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This is How to Convey Coal Skillfully

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However, the tolerances allowed for high speed conveyor components that are substantially tighter than their equivalent low speed counterparts. In particular, to reduce vibration and noise and extend idler life, CDI recommends that idler TIR not to be exceeded 0.4 mm at 7.5 m/s.

Only a handful of companies in the world can consistently manufacture idlers with 0.4 mm TIR. The typical welded end disk idler assembly usually fails to meet spec because the welding process warps the shell. Several leading edge manufacturers have approached the problem by designing press fit end disks. This is the approach Elecon chose when they designed a special idler roll just for Dahej. The result was an idler with consist low TIR.

Tubular Triangular Gallery

Prior to working on the Dahej system, CDI designed two triangular gallery supported conveyors in Nigeria. At Dahej, CDI was responsible for all detail design drawings of the conveyor gallery. This was the first time CDI created complete detail drawing of the triangular galleries. It was also PMC’s first time constructing triangular galleries. CDI’s engineering teams needed to work closely to create a practical design.

Meeting the Tight Structural Tolerances

specified by CDI to minimize vibration on the high speed conveyor proved a significant challenge for PMC particularly in horizontal galleries. Precise alignment was further complicated by the introduction of camber. Each 36 m gallery was constructed from three 12 m modules. Precisely fabricated wedges were butt welded between these modules to create a single 36 m long cambered gallery. Ultimately PMC designed a jig system to control the conveyor alignment to within the straight and horizontally curved galleries. The jig controlled the belt centerline to within w+/-1 mm.

PMC fabricated all galleries and bents in a laydown yard at the port. The gallery design could not accommodate training idlers and PMC engineers recognized that field adjustment of the idlers during commissioning would be difficult. To avoid belt training issues, the locations of the idlers were controlled to within 1mm. In the horizontal curves a custom idler jig was used to position the idlers. The work paid off as no idler adjustments were required during commissioning.

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