SMP No: TL-SMP-35-01

Revision: 01

Effective: August 1, 2020

Supersedes: TL-SMP-35-00 (July 1, 2009)

Prepared by: Shyam Kumar Gujarathi

Power O&M
Approved by: K. Narayanan

Standard Maintenance Procedure for Conveyer Belt

TL-SMP-35-01

1. HAZARD IDENTIFICATION AND ASSESSMENT OF RISK & OPPORTUNITY (HIARO) NO:

2. SUMMARY OF THE OBJECTIVE

This document is created to provide the information to job execution team for carrying out maintenance
with best quality and safety.

3. RECOMMENDED SAFETY PPEs

S.N. Name Function

01 Safety Element Head Protection

02 Safety Shoes Foot Protection

03 Safety Goggles Eye protection

Protection from
04 Nose Mask
dust
05 Hand Gloves Hand Protection

06 Safety Belt Fall Protection

07 Ear plug Hearing Protection

Other specific PPE’s recommended in

08
HIARO to be used

4. FIELD CHECKS FOR SAFE MAINTENANCE

Work Permit No. :- Checks

S.N. Checks Reasons Yes No
1 Adequate Illumination Inadequate illumination causes accident
2 Proper Ventilation Easy breathing & relief from early fatigue
3 Any slippery agent on floor To avoid any accident/ incident
4 Cross checked LOTO & tag To avoid any un safe act
 STANDARD MAINTENANCE PROCEDURE FOR CONEYER BELT
5. TROUBLE SHOOTING CAN HELP WHEN YOU SUSPECT A PROBLEM

Trouble Cause Correction

One or more idlers not at right angles to Advance the end of idler to which the belt
longitudinal centreline of belt. has shifted in the direction of belt travel.

Conveyor frame not lined up properly; or Stretch line along edge to determine how
Conveyor belt runs idler stand, or stands, not centred on belt. much out of line and correct.
to one side at a
particular pint on Sticking idlers. Replace or free idler
the conveyor.
Structure not level, belt tends to shift to low
Level Structure.
side

Improve maintenance. Install scrapers.

Build-up of material on idlers.

Splices not square. Re splice, cutting end square.

One section of
belting runs off to
one side all along Crooked belt caused by storage of If bow is in new belt, it may correct itself
the conveyor. telescoped rolls or one edge close to damp when belt becomes broken in; otherwise
ground or wall. replace it with a new section.

Conveyor belt runs

to one side for some Make changes in loading station and loading
Improper loading of belt.
distance along conditions so that it is centred properly.
conveyor line.

May be due to newness. If so, allow proper

break-in time. It will shorten break- in time if
belt is left loaded on off shift.

Tilt toughing idler forward a maximum of 2

degrees if conveyor is Never reversed in
direction.
Belt has erratic
action, following not Belt too stiff. Use self-aligning idlers. Use more trough
particular pattern. able belt.

Check alignment of pulley and adjacent

toughing idlers.

Remove material; provide better

housekeeping.

TL-SMP-35-01 Effective: August 1, 2020 Page 2 of 8

 STANDARD MAINTENANCE PROCEDURE FOR CONEYER BELT
Adjust at right angle to frame.
Belt running off at Head pulley or toughing idlers approaching
head pulley. head pulley out of alignment. Adjust loading chute to properly centre the
load.

Build-up of material on return idlers.

Belt running off at Return rollers out of line. Unequal loading.

Increase tension or belt take-up device.
tail pulley.
Slippage between belt and drive pulley or
pulleys.

Lag drive pulleys, renew worn-out lagging.

Slippage between belt and drive pulley or Increase arc of contact drive pulley with
pulleys. (Cont.) snub pulley or use tandem drive.

Replace or free.
Excessive wear on
bottom side of belt. Install scrapers in front of tail pulley or
Sticking toughing idlers.
return belt.

Install belt-cleaning plows at head end and

Material ground between pulley and belt.
tail end.

Dirt, frozen or misaligned returns idlers. Clean, repair and align return idlers.

Excessive sag between toughing idlers Increase belt tension if too low.
causing load to move and shift on belt as it
passes over idlers. Reduce idler spacing.
Excessive wear on
Use rubber skirt material. Avoid use of old
carrying side of belt. Abrasive skirt boards.
belting.

Feed load on belt in same direction at same

Poor loading.
speed.

Reduce friction by placing frozen or worn-

out idlers.

Provide better maintenance.

Belt requires too Decrease tension by improving drive.

much tension 1. Lagging on drive pulleys.
Improper maintenance of toughing and 2. Increase arc of contact of drive pulley;
resulting in
return idlers. provide tandem drive.
excessive stretch in
belt. Increase speed, if possible, keeping shift
tonnage the same.

Reduce tonnage at slower speed.

TL-SMP-35-01 Effective: August 1, 2020 Page 3 of 8

 STANDARD MAINTENANCE PROCEDURE FOR CONEYER BELT
Belt requires too Tighten screw take-up just enough to keep
much tension belt from slipping.
Improper maintenance of toughing and
resulting in On a gravity take-up reduce counterweight
return idlers.
excessive stretch in to minimum amount sufficient to keep belt
belt. from slipping.

Tension too high. Mildew. See Paragraph 1.

Use mildew inhibitor on belt.

Fasteners pull out Wrong type of fasteners or fasteners not Replace belt with proper fasteners that have
of belt. tight. the required strength.

Use vulcanized splices if feasible.

Improper starting. Use more acceleration steps in starting.

Short breaks in Impact of lumps falling on belt at loading

Use impact idlers.
carcass of belt station.
parallel to edge and
star breaks in Material trapped between belt and pulley. Install plows or scrapers ahead of pulley.
carcass.

Excessive noise or
Difference of ¼ inch diameters will cause
squealing in tandem Unequal diameters of drive pulley.
noise.
drive.

One or both pulleys loose on shaft.

Thumping noise in
Tighten pulleys. Change gears.
tandem drive. Gear out of mesh, improperly machined or
worn out.

Shaft and Hole tolerance chart

Over Dia
3 6 10 18 30 40 50 65 80 100 120 140 160 180 200 225 250 280
from
Up to
6 10 18 30 40 50 65 80 100 120 140 160 180 200 225 250 280 315
Incl.-MM
Shaft - 0 0 0 0 0 0 0 0 0 0
h7 -0.012 -0.015 -0.018 -0.021 -0.025 -0.03 -0.035 -0.04 -0.046 -0.052
0.012 0.015 0.018 0.021 0.025 0.03 0.035 0.04 0.046 0.052
Hole- H7
0 0 0 0 0 0 0 0 0 0

TL-SMP-35-01 Effective: August 1, 2020 Page 4 of 8

 STANDARD MAINTENANCE PROCEDURE FOR CONEYER BELT
Bearing installation
S.N. Activities
1 Remove the old bearing with the help of bearing puller
Check shaft OD in bearing siting area with respect to bearing ID and make it require tolerance as per
2
chart
3 Check the levelling of rotor with master level and align using shim at plumber block base
4 Check top and bottom plumber block half contact with bearing outer race by blue matching.
4 Check the plumber block and maintain recommended interference.
Straight bearings above 50mm ID should be heated to
5 100°C for is ZZ category, 120°C for other bearings. No heating is required for taper bore bearing.
NOTE: Temperature above 120°C not allowed.
6 Bearing lock-nut tightness to be ensured as per clearance chart. Ensure proper surface of lock nut.
7 Install oil seal/ Dust seal/Gauge glass/ Grease nipple with proper care.

Mechanical seal installation

S.N. Activities
1 Clean the staffing box and shaft at seal location
2 Check and clean sleeve and remove all damaged 'O' rings and fix new rubber 'O' rings.
3 Lap the mating face and check the blue match
4 Fix the stationary mating part O-ring with seal flange.
5 Check and noted the max spring compression of seal externally
6 Fix the rotary part of seal on sleeve and set the adequate seal spring pressure.
7 Fix the seal cooling water line if applicable.

Coupling installation and alignment

S.N. Activities
1 Check the shaft OD at coupling siting area with respect to coupling ID.
2 Check the coupling bore and keyway and make it require tolerance.
3 Heat the coupling max140°C and fix the coupling without hammering.
5 Before alignment ensure drive and driven should not have any push or pull force by piping/cable
4 Check the soft foot error and correct it if required
Fix the two dial for axial and one for radial. Fix alignment clamps on prime mover also ensured clamp is
5
rigid enough. Dial gauge should move freely in full range of its scale.
Do axial and redial alignment with minimum number of shims. Take the TIR and make correction by the
6 shim as per calculation. TIR should be checked in all bolt tightened condition and recheck the reading
and confirm the same.
7 Remove the alignment clamp dial and fix the coupling and lubricant.

TL-SMP-35-01 Effective: August 1, 2020 Page 5 of 8

 STANDARD MAINTENANCE PROCEDURE FOR CONEYER BELT
Maintenance Management Systems
Equipment Name: Conveyer Belt (Coal &lime etc.)
Types: M1- Checks, M2- Minor, M3- Major Maintenance
S. N. Maintenance Activities Yes No N/A Remarks

A M1, M2, M3- Common Checks

1 Is foundation frame sufficiently massive?

2 Check for any mechanical “looseness”.

3 Check static oil level drive gearbox

4 If grease lubricated, make sure not over packed.

5 Checking coupling bolts & spider.

6 Is the coupling guard securing?

7 Check the oil level of fluid coupling if applicable.

8 Check the cleanness of grease nipple for bearings

Check the water nozzle of dust suppression if

9
applicable.

Check the spray water pressure sufficiently

10
available, if applicable

11 Checking the belt joint condition

12 Check the belt edge condition has any damage.

13 Check and clean the pull card and belt sway switch

14 Check the skirt rubber condition

Check the Head, Tail, snub and bend pulley

15
condition.

16 Check the alignment of the belt

17 Check Motor drawing current

TL-SMP-35-01 Effective: August 1, 2020 Page 6 of 8

 STANDARD MAINTENANCE PROCEDURE FOR CONEYER BELT
S.N. Maintenance Activities Checks Tools Yes No

B M2- Minor

1 Check all the joints condition Joint good condition Visual

2 Check the belt thickness Permissible Thick Vernier
3 Check the belt edge condition No damage Visual
4 Check the alignment of the Belt Centre Aligned Visual
5 Check the rollers condition Free Rotation Physical Check
Check the Head, Tail, Snub & Take up
6 Good Condition Visual
Drum Rubber

7 New Grease filling in Bearings. Adequate grease Grease Gun

8 Check the Pull cord function Properly Working Physical Check
9 Check the Drive alignment Permissible limit Dial gauge
10 Check the skirt rubber condition. Good Condition Visual
11 Check Vibration before & after work Vibration meter
12 Check Motor drawing current will be normal
C M3- Major Maintenance

1 Check all the joints condition Joint good condition Visual

2 Check the belt thickness Permissible Thick Venire

3 Check the belt edge condition No damage Visual

4 Check the alignment of the Belt Centre Aligned Visual

5 Check the rollers condition Free Rotation Physical Check

Check the Head, Tail, Snub & Take up

6 Good Condition Visual
Drum Rubber

7 New Grease filling in Bearings. Adequate grease Grease Gun

8 Check the Pull cord function Properly Working Physical Check

9 Check the Drive alignment Permissible limit Dial gauge

10 Check Shore hardness Permissible limit Durometer

11 Overhauling of Gear Box & Motor Fully Overhauled New seals

12 Check the Drive alignment Permissible limit Dial gauge

13 Check Vibration before & after work Vibration Meter

14 Check Motor drawing current Current will be normal

TL-SMP-35-01 Effective: August 1, 2020 Page 7 of 8

 STANDARD MAINTENANCE PROCEDURE FOR CONEYER BELT
Name of Maintenance Engineer:

Department :

Contact No. :

Permit Details:

TL-SMP-35-01 Effective: August 1, 2020 Page 8 of 8