......................................................................... 28

7.6 Pipe conveyor´s principle ........................................................... 29

22135_B1_0_Pipe conveyor_EN_2

Page 4 of 246 Original version

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not

be duplicated, disclosed or utilized without written consent from FLSmidth.

7.7 Pipe Conveyor components......................................................... 31

7.8 Drive station............................................................................. 32

7.9 Drive units ............................................................................... 33

7.10 Pulleys ..................................................................................... 34

7.11 Rubber belt .............................................................................. 35

7.12 Belt scraper.............................................................................. 36

7.13 Idler stations including belt forming idlers .................................... 38

7.13.1 Adjustable idler stations ............................................................. 39

7.13.2 Panels with 12 carrying idlers ..................................................... 40

7.13.3 Belt forming idlers ..................................................................... 41

7.13.4 Safety panels............................................................................ 42

7.13.5 Return idler stations .................................................................. 43

7.13.6 Return guiding wheel ................................................................. 43

7.14 Return station........................................................................... 44

7.15 Vertical gravity take-up.............................................................. 45

7.16 Steel construction ..................................................................... 46

7.16.1 Standard belt frames ................................................................. 46

7.16.2 Walkway bottom covering .......................................................... 46

7.16.3 Support, trestle......................................................................... 46

7.16.4 Standard belt frames at feeding and discharging area.................... 47

7.16.5 Material guidance ...................................................................... 47

7.16.6 Discharge chute ........................................................................ 48

7.16.7 Dust sealing equipment.............................................................. 48

7.17 Electrical components ................................................................ 49

7.17.1 Emergency pull cord switch ........................................................ 50

7.17.2 Belt misalignment switch............................................................ 51

7.17.3 Speed Monitoring ...................................................................... 52

7.17.4 Clogged chute sensor ................................................................ 53

7.17.5 Take-up limit switch and sensor .................................................. 54

7.17.6 Over filling switch...................................................................... 55

7.17.7 Twist switch ............................................................................. 55

7.17.8 Belt rip detection....................................................................... 56

7.17.9 Safety panel switch ................................................................... 57

7.18 Description of attached equipments with pipe conveyor ................. 57

8 Scope of works by the construction company ........................58

8.1 Responsibility of the construction company................................... 58

8.2 Quality of work ......................................................................... 60

8.2.1 Scope and documents................................................................ 60

8.2.2 General quality requirements...................................................... 60

8.3 Welding ................................................................................... 60

8.4 Surface treatment inspection ...................................................... 61

8.5 Machinery installations............................................................... 61

22135_B1_0_Pipe conveyor_EN_2

Page 5 of 246 Original version

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not

be duplicated, disclosed or utilized without written consent from FLSmidth.

8.6 Fastening of bolts...................................................................... 61

8.7 Project plan .............................................................................. 62

8.7.1 General.................................................................................... 62

8.7.2 Project plan .............................................................................. 62

8.7.3 Follow-up of the project plan ...................................................... 63

8.7.4 Mounting works ........................................................................ 63

8.7.5 Common requirements mounting alternatives ............................... 64

8.8 Components to be delivered by FLSmidth..................................... 64

8.8.1 Design ..................................................................................... 64

8.8.2 Components and structures ........................................................ 64

8.8.3 Arrival of components and structures........................................... 64

8.9 Preassembly works.................................................................... 65

8.10 Mounting works ........................................................................ 65

8.10.1 Mounting equipment.................................................................. 65

8.10.2 Mounting works ........................................................................ 66

8.11 Testing .................................................................................... 66

8.11.1 Supervision by FLSmidth............................................................ 66

9 assembly and disassembly Instructions .................................67

9.1 Instructions for the installation and mechanical completion ............ 67

9.1.1 General Safety Instructions ........................................................ 67

9.1.2 Using the machine documentation............................................... 70

9.2 Introduction ............................................................................. 71

9.3 Preparatory work ...................................................................... 73

9.3.1 Important mounting equipment and tools..................................... 74

9.3.2 Drawings and documents ........................................................... 74

9.3.3 Reference axes and levels .......................................................... 75

9.3.4 Tightening torque and tensile force.............................................. 76

9.4 Sequence of the mounting of the conveyor................................... 78

9.4.1 Pre-assembly............................................................................ 78

9.4.2 Materialization of the conveyor centreline..................................... 83

9.4.3 Installing the frame of the drive pulley......................................... 83

9.4.4 Installing the substructure.......................................................... 83

9.4.5 Installing the return frame ......................................................... 84

9.4.6 Installing the counterweight ....................................................... 84

9.4.7 Installing the idler supports ........................................................ 85

9.4.8 Adjustable carrying idler station .................................................. 85

9.4.9 Belt forming idler ...................................................................... 86

9.4.10 Safety panel ............................................................................. 86

9.4.11 Carrying idlers – Panel ............................................................... 86

9.4.12 Installation of the belt................................................................ 87

9.4.13 Installing the drive unit .............................................................. 91

9.4.14 Installing the steel plate items and various fittings ........................ 91

9.4.15 Skirt board ............................................................................... 92

9.4.16 Installing the electrical components............................................. 92

9.4.17 Adjusting the belt tension and providing various settings ............... 93

22135_B1_0_Pipe conveyor_EN_2

Page 6 of 246 Original version

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not

be duplicated, disclosed or utilized without written consent from FLSmidth.

9.4.18 Preparing the tests .................................................................... 94

9.4.19 Allowable tolerances .................................................................. 95

9.5 Settings ................................................................................. 101

9.5.1 Materialization of the axes of reference ...................................... 101

9.5.2 Pulleys ................................................................................... 102

9.5.3 Substructure........................................................................... 104

9.5.4 Idler supports ......................................................................... 106

9.5.5 Guides of the counterweight box ............................................... 109

9.5.6 Counterweight variations.......................................................... 111

9.5.7 General description on works in case of belt misalignment ........... 111

9.5.8 Conveyor belt ......................................................................... 112

9.5.9 Conveyor pulleys..................................................................... 112

9.5.10 Take-up stations ..................................................................... 112

9.5.11 Idler stations .......................................................................... 112

9.5.12 Transfer chutes....................................................................... 113

9.5.13 Belt cleaning equipment........................................................... 114

9.5.14 Conveyor structure.................................................................. 115

9.5.15 General belt misalignment........................................................ 115

9.5.16 General inspection of the pipe conveyor prior to aligning the belt

without material...................................................................... 115

9.5.17 Inspection of the take-up station............................................... 116

9.6 Interferences, faults and repair ................................................. 117

9.6.1 Correct fixing of belt forming idler ............................................. 117

9.6.2 Belt twist ............................................................................... 118

9.6.3 Overlapping of the belt ............................................................ 119

9.6.4 Belt correction at twisted belt ................................................... 120

9.6.5 Correction of belt running......................................................... 121

9.6.6 Belt tension ............................................................................ 122

9.7 Installing the attached equipents with conveyor .......................... 123

9.8 Installation of cable trays and cables ......................................... 124

9.9 Final assembly ........................................................................ 126

9.10 Pre-operational verification....................................................... 127

9.11 Test on mechanical completion ................................................. 127

9.12 Commissioning ....................................................................... 127

9.13 General conclusion .................................................................. 127

10 Start-up / Commissioning / Operating Instructions.............128

10.1 Check list ............................................................................... 128

10.2 General remarks ..................................................................... 131

10.3 Procedure............................................................................... 131

10.4 Positioning of personnel ........................................................... 131

10.5 Preparation ............................................................................ 132

10.6 Activation............................................................................... 132

22135_B1_0_Pipe conveyor_EN_2

Page 7 of 246 Original version

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not

be duplicated, disclosed or utilized without written consent from FLSmidth.

10.7 1st Test run............................................................................ 133

10.8 2nd Test run........................................................................... 133

10.9 3rd Test run ........................................................................... 133

10.10 Run-in ................................................................................... 134

10.11 Operation............................................................................... 134

10.12 Pre-operational check .............................................................. 134

10.13 Trial-run with application of material ......................................... 135

10.14 Start...................................................................................... 135

10.15 Shutdown procedures .............................................................. 135

10.16 Operation modes..................................................................... 136

10.17 Emergency shutdown............................................................... 137

10.18 Local control stations ............................................................... 137

11 General Maintenance Instructions........................................138

11.1 Introduction ........................................................................... 138

11.2 Regulations for maintenance works ........................................... 138

11.3 General inspection and maintenance routine instructions.............. 139

11.4 Maintenance & assembly instructions for standard equipment ....... 140

11.5 General maintenance instructions for pipe conveyors................... 140

11.5.1 Cleaning................................................................................. 142

11.5.2 Steel structure ........................................................................ 142

11.5.3 Bolts...................................................................................... 142

11.5.4 Gear, gear motor .................................................................... 142

11.5.5 Motor..................................................................................... 142

11.5.6 Brake .................................................................................... 143

11.5.7 Fluid coupling ......................................................................... 143

11.5.8 Flexible coupling ..................................................................... 143

11.5.9 Shrink disk ............................................................................. 143

11.5.10 Bush at torque arm ............................................................. 143

11.5.11 Roller bearings.................................................................... 143

11.5.12 Sealing ring ........................................................................ 144

11.5.13 Pulleys ............................................................................... 144

11.5.14 Idler stations ...................................................................... 144

11.5.15 Rubber belt ........................................................................ 145

11.5.16 Status check of roller bearings .............................................. 148

11.5.17 Functional test .................................................................... 148

11.5.18 Electrical equipment ............................................................ 149

11.5.19 Maintenance and modification works on and around pipe conveyors

and its secondary structures ..................................................... 150

11.5.20 Commissioning after maintenance and modification works........ 150

11.5.21 General description on maintenance works in case of belt

misalignment.......................................................................... 151

11.5.22 General description on maintenance works in case of fault ....... 151

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The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not

be duplicated, disclosed or utilized without written consent from FLSmidth.

11.6 Dismantling and disposal.......................................................... 152

11.6.1 Dismantling work .................................................................... 152

11.6.2 Disposal ................................................................................. 153

12 Instructions for the Lubrication of the Equipment................154

12.1 General safety instructions ....................................................... 154

12.1.1 Personal safety - Health and safety instructions .......................... 155

12.1.2 Personal protective equipment .................................................. 155

12.1.3 Regulations for the prevention of accidents ................................ 155

12.2 Storage of lubricants ............................................................... 156

12.3 Cleaning of machines............................................................... 156

12.4 Disposal of waste lubricants...................................................... 157

12.5 Types of lubricants .................................................................. 157

12.5.1 General application of oil and grease ......................................... 157

12.5.2 Methods of lubrication.............................................................. 157

12.5.3 Oil......................................................................................... 158

12.5.4 Grease................................................................................... 158

12.5.5 Synthetic lubricants ................................................................. 158

12.6 Lubrication plans..................................................................... 159

12.6.1 Use of lubrication plans ............................................................ 160

12.6.2 Factory filling.......................................................................... 160

12.6.3 General lubrication instructions ................................................. 161

13 Specific Instructions and Information..................................162

13.1 Assembly drawing list .............................................................. 162

13.2 Technical data ........................................................................ 163

13.3 Spare parts ............................................................................ 169

13.3.1 Spare parts catalog for Pipe conveyor 0720-PC-1021................... 170

13.3.2 Spare parts catalog for Pipe conveyor 0320-PC-1012................... 186

13.4 Lubrication plan ...................................................................... 203

13.4.1 Lubrication plan for Pipe conveyor 0720-PC-1021........................ 205

13.4.2 Lubrication plan for Pipe conveyor 0320-PC-1012........................ 212

13.4.3 SEW Lubricant ........................................................................ 221

SEW Lubricant .................................................................................. 223

13.5 Inspection & maintenance schedule guideline ............................. 225

13.6 Troubleshooting chart .............................................................. 232

13.6.1 General.................................................................................. 233

13.6.2 Gear unit................................................................................ 234

13.6.3 Motor..................................................................................... 235

13.6.4 Fluid coupling ......................................................................... 236

13.6.5 Disc brake .............................................................................. 237

13.6.6 Thruster at disc brake.............................................................. 238

13.6.7 Elastic coupling ....................................................................... 238

13.6.8 Shrink disc ............................................................................. 239

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The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not

be duplicated, disclosed or utilized without written consent from FLSmidth.

13.6.9 Silent block ............................................................................ 239

13.6.10 Pulley ................................................................................ 240

13.6.11 Belt ................................................................................... 241

13.6.12 Belt cleaner ........................................................................ 242

13.6.13 Idler .................................................................................. 243

13.6.14 Belt forming idler ................................................................ 243

13.6.15 Tension guidance with take-up station ................................... 244

13.6.16 Skirt board ......................................................................... 244

13.6.17 Dust sealing equipment ....................................................... 245

13.6.18 Discharge hood and chute .................................................... 245

13.6.19 Belt scale ........................................................................... 246

13.6.20 Additional equipments (belt scale, maintenance hoist, etc.)...... 246











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