International Journal of Advanced Technology & Engineering Research (IJATER)

ISSN NO: 2250-3536 VOLUME 2, ISSUE 3, MAY 2012 195

Failure Analysis of Belt Conveyor system in a Thermal
Power Plant
Dr. Pratesh jayashwal*, Mr.Raghvendra Singh gurjar1, Mr.Arvind yadav2,
*HOD of Mechanical department, MITS COLLEGE GWALIOR (M.P.) 474005, INDIA
1&2 Student of Mechanical department, MITS COLLEGE GWALIOR (M.P.) 474005, INDIA
E-mail: raghvendra.gurjar354@gmail.com,arvind yadav647@yahoo.in

Abstract

Compared with actual situation of the thermal power
plant, this paper studies typical failure the belt conveyor
and maintenance of coal handling system in thermal
power plant. Analyze technical characteristics of coal
handling system and operating characteristics of relevant
machinery and equipment and describes the maintenance
method of prevention and elimination failure to ensure the
operation of belt conveyor. Then the safe operation of
coal handling system and the proper method of the
equipment maintenance are summed up. Analysis the
cause of failure, proposed some effective methods to
solve the problem.
Keywords: belt conveyor; failure analysis; solutions.
Introduction

Belt conveyor is a commonly used equipment of
continuous transport; it has a high efficiency and large
conveying capacity, simpler construction, small amount
of maintenance. Can be achieved at different distances,
different materials transportation. It is widely used in
mining coal handling system in thermal power plant and
other projects. Belt conveyor will often occur some
typical problems in the course, this paper based on
research common typical failure of belt conveyor during
use, analysis the cause of failure, proposed some effective
methods to solve the problems.
Belt Conveyor System

The belt conveyor system (BCS) consists of
Drive unit (electric motor, coupling multistage
gearbox ),
pulleys (drive pulley and other),
idlers,
belts (textile or with steel cords) with their joints,


Figure 1 simple belt conveyor system

Type of Failures in Conveyor Belt
System

Appears in belt conveyor system with reference to
conveyor components. It will be focused mainly to drive
units, pulley, idlers and belts as the most significant
components. It should be noted that there are nearly no
investigation in this area.
Drive Unit

The drive unit consist of electric motor, damping
coupling, two or three stage gearbox and coupling that
connect output shaft with pulley (fig). A crucial object in
this subsystem is gearbox. According to Matuszewski [5]
in a considered lignite open coal handling system even 14
% of gear boxes may be replaced each year due to
unexpected failures. These failures are related to the
geared wheel wear or damages (broken tooth) and bearing
(mainly over limit backlash due to environmental impact,
also typical failures like outer/inner race, rolling element).
International Journal of Advanced Technology & Engineering Research (IJATER)


ISSN NO: 2250-3536 VOLUME 2, ISSUE 3, MAY 2012 196

Figure 2 scheme of drive unit in belt conveyor system

It is easy to notice the significant decreasing number of
failure for 2004-2006 one of possible reason is that coal
handling system using condition monitoring techniques.
In this section will be consider the types of fault that


Figure 3 Number of failure of drive unit gearbox used in
belt conveyor system

Analysis for drive units used in coal handling system
done by [6]show that over 50% problems are related to
input stage that is a bevel stage.

















Figure 4 Percentage of failure for gearboxes used in coal
handling system




Figure 5 Example of damaged geared wheel

Pulleys

The pulley consists of two bearing, shaft, shell and
coating (special material in order to improve belt-pulley
contact), fig




Figure 6- pulley
0
5
10
15
20
25
30
35
1
9
9
3
1
9
9
4
1
9
9
5
1
9
9
6
1
9
9
7
1
9
9
8
1
9
9
9
2
0
0
0
2
0
0
1
2
0
0
2
2
0
0
3
2
0
0
4
total
number
of
failure
geared
wheel
bearing
International Journal of Advanced Technology & Engineering Research (IJATER)


ISSN NO: 2250-3536 VOLUME 2, ISSUE 3, MAY 2012 197
As it is shown on fig. (The number of failures depending
on pulley type) especially drives are very sensitive
elements.

Figure 7 Number of failure for different types of pulleys
used in coal handling machines
As Matuszewski [5] shown number of pulley failures may
reach over 60 per year that is 12% of used pulleys, fig.
one may notice two sources of primary problems, namely:
bearing, shell and coating.

In fig.8 one may see examples of damaged pulley coating
and bearing



Fig. 9 Examples of pulley faults

Motor-Coupling-Gearbox-Pulley in Coal
Handling System

Based on data obtained from maintenance department
(data from period January- November 2008) in one coal
handling system a simple analysis have been performed in
order to get the convince that many breakdown situations
could be omitted if CM is used. In fig. we show that for
so called department /flat BCS (MBCS) number of
breakdowns is much higher than that for smaller, so called
department/flat BCS (DBCS). The reason of this is that
MBCS is heavier loaded than DBCS (SEE FIG.)



Figure-10 Number of failure related to MBCS and DBCS
In fig.9 the number of failure related to elements of drive
unit is presented. As one may see the number of failure is
more or less similar for each element, however the
number of failures of gearboxes is in the highest value.
0
5
10
15
20
25
30
35
KWK
1500s
KWK
800M
Rs 560 SchRs
900
dropp
ing
other
drive
0
10
20
30
40
50
60
70
1
9
9
3
1
9
9
4
1
9
9
5
1
9
9
6
1
9
9
7
1
9
9
8
1
9
9
9
2
0
0
0
2
0
0
1
2
0
0
2
2
0
0
3
2
0
0
4
total
num
ber
of
failur
e
beari
ng
0
10
20
30
40
50
60
M
a
i
n
D
e
p
a
r
t
m
e
n
t
Number of failure vs type of
belt conveyor
Number of
failure vs type
of belt
conveyor
International Journal of Advanced Technology & Engineering Research (IJATER)


ISSN NO: 2250-3536 VOLUME 2, ISSUE 3, MAY 2012 198



Figure 11 Number of failure related to elements of drive unit
(motor-coupling-gearbox-pulley)

IDLERS

The failure analysis of idlers and belts are a bit different
issue [7, 8, and 11]. Idler are used for supporting belt with
transport materials. In some sense idlers are similar to
pulleys and consist of bearing and shell. One may expect
similar types of failures. The support system for belt
consists of three idlers. Because of different load of each
idler usually side idlers are more subjected to damage.
Worn Bearing in idlers will significantly increase external
load for drive units so power consumption will increase.
Damaged idlers and pulleys may be reason of damage for
belts.

Figure 12 - Distribution of load along belt - idler contact area
If one consider the impact of damaged idlers it is another
story. The idlers are quite small in comparison to pulley;
however, number of idlers is huge. Damaged idlers may
cause failure of belt (the cut of a belt ) or even may start
fire (belt slipping on damaged idler may increase
temperature up to 400
o
C, 450
o
C is the limit for so called
difficult-to-burn belt ) and as it was mentioned energy
consumption is a rising dramatically.
Belt
Depends on application, belt used in conveyor system
may be divided into two groups: textile belts and steel
cords belts. In coal handling thermal plant usually textile
belts are used. Expected problems for belts are related to
belt (tear, puncture, cut of belt and abrasion of bottom/top
covers) and its joints (connected using glue, vulcanized or
mechanical joint) [10, 11]. Because of dimension and
weight of a belt it needs to be transported in rolls, pieces
up to 100-400 m long, depends on a belt type. In order to
replace damaged a gearbox or pulley heavy machinery is
required. In some cases due to environment impact (for
example rain) it takes a few times longer time.
Typical faults of belt
Conveyor belt deviation
In the belt conveyor, as the conveyor belt is traction
components, transmit power and motion, and also is
carrying components, support material load. Working
more complex, so at work often happen belt deviation.
Deviation is the conveyor belt during operation, the center
line of belt deviation the center line of conveyor. as the
conveyor belt deviation may cause between the belt edge
and rack wear, cause belt edge premature damage,
ranging impact the life of conveyor, affect the throughput
of material, weight is caused by withdrawal material, even
happen stop occurrence, direct impact on production. As
the conveyor belt is more important, the most expensive
parts. Its price about 25%-50% to the conveyor. So
analysis the reason of belt deviation, reduce and eliminate
belt deviation, it is an important part of ensure belt to
work, extent equipment life. Cause the belt occurs
deviation because of the following factors.
In the device itself
a. Rack rigid is poor, large deformation under load,
causing the belt deviation.
b. The larger error of roller outer cylindrical,
caused deviation when the conveyor belt running
c. The supporting roller rotation is not flexible,
because the conveyor belt both sides stress to be
uneven, because the conveyor belt deviation.
d. The parallelism error cylindrical axis and roller
axis is too big \, causes the conveyor belt
deviation.
e. Conveyor belt itself is questionable quality, thin
and thick uneven, caused a shock lead running
conveyor belt deviation.
f. Not parallel with belt connector, connection error
is too big, cause belt deviation.
Installation adjustment
a. Drive change roller axis and conveyor centerline
vertical error is too big; make conveyor and
horizontal line have a bigger inclination, cause
belt deviation.
b. Roller axis and conveyor centerline vertical error
is big will cause belt deviation also.
0
10
20
30
couplinggearbox motor pulley
number of failure of drive
unit
number
of
failure
of drive
unit
International Journal of Advanced Technology & Engineering Research (IJATER)


ISSN NO: 2250-3536 VOLUME 2, ISSUE 3, MAY 2012 199
c. The connection strength between rack and
ground is not enough, the rack unstable, causing
belt deviation.
d. The feeding plate of discharge through and
improperly located, both sides of the conveyor
belt uneven force cause belt deviation.
With maintenance
a. The cleaning performance of sweeper is poor;
make the roller cylindrical diameter local
increases.
b. Feeding mouth location is wrong, so that the
material partial load on the conveyor belt, cause
belt deviation.
c. Poor maintenance and improper adjustment,
resulting in the conveyor belt deviation.
d. For the steel cord belt, as the manufacture of
steel cord is uneven force, so that a deviation
occurs in the operation, or a strong difference of
belt, large elongation under load, causing the
vibration, the belt will deviation.
e. Also, the vibration of running conveyor belt
system can cause the deviation.
f. In addition, when conveying some viscous
material, make the roller, etc. bonding material;
make the cylindrical diameter of roller part
increases, causing conveyor belt deviation.
Measures to prevent the belt
deviation
1. Due to equipment in the manufacture of
conveyor belt causes the deviation, primarily
through improved design, manufacture precision
to prevent and reduce the occurrence of conveyor
belt deviation.
2. For installation adjust improper and daily use
causes deviation, mainly the following aspects
should be considered:
Conveyor belt in drive roller or on rear rollers
deviation, usually by adjusting the position of roller
bearing ways to eliminate,
a. The longitudinal centerline of the roller rotation
axis and conveyor is not perpendicular, resulting
in the conveyor belt one side loose and other
tight, belt move from the tight side to the loose
side, occurs deviation phenomenon. Should be
adjusted bearing position of tighten deviation
side. Make horizontal pull of belt equal,
eliminate deviation. When tail roller device both
sides screw rod are not equal, resulting in caused
by imbalance.
b. Cylindrical axis is not horizontal, at both ends
bearing of height difference is cause another
reason of head or tail deviation. At this point, at
both ends roller bearing should add subtract
shims way to leveling roller axis, to eliminate
conveyor belt deviation.
c. Roller surface adhesion material, equivalent to
increasing the roller local diameter, will cause
the conveyor belt deviation, should strengthen
empty segment cleaning of conveyor belt to
reduce the adhesive material or dust
accumulation on the conveyor belt. In addition,
the conveyor belt between the nose and tail parts
deviation, called central or local deviation. Such
deviation reasons are more complex, it is with
the conveyor belt along device exposure to a
relationship. Need a detailed analysis for specific
issues. Using the following method can resolve
these issues.
A. Load or no- load branch roller axis with the
conveyor belt running centerline is not
perpendicular, causing tape at the roller
deviation. Deviation ends should adjustment
to the conveyor belt running direction. At
this often need to adjust the adjacent groups
of order to achieve the purpose of
eliminating deviation; adjusting deviation
angle should not be too big.
B. Conveyor belt joint with the tape centerline
(trumpet) is not perpendicular, to cause the
deviation, should improved installation
connection accuracy to eliminate deviation.
C. If material loaded on the conveyer belt is
straight; make the material block and weight
distribution along bandwidth direction
distribution serious inequality, cause
deviation, through adjustment blanking tube
and skirt plate location method to be
eliminated.
Recently, it was suggested that the method of
application film for transfer partial conveyor belt
because of high manufacturing costs and some
technical problems not well solved, makes this
method very difficult to promote the use.

Solutions
a. In the roller manufacturing process guarantee the
accuracy requirements, for example, pressing bearing
bore to achieve three precision, tubes at both ends of
dimensional tolerances, concentricity and ovality must
meet national standards. The products have strict
quality inspection to ensure that all products qualified.
Sealed lubrication, in addition to manufacturing quality
assurance, go with good lubricating materials. Such as
use of lithium-based grease, can improve the
lubrication of bearing which extend the life of the
roller is necessary.
International Journal of Advanced Technology & Engineering Research (IJATER)


ISSN NO: 2250-3536 VOLUME 2, ISSUE 3, MAY 2012 200
b. Bearing used to ball bearing support, plastic
sealing ring labyrinth seal structure, this can
ensure roller worked reasonable force, while
ensuring dust effect good, resistance small, easy
assembly and disassembly, easy to maintain,
reduce conveyor operating costs.
c. For gearboxes (geared wheel and bearing) and
pulleys (bearings) may use a vibration measure
based techniques [2] and temperature
measurement for bearing.
d. For idler condition thermography measurement
or noise may be used [13].
e. For belt with steel cords nondestructive
techniques may be applied(measurement of
magnetic field of steel cords)[14].for belt joint
for condition measurement some magnetic field
source may be placed in a joint area and by the
measurement of magnetic field the distance
between these points may be easily calculated
[15]. In order to detect cut of cover it was
proposed by one of belt produce to place kind of
electromagnetic field transmitter. If belt is cut,
electric circuit will be damaged and transmitter
will stop working [16, 17].
Conclusion
Wide ranges applications of belt conveyors, and the work
environment is generally more difficult, to keep
equipment running in good working condition, extend
equipment life, improve the quality of operation, reduce
operating costs has been the goal of engineering and
technical personnel. Analyze and resolve the impact
normal operation of the main problems, to ensure the
good functioning of device, it is an important work of
equipment maintenance. This paper analyzes the proposed
method. Helpful improve site maintenance staff levels to
solve practical problems, for practical project has
important significance.
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