Bulk-Handling Conveyors

Table of Contents

Chapter 1: Conveyor Components

Topics: Conveyor profiles, pulleys, and idlers; Bulk-handling conveyor belts; Conveyor drive packages; Support components

Learning Objectives:

• Describe the basic operation of a bulk-handling belt conveyor and identify its major components.
• Name and explain the function of the different pulleys used in belt conveyors.
• Describe four popular conveyor drive-package arrangements.
• Explain the purpose and the operation of at least four of the support components of a bulk-handling belt conveyor.

Chapter 2: Bulk-Conveyor Belting

Topics: Belt plies; Storing and handling belts; Installation; Squaring ends, cutting; Belt fasteners; Vulcanized splicing; Tensioning, repairing, and replacing the belt; Troubleshooting

Learning Objectives:

• Describe the composition and structure of the three components of a bulk-handling conveyor belt.
• State correct storage and handling procedures for bulk conveyor belts.
• Detail the installation of a belt in a bulk conveyor system, including splicing and tensioning.
• Name the five points that require special attention in a preventive maintenance program for a belt conveyor system.

Chapter 3: Belt Cleaners and Idlers

Topics: Blade, brush, and plow type belt cleaners; Cleaning by rollover; Deck plates; Return idlers; Wing pulleys; PM, inspection, and troubleshooting

Learning Objectives:

• Describe the design and placement of blade, brush, and plow belt cleaners and the applications for which each one would be used.
• Name and describe the different types of blade belt cleaners.
• Describe the process of belt cleaning by rollover.
• Explain how devices such as wing pulleys, self-cleaning return idlers, and deck plates function as parts of a belt cleaning system.
• Describe the appropriate safety precautions to take when installing or maintaining belt cleaners.
• List the essential features of preventive maintenance and inspection for a belt cleaning system.

Chapter 4: Feed and Discharge Devices

Topics: Factors in loading and discharge; Skirting devices; Hoppers and accessories; Loading and discharge chutes; Spouting; Inspection; Troubleshooting

Learning Objectives:

• Explain two important factors in efficient conveyor loading and how they are affected by the two ways (directions) in which belt conveyors are loaded.
• Describe the construction and the purpose of skirtboards.
• Differentiate between a deadbed and a bed of fines and detail the use of both in chute loading of conveyors.
• Name and explain the operation of three special types of discharge spouts.

Chapter 5: Safety and Troubleshooting

Topics: Loading and discharge points; Emergency controls; Preparing for maintenance; Common problems, possible remedies

Learning Objectives:

• Differentiate between a conveyor profile and a system profile.
• Point out the special hazards for workers at conveyor loading and discharge points.
• Explain the function and operation of the following emergency controls: electrical interlocks, backstops, level switches, pull-cords, and conveyor belt alignment switches.
• Name at least five safety measures employees should take to protect themselves when working on or near bulk-handling conveyors.
• Describe the three-step procedure for preventing accidental startup of a conveyor during maintenance work.
• Name at least one specific shore or safety caution required in maintenance work on each of the following: belts, idlers, pulleys, and drive systems.
• Identify common problems (and their probable causes) found in troubleshooting idlers, pulleys, takeup bearings, and conveyor drives.

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