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Thread: Typical Mistakes in Construction of a New Pipe Conveyor

  1. Typical Mistakes in Construction of a New Pipe Conveyor

    Based on your experience; Is there a repetitive bad practice or tipical mistake on construction of a new pipe conveyor??(for example: Bad design , bad detail engineering or bad assembly, bad manufacture.....).

    Statistically , what mistakes are more common?

    Last edited by Author; 9th September 2014 at 9:35.

  2. #2
    A. R. Singh

    A. R. Singh, B.Sc. Engineering




    Pipe conveyor problems

    Common problems in pipe conveyors are
    1.0 Not selecting proper belt and belt manufacturer.
    2.0 Motor is short of power
    3.0 Pipe conveyor pulley failure
    4.0 Pipe conveyor belt skewing
    5.0 Pipe not opening at head pulley
    Following precautions are to be considered while installing a New pipe conveyor
    1.0 Pipe conveyor expert should be involved in design of pipe conveyor
    2.0 Only experienced belt manufacturer to be selected for pipe conveyor belt
    3.0 Belt Selection is very very important. Most important is belt rigidity / Belt troughablity . If belt is not selected properly pipe formation will not be proper and conveyor may require abnormal power
    4.0 Motor shall have sufficient margin to cater for new Belt rigidity
    5.0 Belt profile should be very carefully selected considering proper horizontal and vertical curves considering pipe diameter, belt tension and belt rigidity
    6.0 Transition distances for pipe formation should be properly designed based on type of belt , tension rating and pipe diameter
    7.0 Idler diameter and spacing should be properly selected
    8.0 While selecting pulley shaft diameter higher shaft sizes to be selected to cater for higher tension rating due to stiff belts and higher motor ratings
    9.0 Fabrication and erection of conveyor Galleries and idler supporting structure should be very accurate particularly at curve portions.
    10.0 During commissioning alignment of idlers and pulleys is very important
    PLOT NO.325,SECTOR-24

  3. #3

    Smile Hirohito's Revenge?

    Another major mistake is choosing a pipe conveyor.

  4. #4
    Lawrence K. Nordell

    Lawrence K. Nordell

    President and CEO

    Conveyor Dynamics Inc.

    Conveyor Dynamics Inc.

    Professional Experience 60 Years / 11 Month Lawrence K. Nordell has 60 Years and 11 Month professional experience

    Discussions 304 Lawrence K. Nordell acceded to 304 discussions, Publications 0 Lawrence K. Nordell Nordell released 0 publications

    Know-How Design (1524) Lawrence K. Nordell used this tag 1524 times, Pipe Conveyor (239) Lawrence K. Nordell used this tag 239 times, Chutes (119) Lawrence K. Nordell used this tag 119 times

    Pipe Conveyor Selection

    Quote Originally Posted by johngateley View Post
    Another major mistake is choosing a pipe conveyor.

    If these comments build no understanding, what is the point of the comment?


    Pipe conveyors are more complex due to added degrees of freedom in the belt's construction as noted by Mr. Singh.

    Few of the designers of pipe conveyors have the necessary tools to keep from making same mistakes on belt construction, power analysis, wear life vs. idler configurations & installation tolerances, ....

    Most local designers are not informed, not educated, don't have proper engineering tools to provide pipe necessaries including: installation accuracy, fabric reinforcements, fabric types, constructions, behavior, in concert with tensile reinforcements, and what influence they have on pipe conveyor power, wear life, behavior of seam twisting, spillage, alignment leading to edge tracking errors and spillage. Yet, Indian companies give these illiterates orders because they are cheap. In India, initial bid money trumps design, trumps safety, trumps client's own best interest and common sense.

    They tell client belt warranty is 1-5 years. Rubbish. A well designed +1 km pipe conveyor should last 10 or more years unless abused. Many installations perform substandard to their potential, and is most often based on poor design.

    People extoll the benefits of pipe conveyor and spillage control. Go to any cement plant and observe it's pipe conveyors covered in cement powder, walkways covered in cement powder, terminal equipment covered in cement. This is accepted, because they have no installation to copy where this is not the norm. You need to spend the capital to provide the control.
    Lawrence Nordell
    Conveyor Dynamics, Inc.

    website, email & phone contacts:
    phone: USA 360-671-2200
    fax: USA 360-671-8450

  5. #5

    Talking Indians? I Didn't Even See the Arrows!

    Quote Originally Posted by nordell View Post

    If these comments build no understanding, what is the point of the comment?


    ..... Yet, Indian companies give these illiterates orders because they are cheap. In India, initial bid money trumps design, trumps safety, trumps client's own best interest and common sense.....
    One point of my comment was that pipe conveyors promise the earth and often deliver troubles. Somewhere between Indian and many other firms raising an enquiry/RFQ and giving orders to the cheapest bid there should be a tender review where the responsibility for correct selection is to the Client's account. Literacy is especially the Client's responsibility. If the initial enquiry was specifically pertaining to pipe conveyors then all other alternatives were probably excluded. With much EPC work, and similar, the Client places trust in his Consultant or main Contractor with or without prior knowledge. A Punter (Client) only wants to know what it will do for him? How much it will cost? When will he get it?
    Pipe conveyors seem to be fashionable in some parts of the world and I personally suspect that this quest for fashion overrides well trodden and simpler technology. Covered troughed conveyors used to give weather protection in days of yore so what's the difference today? Pipe belts use considerably more rubber and rollers, and then some, so where is a blanket justification for their selection originating from?
    Until mentioned by Larry, I was blissfully ignorant that cheaper Suppliers aligned stringer sections rather than individual idler sets. That, for me, explains a lower CAPEX price and at the same time raises suspicions about such a Suppliers quote and their subsequent detail design etc. etc.

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