FUNDAMENTALS OF CONVEYOR SYSTEMS Presented by: Laura Hoggan, Rubber & Plastics.

FUNDAMENTALS OF CONVEYOR SYSTEMS

Presented by:

Laura Hoggan, Rubber & Plastics

Topics to be Covered System Maintenance

Belt Maintenance

Anatomy of a belt

Common Frac Sand belt specifications and designs

Section I: System Maintenance

System Square

A conveyor system frame is like a car frame, if your frame is not square it will throw off other components, creating wear and tear.

The Dragon Tail is the most susceptible area for being out of square, check it often!

Cleaning

• Good system maintenance can be summed up in two words, “Good Housekeeping”.

• Check pulleys and rollers for material build-up.

Loading Area

Having the right equipment and a good transaction area is a key component in system life and belt life.

Bad Loading can result in:

Catastrophic failure

Damage to belt

Tracking issues

TO-DO LIST! Follow OEM guide for lubrication

schedule

Visually inspect: Rollers, Pulleys, Return rollers & belt

guides for excessive wear, built up material and damage.

Belt Splice for wear on lace, cracks, missing components.

Sidewall for damage and missing sections

Inspect belts: Tracking properly

Tension

Section II: Belt Maintenance

Belt Tracking/Training Considerations Conveyor belt moves toward the end of the roller/idler it contacts first

Check conveyor system for structural misalignments

Check pulleys and idlers for misalignment and material build-up

Check belt splice for accuracy and straightness

Observe belt in operation empty and loaded for tracking tendencies

Eliminate Spillage, Off-center loading and build-up of materials, factors that cause tracking issues

Splice Failures

Inspect lace to ensure all parts are still present

Inspect Vulcanized splices for cracking, splitting and loose sidewall sections

Belt Repair Flexco® offers a variety of rip Flexco® offers a variety of rip

repair fasteners. With these you repair fasteners. With these you can patch soft spots before they can patch soft spots before they become rips or a cut or tear in become rips or a cut or tear in your belt to extend your belt lifeyour belt to extend your belt life

Eli-Flex rubber repair kits for Eli-Flex rubber repair kits for holes, tears, splits, gouges and holes, tears, splits, gouges and excess wear areasexcess wear areas

SuperScrew patch kits for holes SuperScrew patch kits for holes and tears. Provides water tight and tears. Provides water tight

What happens if I install the wrong belt spec?

Belt will wear faster than expected

Belt may potentially fail

Cleats and/or Sidewall may separate from belt

Section III: Anatomy of a belt

Belt Specification Breakdown

3 = Number of Tension Plies2 = Number of Cross Rigid

Plies

What is a Ply? A rubber coated layer of fabric

Each “fabric” layer is a ply

Commonly a Polyester/Nylon material

Are the strength member of the belt

How do you know how many plies you have? Count the number of layers of fabric visible in the belt

CROSS RIGID BELT Engineered for applications that

take a sharp upturn, with a heavy cleat and/or corrugated sidewall.

Cross Rigid belts are rigid across the belt (fill or weft direction)

Provides lateral reinforcement that keeps the belting rigid

Cross Rigid belting will withstand deflection from horizontal to incline without bowing or sagging during operations.


3 = Number of Tension Plies

2 = Number of Cross Rigid Plies

330 = Working tension per inch width

Working Tension Working tension is a factor of the fabric/ply

Rated on a per inch width

Fabric strength has a direct impact on minimum pulley diameter requirements

Why does it matter? Belt can snap in operation if not rated for the tension of the system





1/8 = Thickness of Rubber top cover

Top Cover Thickness Provides an impact and abrasion resistance layer, protecting the belt fabric

There are standard cover thicknesses which vary based on the plies and tension rating of the belt

Custom thicknesses are available but usually require a minimum quantity purchase






1/16 = Thickness of Rubber bottom cover

Bottom Cover of a Conveyor Belt May have a rubber bottom or a “bare-back” bottom

PVC belts are: COS = Cover one Side

CBS = Cover both sides

Rubber Belts are: Called out by actual thickness of cover materials

What is a “Bare-Back”? A conveyor belt with no bottom rubber cover

Bottom of conveyor belt is the fabric from the bottom ply

Why use a “Bare-Back”? Slider Bed Applications

Fabric bottom has a lower coefficient of friction than a Rubber bottom






1/16 = Thickness of Rubber bottom cover

MOR / Grd II = The type of Rubber Material used in the belt

What Rubber Compounds are common?RMA GRADE 2 RMA GRADE 2

MOST COMMON MOST COMMON COMPOUND COMPOUND

GREAT FOR ALL GENERAL GREAT FOR ALL GENERAL MATERIALS AND MATERIALS AND PRODUCTSPRODUCTS

GOOD IMPACT AND GOOD IMPACT AND ABRASION RESISTANCEABRASION RESISTANCE

MORMOR

MAINLY FOR ANY APPLICATION WHERE OILS WILL BE PRESENT. IS MODERATELY RESISTANT TO OILS AND SOLVENTS

RMA GRADE 1RMA GRADE 1

MAINLY FOR HIGH IMPACT, CUTTING AND ABRASION APPLICATIONS

MORE NATURAL RUBBER

BEST IMPACT, ABRASION AND GOUGE RESISTANCE

Section IV: Common Belt Specifications and Designs in Fracking

Profile Belts Why use a profile belt?

Inclines greater than 20°

To prevent roll back of material

Common Profiles Herringbone

Chevron

V-Cleat

MaxClimb

MegaClimb

Sidewall Belt; No cleats

Frac Sand Belt Configurations

Typically on Sand Delivery Units

Sand Delivery Units receive sand transported to the well site.

Uses a combination of hoppers and conveyor belts to move frac sand to the T-Belt during fracking operations.

Operates on Troughing Idlers

Details: Sidewall height

from 2” to 4” Available on any

belt specification

Narrow Width MaxClimb w/ Sidewall


Typically on the T-Belt (Dual Belt Units)

Takes discharge from multiple Sand Delivery Units and delivers to the blenders.

Compartmented belt allows for high angle discharge of materials.

Details:

30” and Narrower belts

1-1/4” tall cleats

Sidewall heights of 2” to 6”

MaxClimb w/ Sidewall


Typically on the T-Belt (Single Belt Units) Takes discharge from multiple Sand

Delivery Units and delivers to the blenders.

Compartmented belt allows for high angle discharge of materials.

Details: 30” and Wider belts 1-1/4” tall cleats Sidewall heights of 2” to 6”

3” Peg Belt w/ Sidewall


“Peg” or “Finger” Belt

Conveys continuous flow of material

Powder to moderate lump sizes

Up to 45° Angles

High material capacity

Can be on Delivery Units or T-Belt Units

Details:

24” or 30” Wide (Peg pattern is 20”)

Available on any belt specification

Pegs are 70 durometer

Hot Vulcanized Super Screw

Mechanically fastened to belt

Can be installed on one end to expedite field installation

Reduces the installation time and tools required

Provides 5x greater adhesion than chemical bonds

Prevents product spillage through the splice

Belt End Preparation

Frack Sand can corrode and wear down metal fasteners that are not

protected with a rubber cover. Inspect often to prevent failure!

Mechanical Splice

Installed in Factory, no tools needed in field

How do I know what belt to use? Belt selection is based on;

Minimum pulley diameter

The configuration of the conveyor system including; Type & Style of return

Incline

Changes in incline

Slider bed or troughed rollers

Overall length

Height of incline

Weight of material

Can I change Styles of Frac Belts? For the most part, Yes.

Ensure new belt configuration fits the system, checking the following: Sidewall Height

Cleat clearances (recess, height, etc.)

Belt configuration may alter the speed at which a belt operates to deliver the same tonnage per minute.

Frac Sand Environmental Concerns• Small Pulley Diameters

• Small pulley diameters put chemical bonds under stress, causing pre-mature failure

• Extreme Environments• Extreme cold in South Dakota, Pennsylvania, Canadian markets

• Cold temperatures degrade the chemical bond, causing pre-mature failure

• Hot vulcanized sidewall is lasting 5x longer than Chemical bonds

• Field Location Difficulties• Timeliness to get to breakdown area

• Exposure to environment

• Potential lack of equipment / power sources

How to determine quality of a belt Import vs. Domestic

Location of manufacturing doesn’t matter, the quality does.

Safety Factors

Ply Adhesion

Elongation

Quality of Value-Add Process; Key term: Hot Vulcanization

FUNDAMENTALS OF CONVEYOR SYSTEMS Presented by: Laura Hoggan, Rubber & Plastics.

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Transcript of FUNDAMENTALS OF CONVEYOR SYSTEMS Presented by: Laura Hoggan, Rubber & Plastics.