Conveyor belts are often a critical link in production lines in cement plants, mining, thermal power plants and seaports. A single seized idler or a failed belt splice can stop the entire line. Regular maintenance following the checklist below helps detect damage early.
1. Idlers
- Listen for abnormal noise and check for idlers that do not turn or turn stiffly.
- A seized idler is constantly rubbed by the belt until its shell wears through; it wears the belt, increases the pulling force and can even create a fire hazard.
- Check bearing temperatures with an infrared thermometer and compare them between idlers.
- Replace damaged idlers promptly, using the correct diameter, length and seal type.
2. Belt misalignment
A mistracking belt wears the belt edges, spills material and damages the frame structure. Common causes: frame or idlers not installed square, off-center loading, material buildup on pulleys and idlers, and a belt splice that is not straight. Fix the root cause before using self-aligning idlers to correct tracking.
3. Loading zone
At the material drop point, the belt takes the heaviest impact. Use impact idlers (with rubber rings) or impact beds, and adjust the loading chute so that material lands in the center of the belt, in the direction of belt travel.
4. Belt cleaning
Material sticking to the return side of the belt builds up on idlers and pulleys, causing mistracking and wear. Check the belt scrapers, and use return idlers with rubber rings or discs for sticky, wet material.
5. Belt and splices
- Check for top cover wear, cuts, tears and ply separation.
- Check the splices (hot vulcanized, cold bonded or mechanical) for cracks, separation and misalignment.
- Choose the right cover when replacing the belt: abrasion-resistant, heat-resistant, fire-resistant or oil-resistant, depending on the material conveyed.
6. Pulleys and take-up
- Check the rubber lagging on the drive pulley: worn lagging causes belt slip.
- Check the pulley bearings and lubricate them with the correct grease at the correct intervals.
- Check the take-up: insufficient tension causes slip, while excessive tension damages splices and bearings.
Dong Tam supplies Rulmeca idlers and pulleys and Semperit conveyor belts, together with support for inspecting conveyor systems.
Need specific advice for your plant? Contact Dong Tam for support from our engineers.