Conveyor Auxiliaries - WP

Document Number: 515P-02004-TR-CM-0001
Intentionally Blank
Page No:2
Operator Training Module

Port Expansion Project
Conveyor Auxiliaries
Table of Contents
Control Page .................................................................................................. 1
Table of Contents .......................................................................................... 3
1 .
Learning Outcome ................................................................................. 5
2 .
Assessment Criteria ............................................................................... 5
3 .
Prerequisite ............................................................................................ 5
4 .
Conveyor Auxiliaries ............................................................................ 6

4.1 Monitoring and Measuring Instruments ......................................................... 6
4.2 Conveyor Take-up Unit ................................................................................. 9
5 .
Belt Cleaners ....................................................................................... 13

5.1 Primary Belt Cleaner .................................................................................... 13
5.2 Secondary Belt Cleaner ................................................................................ 14
5.3 Return Belt Cleaner (Belt Plough) ............................................................... 15
6 .
Tramp Iron Magnet ............................................................................. 17

6.1 Components and Functions .......................................................................... 17
6.2 Controls ........................................................................................................ 20
7 .
Metal Detector ..................................................................................... 25

7.1 Principle of Operation .................................................................................. 25
7.2 Components of Metal Detector .................................................................... 27
8 .
Shuttle Assembly................................................................................. 32
9 .
Questions on Conveyor Auxiliaries .................................................... 34
8 .
Answers to Questions .......................................................................... 41
Document No: 515P-02004-TR-CM-0001 : Rev 0
Page No:3
Intentionally Blank
Page No:4

1.
Learning Outcome
When completing this training module, the trainee will able to:
Describe functions of any one of the conveyor monitoring and measuring instruments;
Identify and describe functions of major components in:

o
o
o
o
o
2.
A typical conveyor take-up unit;

Any one of the three types of conveyor belt cleaners;
A conveyor tramp iron Magnet;
A conveyor metal detector; and
A typical shuttle assembly.
Assessment Criteria
The trainee will be assessed in a written examination in which he or she must correctly answer at
least 85% of the questions. These questions will relate to:
Functions of any one of the conveyor monitoring and measuring instruments;
Identification and functions of major components in:

o
o
o
o
o
3.
A typical conveyor take-up unit;

Any one of the three types of conveyor belt cleaners;
A conveyor tramp iron magnet;
A conveyor metal detector; and
A typical shuttle assembly.
Prerequisite
Before starting on this module, the trainee must successfully complete the following training
module:
The Conveyor Drive Unit training module, numbered 515P-02004-TR-CN-0002.
Page No:5
4.
A conveyor, apart from its drive unit, normally contains the following auxiliaries to allow it to
function correctly:
Monitoring and measuring instruments;
Take-up unit
Belt cleaners;
Tramp iron magnet;
Metal detectors; and
Shuttle assembly.
4 .1
Monitoring and Measuring Instruments
4.1.1
Each conveyor normally has the following monitoring and measuring instruments that
provide the necessary information about the operational state of the conveyor to the control system:
Pull-wire switches;
Belt-drift switches;
Belt-rip detectors;
Blocked-chute switches;
Under-speed switches;
Tachometers; and
Belt weighers.
Should the signals transmitted by these monitoring and measuring instruments indicate faulty
situations detrimental to the conveyor or process system, the control system trips the conveyor.
4.1.2
Pull-wire switches are installed
at nearly equal intervals on both sides of a
conveyor. They are connected to trip wires that
run along the sides of the conveyor. The
purpose of these switches is to stop the conveyor
in emergency cases. To activate a pull-wire
switch, you can simply pull the trip wire.
Once activated, a pull-wire switch stops the conveyor immediately if it is running in any mode and
will not allow it to restart. You need to manually reset an activated pull-wire switch to allow the
conveyor to start.
Page No:6

4.1.3
Belt-drift switches continuously monitor
the correct positioning of a conveyor belt along the
conveyor profile at various points. If the belt of a
conveyor drifts to one side, it will push the activating arm
of the belt-drift switch in that vicinity to activate the
switch. This causes the control system to trip the
conveyor if the conveyor is running in automatic or
remote manual mode. It will also prevent the conveyor
to start in automatic or remote manual mode. However,
these switches do not affect the conveyor operation in
local manual mode.
After correcting the drift of the belt, you can reset an
activated belt-drift switch by running the conveyor in
local mode for a short time.
4.1.4
Belt-rip detectors continuously
monitor a conveyor for any tear in the conveyor
belt. One type of belt-rip detectors used in the
Port Expansion Project is the wire-type detectors
shown here. In this type of detectors, a wire line
runs closely under the load-carrying belt with one
side of it holding a spring-loaded trigger of a
switch. If there is a tear in the belt, the torn piece
will cut the wire line, causing the trigger to retreat
and activate the switch.
When a belt-rip detector switch activates, the
control system stops the conveyor if it is running
in automatic or remote manual mode and prevent
it from starting in these modes.
After repairing the belt, you have to manually reset the detector to allow the conveyor to start in
automatic or remote manual mode. You can do this by replacing the broken wire line.
4.1.5
There is also a pan type rip
detector that the project uses to detect a tear in a
conveyor belt. This type has a tray under the belt
with the tray kept in its horizontal position by a
balance weight that can slide on a cantilever for
proper adjustment. With the tray in its horizontal
position, a target plate on the cantilever rests on a
proximity switch for the switch to signal the
control system, indicating healthy state of the
conveyor belt. If the belt develops a tear, some
of the material carried by the belt falls on the tray
through the tear, causing the tray to go down.
This moves the target plate on the cantilever
upwards away from the proximity switch,
causing the control system to trip the conveyor if
it is running in automatic or remote manual
mode.
You can manually reset this type of detectors by simply removing the material that is on the tray.
Page No:7
4.1.6
Blocked-chute switches are installed in the
discharge chutes of conveyors to detect build-up of material in
these chutes. A blocked chute switch mainly consists of a
hanging tilt switch that while it remains in its vertical position
(not tilted) it sends no signal to the control system, indicating
that the chute is clear. If the build-up of material rises to the
point that it tilts the switch, the switch starts signalling the
control system, which causes the control system to trip the
conveyor if the conveyor is running in automatic or remote
manual mode. However, the control system does not stop the
conveyor if it is running in local mode. When a blocked-chute
switch is active, the control system does not allow the related
conveyor to start in any mode. To reset a blocked-chute switch,
you simply need to clear the material from inside the chute.
4.1.7
An under-speed switch measures the speed of a non-driven pulley of a conveyor,
normally the tail end, to determine whether or not the conveyor belt is slipping. For each conveyor,
the control system knows the speed at which the non-driven pulley must rotate if there is no belt
slippage. Consequently, it allows the conveyor to run in automatic or remote manual mode
provided the speed signal sent by the under-speed switch agrees with the correct pulley speed to
within an acceptable range of deviation. If the speed signal indicates a speed outside the acceptable
range for a few seconds, the control system trips the conveyor. However, if the conveyor is running
in local manual mode, the control system ignores the speed signal sent by the under-speed switch.
The under-speed switch consists of a proximity
switch that continuously counts the number of
times flags of a target plate pass beside it. Since
a target plat normally has eight flags, one-eighth
of the flag count every minute represents the
revolution per minutes of the pulley, which is
proportional to the speed of the belt. Since the
speed of each conveyor belt is different, the
number of counts that corresponds to the correct
speed of a belt differs from one conveyor to
another. Consequently, each under-speed switch
has a different set point that represents the
minimum acceptable number of counts in a
minute for its conveyor.
The switch requires no resetting and allows the conveyor to restart immediately after stopping it.
Also, when a conveyor starts in automatic or remote manual mode, the control system initially
ignores the speed signal of its under-speed switch to allow the conveyor to run up to its correct
speed.
4.1.8
Each conveyor that has a belt weigher has also a tachometer, normally at its nondriven tail pulley, for measuring the speed of the belt. A tachometer is very similar to an underspeed switch. It supplies the belt weigher with a signal that represents the speed of the belt.
4.1.9
A belt weigher is a measuring instrument that is installed in a convenient location
under the conveyor belt and measures the conveyor load per meter run of the belt. It is installed on
conveyors whose tonnage rate measurement is critical in correct operation of the plant.
Page No:8

A belt weigher combines its measurement with the speed signal it receives from the conveyor
tachometer to arrive at the instantaneous tonnage rate of the conveyor. It then signals the tonnage
rate of the conveyor to the control system. The control system uses the signal for control purposes
and shows it on the control room monitor, normally in tonnes per day (t/d).
4 .2
Conveyor Take-up Unit
4.2.1
Generally, conveyors in the port ore handling plant use two methods of maintaining the
correct tension in their belts:
gravity take-up; and

hydraulic take-up.
There are also two types of gravity take-up:
The festoon type in which the belt goes around a freely hanging take-up pulley that is being
pulled down by a hanging weight.
The trolley type in which the take-up pulley is on a rail-mounted trolley at ground level. A
hanging weight applies a horizontal pull at the trolley through a system of wire ropes and
sheaves.
4.2.2
Figure 1 shows the main features of a typical festoon-type gravity take-up. In this type,
the conveyor take-up pulley is mounted on top of a take-up frame that hangs freely within a take-up
tower. A mass of mainly concrete on the floor of the take-up frame continuously applies a pull on
the conveyor take-up pulley. This takes up the slack and keeps the belt under a constant tension.
4.2.3
The take-up pulley, although under the constant pull of the hanging weight, is not
stationary; a few factors influence its height within the take-up tower:
When the conveyor starts, the take-up frame goes down and then up, and then continues its
up-and-down motion that progressively becomes smaller until eventually it settles at its stable
position. The softer the conveyor start is, the smaller the magnitude of the initial up-anddown movement of the take-up frame will be. So, if something goes wrong with the soft start
of a conveyor, it is possible for the take-up frame to bounce high enough to hit the upper
structure of the take-up tower and cause some damage. That is why there is a take-up limit
switch at a distance above the take-up frame that immediately stops the conveyor if the takeup frame bounces up to that height while the conveyor is running in automatic or remote
manual mode.
Conveyor belts stretch when the weather is hot and contract when the weather gets cold. So,
the stable height of the take-up pulley (or frame) changes with the atmospheric temperature.
Conveyor load is another factor that influences the length of a conveyor belt. The heavier the
conveyor load is, the longer the conveyor belt will stretch, which causes the stable height of
the take-up pulley to become shorter.
Age is yet another factor to consider. As conveyor belts get older, they stretch and become
longer. So, the stable height of the take-up pulley gradually decreases as the conveyor belt
gets older. Consequently, you have to cut a piece of conveyor belt periodically to return the
belt to its original length and the take-up pulley to its original height.
4.2.4
There is a winch near the floor of the take-up tower that is not normally used. When
there is a need for slacking the conveyor belt for maintenance, you can use the winch to lift the
take- up frame. The winch has a motor that incorporates a brake. While the motor power is on, the
Page No:9
motor brake holds the winch in its position when the motor is not running in either forward or
reverse direction. The winch has a locking claw that you can manually engage to prevent the winch
from rotating backward and dropping the take-up frame when the power supply is turned off.
Figure 1: Main Features of a Typical Festoon-Type Gravity Take-up
Page No:10

4.2.5
Figure 2 shows the main features of a typical trolley-type gravity take-up of a conveyor.
In this type of gravity take-up, there is a take-up trolley that can move horizontally on rails. The
design normally uses a number of bend pulleys to bring the belt into a horizontal position, as shown
in figure 2. However, there are some conveyors whose tail pulleys are already in a horizontal
position and can be used as take-up pulleys without the use of bend pulleys.
Figure 2: Main Features of Trolley-Type Gravity Take-up

4.2.6
Close to the take-up pulley, a take-up weight hangs in a take-up tower through a system
of wire ropes and sheaves. One end of the wire rope is held firmly by a winch at the tower floor
level while the other end, after passing through all the necessary sheaves, is solidly anchored at the
first guide sheave frame ahead of the trolley. A sheave at the front end of the trolley converts the
downward pull of the take-up weight into a horizontal pull on the trolley, maintaining a constant
tension in the conveyor belt.
4.2.7
As the belt stretches with age, the stable position of the trolley moves forward and the
stable position of the take-up weight moves down. Periodically, you can raise the take-up weight to
its original position by using the winch to shorten the length of the wire rope. However, this does
not change the position of the trolley. Eventually, when the trolley moves too far forward, you need
to cut a piece of the belt to return the belt to its original length and the trolley to its original stable
position.
Page No:11
4.2.8
Short conveyors such as belt feeders normally use hydraulic cylinders at their tail ends
to maintain correct tension in their belts. Figure 3 shows the main features of a typical take-up unit
that uses hydraulic take-up unit.
Figure 3: Main Features of a Typical Hydraulic Take-up Unit

4.2.9
A hydraulic take-up unit uses two hydraulic cylinders that each connects to the end
bearing of the tail pulley shaft at one end and to the steel frame of the conveyor at the other end.
The end bearings of the tail pulley shaft can slide back and forth. Inside the hydraulic cylinders,
pressurised grease exerts enough force on each bearing of the tail pulley to correctly tension the
conveyor belt. The amount of grease pressure in the cylinders depends on the cylinder size and the
required tension in the belt. It is often around 4.5 MPa which translates into about 3.0 t of force
being exerted on the tail pulley bearings.
4.2.10
Since conveyors that use hydraulic take-up units are often short, temperature variation
has little effect on the pressure inside the hydraulic cylinders. So the grease pressure inside the
cylinders will not rise considerably. However, the pressure will gradually drop due to small
leakages. So, periodically you need to use a grease gun to increase the grease pressure inside the
hydraulic cylinders to re-tension the belts.
Page No:12

5.
Belt Cleaners
5.0.1
There are three types of belt cleaners that conveyors in the port ore handling plant use to
keep the belts clean:
Primary belt cleaners that clean the load-bearing surfaces of the belt at just below the
horizontal centreline of the conveyor head pulley.
Secondary belt cleaners that clean the load-bearing surfaces of the belt normally under the
head pulley.
Return belt cleaners or belt ploughs that ride on the backside of the belt for moving and
dropping the fugitive material off the side of the belt.
5 .1
Primary Belt Cleaner
5.1.1
Figure 4 shows the main features of a primary belt cleaner. The cleaner consists of a
number of scraper modules each consisting of a cushion base bolted to a suspension frame with the
scraper tip also bolted to the suspension frame on top. Scraper modules are mounted on a main
shaft supported by a mounting bracket at each side. The main shaft can rotate inwards and
outwards by raising or lowering the adjustment arms with the use of adjustment nuts.
Figure 4: Main Features of a Primary Belt Cleaner

5.1.2
As the scraper tips continue to clean the belt, they gradually wear and eventually lose
contact with the belt surface. Materials carried by the belt or scraped off the belt can also foul the
scraper modules. Consequently, to maintain a high cleaning efficiency, it is necessary to perform
routine inspection of a primary belt cleaner and, if necessary, adjust it as well as cleaning the
modules once every week. If the scraper tips have lost contact with the belt, you need to raise the
Page No:13
adjustment arms to bring the scarper tips in contact with the conveyor belt as well as ensuring that
all tips apply a small cleaning pressure across the cleaning face.
WARNING
When you intend to do maintenance on a belt cleaner, you
must first stop and isolate the conveyor.
5.1.3
In your weekly routine inspection of a primary cleaner, you should do as follows:
(a)
Stop and isolate the conveyor.
(b)
Access the primary cleaner and check the condition of the scraper modules. If they are fouled
by material, clean them with a hard bristle brush or, if allowed, wash them with water.
(c)
Check to ensure that all blades are lightly touching the belt surface. If not, use the adjustment
nuts on both sides to rotate the main shaft towards the conveyor belt until all scraper tips
lightly press on the belt surface.
Caution
Applying excessive scraper tip pressure does not increase
the cleaning efficiency. Instead, it causes the tips to rapidly
wear out.
(d)
If one or more scraper tips are worn, replace all of the tips with new ones and correctly adjust
the cleaner for all tips to lightly press on the belt surface.
5 .2
Secondary Belt Cleaner
5.2.1
Figure 5 shows the main features of a secondary belt cleaner. The cleaner consists of a
number of scraper modules each consisting of a cushion base bolted to the scraper tip. Scraper
modules are mounted on a main shaft that is held at each end by a shaft clamp. Each clamp is on an
adjustment bracket. The adjustment brackets are bolted to mounting brackets, but can be raised or
lowered by slackening the adjustment bracket nuts and sliding the clamps up or down before
tightening the nuts.
5.2.2
A secondary belt cleaner works in conjunction with the primary belt cleaner. It is normally
placed under the head pulley of the conveyor so that its scraper tips contact the belt at a
perpendicular angle to the belt as the belt leaves the head pulley.
5.2.3
Similar to the primary belt cleaner, secondary belt cleaner scraper tips wear as they
continue to operate. Materials cleaned off the belt can also foul scraper modules. Consequently, to
maintain a high cleaning efficiency, you need to do a routine inspection of a secondary belt cleaner
and, if necessary, clean and adjust it once every week.
5.2.4
(a)
In your weekly routine inspection of a secondary belt cleaner, do as follows:

Stop and isolate the conveyor.
Page No:14

(b)
Access the secondary cleaner and check the condition of the scraper modules. If they are
fouled by material, clean them with a hard bristle brush or, if allowed, wash them with water.
(c)
Check to ensure that all blades are lightly touching the belt surface. If not, raise the
adjustment brackets on both sides to raise the main shaft towards the conveyor belt until all
scraper tips lightly press on the belt surface.
(d)
If one or more scraper tips are worn, replace all of the tips with new ones and correctly adjust
the cleaner for all tips to lightly press on the belt surface.
Figure 5: Main Features of a Secondary Belt Cleaner
5 .3
Return Belt Cleaner (Belt Plough)
5.3.1
Figure 6 shows the main features of a return belt cleaner (or belt plough). The cleaner
consists of two locking pipes that support the plough through three polyurethane support straps.
These straps are resilient enough to keep the plough in contact with the belt surface. The cleaning
part of the plough consists of a polyurethane shovel-nose blade and two polyurethane blade wings.
These blades are mounted on a triangular steel frame with nuts and bolts.
5.3.2
A plough is normally placed before the tail pulley or any other position where fugitive
material can become trapped between the belt and a pulley. The cleaner job is to ride on the
backside of the belt for moving and dropping the fugitive material off the sides of the belt. This
ensures that the material does not reach the belt pulley to become trapped and cause damage to the
belt and pulley.
5.3.3
Like all other belt cleaners, you need to inspect a plough once every week to ensure that it
is clean and all three of its blades are in continuous contact with the belt without pressing down on
the belt excessively. You can adjust the tension of a plough by unlocking all eight collar
lockscrews and rotating the locking pipes either clockwise or anticlockwise. Rotating a locking
pipe in one direction increases the pressure of the blades on the belt while rotating the pipe in the
opposite direction decreases the pressure.
Page No:15
Figure 6: Main Features of a Return Belt Cleaner (Belt Plough)

5.3.4
To correct the tension of a belt plough, you need to unlock the collar lockscrews and first
rotate the locking pipes so that the plough lifts from the belt. Then, you should slowly rotate the
locking pipes in the opposite direction until the blade tips lightly press on the belt surface before
locking the collar lockscrews. The shovel-nose blade and blade wings of a plough must be replaced
with new ones if they wear to an extent that the metal frame is between 2 to 1 cm away from
touching the belt.
Page No:16

6.
Tramp Iron Magnet
6 .1
Components and Functions
6.1.1
A tramp iron magnet (magnet for short) mainly consists of an electromagnetic coil within
an oil tank that, when energised, produces a powerful magnetic field. The function of a magnet is
to hang over a running conveyor and attract ferromagnetic materials such as tramp irons towards
the tank base plate. This ensures that the conveyor product passed the magnet is free from tramp
irons, protecting the downstream equipment from receiving damages that a tramp iron can cause.
Figure 7 shows the main features of a magnet.
Figure 7: Main Features of a Tramp Iron Magnet

6.1.2
A magnet has a hoist that uses four 4.6-kW electric motors to raise or lower the magnet
above the associated conveyor. The magnet has also a rail-mounted trolley that uses a 0.75-kW
electric motor to move the magnet from above the conveyor to over a dump bin and return it from
over the dump bin to above the conveyor. When a magnet is operating in automatic mode over its
running conveyor, it performs a dump operation periodically, normally once every eight hours.
During this dump operation, the hoist and trolley work together to move the magnet to over the
dump bin where the magnet de-energises, allowing the attracted materials to drop into the bin.
After a short pause, the trolley and hoist work together again to move the de-energised magnet over
the running conveyor where the magnet energises to resume its normal function.
Page No:17
6.1.3
A magnet performs a dump operation when its conveyor stops running, regardless of the
lapse time from its last dump operation. However, it will not energise when returning over its
conveyor. It will energise when the conveyor restarts running in automatic mode.
6.1.4
When a magnet is energised, the power that is spent in producing the magnetic field turns
into heat energy that heats the oil in the magnet oil tank. If the oil is not cooled through a cooling
circuit, the oil temperature close to the electromagnetic coil (core temperature) rises to 125C with
the temperature of the oil tank surfaces rising to 90C. The heat energy that surrounds the
electromagnetic coil reduces the strength of the magnetic field.
6.1.5
To ensure that the magnet runs at its intended magnetic field strength, the magnet is
provided with an oil cooling circuit. Figure 8 shows a schematic diagram of the magnets oil
cooling circuit. The circuit contains an oil pump driven by a 0.75-kW electric motor. When the
magnet starts to operate in automatic mode, the oil pump starts running to take the oil from the oil
tank near the tank bottom and circulate it through an oil cooler.
Figure 8: Magnets Oil Cooling Circuit Schematic Diagram

6.1.6
The oil cooler has a fan that is driven by a 0.75-kW electric motor. The fan runs
continuously when the magnet is operating in automatic mode to cool the oil with air. A combined
temperature/flow switch unit at the oil inlet to the oil cooler continuously monitors the oil
temperature and provides the control room operator with a warning if the oil temperature rises
above 90C. The flow switch of the unit provides the operator with a warning if the oil flow drops
below an acceptable level. Any one of the following conditions will cause the oil flow to stop or
become unacceptably low:
An oil isolation valve being closed or partially closed.

A fault occurring in the oil pump.
A blockage occurring in the oil line.
A low oil flow will eventually cause the oil temperature to rise above its warning level.
Page No:18

6.1.7
The magnet has an oil fill plug on top and an oil level plug on its front face. You can
check the oil level through the oil level plug when the magnet is isolated and cold. The normal oil
capacity of the tank is 2870 L. The oil used in the tank must either be BP Inhibited Transformer
Oil or equivalent. However, you must not mix two different brands of oil even though each one
may be suitable for use.
When the magnet is cold and you remove the oil level plug, you should be able to see the oil level
close to the lower edge of the oil level opening. The oil should also be clear and not turbid or
cloudy. If the oil is not clear, it is no longer suitable for use in the tank and you should drain the
entire tank before refilling it with new oil.
6.1.8
To top up the oil in the magnets oil tank, you should perform as follows:
WARNING
Do not perform any maintenance on a magnet unless it is
Isolated and cold. It takes a magnet at least six hours from
de-energisation to cool down.
(a)
Follow the site isolation procedure to isolate the magnet.
(b)
Allow the magnet to cool down.
(c)
Ensure that all oil isolation valves are fully open.
(d)
Thoroughly clean the oil fill plug and oil level plug as well as their surrounding areas to
ensure that no dirt can enter the tank when the plugs are removed.
(e)
Remove the oil fill and oil level plugs, and their oil seals.
(f)
Check to ensure that oil in the tank is visible from the oil level opening and it is clear.
(g)
Add oil through the oil fill opening, preferably through a fine strainer, until the oil level rises
to just below the lower edge of the oil level opening.
(h)
Renew the plug oil seals and then refit the oil fill and oil level plugs.
WARNING
Checking the correct operation of the oil tank pressure
relief valve must occur when the magnet is isolated and
cold. If testing occurs when the magnet is hot, hot oil
can spray out of the valve and scold personnel.
6.1.9
When the magnet energises, the tank oil temperature rises, which causes the oil to expand.
The expansion of oil compresses the air on top of the oil, causing the tank pressure to rise. A
pressure relief valve on top of the oil tank safeguards the tank against overpressurisation. The valve
opens to relieve the excess pressure if the tank pressure rises above 450 kPa. To ensure that the
pressure relief valve remains in good operating conditions, you need to periodically lift its springloaded cap and then release it during the time when the magnet is isolated and cold. The cap should
return to its depressed position sharply and show no sign of resistance to the retracting force of the
valve spring. You can also lubricate the relief valve with WD40 while checking its operation.
Page No:19
6.1.10 A magnet normally operates between two metal detectors. The metal detector upstream of
the magnet acts as a sensor for pre-warning the control system of the arrival of a tramp iron. The
metal detector downstream of the magnet acts as a shutdown device if the magnet fails to remove
the tram iron.
6.1.11
The magnet can energise at three different levels:
Low level;
Medium level; and
High level.
When operating under automatic control, the magnet energises at low level while the upstream
metal detector does not detect any tramp iron. It switches to high-level energisation immediately
the upstream metal detector detects a tramp iron. This action is to generate a magnetic field that
can penetrate deep into the ore and remove the tramp iron. However, the magnet can sustain this
high-level of energisation for as long as 120 seconds without being prone to damage.
Consequently, after 120 seconds of maintaining high energisation level, the control system switches
the magnet back to its low energisation level. The control system will not revert to high
energisation level for at least 20 second after switching to low-energisation level to prevent the
magnet from receiving damages. Should a fault causes the magnet to remain at high energisation
level for longer than 125 seconds, the control system trips the magnet to prevent it from getting
damaged.
When the magnet operates in a mode other than automatic, it energises at medium level and will not
switch to either low or high energisation level.
6 .2
6.2.1
Controls
Like all other items of equipment, a magnet has three mode of operation:
Automatic;
Remote manual; and
Local manual.
Provided all drives and magnetisation circuit of the magnet are healthy, the control room operator
can select the magnet for automatic operation. In the automatic mode, the control system controls
the operation of all drives and magnetisation circuit of the magnet by:
Energising the magnet over its conveyor when the conveyor starts running in automatic mode.
Periodically (normally once every eight hours), taking the magnet through its dump operation
before returning it back to its operating position.
Switching the energisation level of the magnet between low and high appropriate to the
upstream metal detector state of activation.
When the magnets conveyor stops running in automatic mode, taking the magnet through its
dump operation and returning it to its operating position, but stopping the oil circulation and
cooling, and keeping the magnet in its de-energised state.
6.2.2
The control room operator can select the magnet to remote manual control, in which case
the operator takes control of the drives and magnetisation circuit of the magnet from the control
room. The control room operator can also select the magnet to local manual control, in which case
all drives and magnetisation circuit of the magnet go under the control of the magnets local control
panel push-buttons.
Page No:20

6.2.3
When a magnet is under automatic control, the control system starts its operation at the
same time it start the operation of the conveyor to which the magnet belongs. The automatic
starting sequence of a magnet is as follows:
(a)
If the magnet is not over the conveyor:

(1)
A siren sounds for 10 seconds.
(2)
The magnet moves to its elevated operating position.
(3)
The magnet moves down to its correct operating position above the conveyor belt.
(b)
The magnets oil pump starts running.
(c)
The magnets cooling fan starts running.
(d)
The magnet energises at its low energisation level.
6.2.4
When the magnet is operating under automatic control, the control system takes it through
its dump operation about once every eight hours according to the following sequence:
(a)
A siren sounds for 10 seconds.
(b)
The magnet moves up to its elevated operating position.
(c)
The magnet moves to above its dump bin (dump position).
(d)
The magnet de-energises to release the attracted materials.
Caution
Not allowing at least 60 seconds between de-energisation and
energisation of the magnet can damage the magnets rectifier.
(e)
The magnet remains de-energised for at least 60 seconds in its dump position.
(f)
The magnet moves to its elevated operating position.
(g)
The magnet moves down to its correct operating position above the conveyor belt.
(h)
The magnet energises at its low energisation level.
6.2.5
When the magnets conveyor stops running in automatic mode, the control system takes
the magnet through its dump operation, but without energising the magnet when the magnet is in its
correct operating position. The control system then stops the magnets oil pump and cooling fan.
WARNING
When operating the magnet under local manual mode, do as
follows to ensure of your safety and safety of others:
Do not allow a person with pacemaker to get to within

10 m of the energised magnet.
Do not get to within 1 m of the energised magnet and

ensure that nobody else does.
Do not carry any electromagnetic object with you and

ensure that no loose electromagnetic object is near the
magnet before energising the magnet.
Page No:21
6.2.6
Figure 9 shows features of a magnet local control panel located close to the magnet. The
control panel push-buttons, except the EMERGENCY and LAMP TEST buttons that are active at all
times, become active when the control room operator selects the magnet for local manual mode of
operation. However, the panel indicators remain operational under all magnets modes of
operation. The panel indicators and push-buttons function as follows:
The MODE REMOTE white indicator light comes on when the magnet is selected for either
automatic or remote manual mode of operation. When this light is on panel push-buttons,
except the EMERGENCY and LAMP TEST buttons, are inactive.
The MODE LOCAL whit indicator light comes on when the magnet is selected for local manual
mode of operation. When this light is on all panel push-buttons are functional as described in
the following paragraphs.
Figure 9: Features of Magnet Local Control Panel

Page No:22

The MAGNET ENERGISE red push-button, when active and you press it, it energises the magnet
at its medium magnetisation level. This will also cause:
The MAGNET green indicator light to come on;

The voltmeter to show about 230 Vdc applied across the magnet coil; and
The ammeter to show about 104 A if the magnet is cold or about 83 A if the magnet is
hot.
The MAGNET DE-ENERGISE green push-button, when active and you press it, it de-energise
the magnet and causes:
The MAGNET green indicator light to go off;

The voltmeter reading to go down to zero voltage; and
The ammeter reading to go down to zero ampere.
The FAN START green push-button, when active and you press it, starts the magnets cooling
fan, which also brings on the FAN green indicator light.
The FAN STOP red push-button, when active and you press it, stops the magnets cooling fan,
which also turns off the FAN green indicator light.
The PUMP START green push-button, when active and you press it, starts the magnets oil
pump, which also brings on the PUMP green indicator light.
The PUMP STOP red push-button, when active and you press it, stops the magnets oil pump,
which also turns off the PUMP green indicator light.
The TROLLEY IN black push-button, when active and you press it, moves the magnet towards
its operating position above the conveyor belt. The magnet will continue to move with one
press of the button until either you press the TROLLEY STOP red push-button or the magnet
reaches its operating position.
The TROLLEY OUT black push-button, when active and you press it, moves the magnet
towards its dump position above the dump bin. The magnet will continue to move with one
press of the button until either you press the TROLLEY STOP red push-button or the magnet
reaches its dump position.
The TROLLEY OPERATING POSITION blue indicator light comes on when the magnet is in its
correct operating position above the conveyor belt. It goes out immediately the magnet starts
moving away from its correct operating position.
The TROLLEY DUMP POSITION blue indicator light comes on when the magnet is in its dump
position above the dump bin. It goes out immediately the magnet starts moving away from its
dump position.
The HOIST UP black push-button, when active and you press it continuously, moves the
magnet upwards. The magnet stops moving up when you stop pressing the button or when
the magnet reaches its top position.
Caution
The hoist is not designed to support the magnet for a long period
of time. That is why the hoist does not take any load when the
magnet is in its bottom position. Consequently, you must not keep
the magnet at high position longer than 10 minutes to avoid
damaging the magnets hoist.
Page No:23
The HOIST DOWN black push-button, when active and you press it continuously, moves the
magnet downwards. The magnet stops moving down when you stop pressing the button or
when the magnet reaches its bottom position.
The HOIST TOP blue indicator light comes on when the magnet is in its top position. It goes
out immediately the magnet starts moving down away from its top position.
The HOIST BOTTOM blue indicator light comes on when the magnet is in its bottom position.
It goes out immediately the magnet starts moving up away from its bottom position.
The LAMP TEST white push-button is active at all times. If you continue to press the button, it
brings all of the panel indicator lights on. If any one of the indicator lights remains off while
you are pressing the LAMP TEST button, the bulb of the indicator is burnt out and you need to
renew it as soon as possible.
The EMERGENCY button is active at all times. If you press it, the button latches in its
depressed position and shuts down the magnet by stopping drives and de-energising the
magnet. While the button remains in its depressed position, it does not allow the drives and
magnetisation circuit of the magnet to operate in any mode. To reset the button, you need to
pull it out of its depressed position.
Page No:24

7.
Metal Detector
7 .1
Principle of Operation
7.1.1
A conveyor whose load could contain tramp iron normally has two metal detectors, one
upstream and one downstream of the tramp iron magnet. The upstream metal detector acts as a
sensor for pre-warning the control system of the arrival of a tramp iron. The metal detector
downstream of the magnet is to detect any pieces of tramp iron that the magnet may fail to remove.
When a downstream metal detector detects a piece of tram iron in the ore, it does the following:
Marks the place where the tramp iron was detected with a flag.
Signals the process control system for tripping the conveyor and warning the control room
operator.
Raises a local alarm that consists of a flashing red beacon and an undulating horn.
Conveyors that have metal detectors will not normally run in automatic mode without their metal
detectors operating normally.
7.1.2
A metal detector has a transmitter coil above the conveyor belt that generates pulses of
magnetic field that radiate outward. This is the primary magnetic field that can then generate an
output signal in the receiver coil of the detector under the conveyor belt (see figure 10).
Figure 10: Generation of Magnetic Fields in Metal Detector

7.1.3
When the pulse is turned off, eddy currents induced in the tramp metal produce a
secondary magnetic field. This new field also generates an output signal in the receiver coil. The
detector then measures the effect of this secondary magnetic field when the primary field is off.
Page No:25
7.1.4
Iron ore carried by the conveyor belt also produces a secondary magnetic field. However,
because iron ore has conductivity characteristics that are considerably poorer than tramp iron, its
field decays quicker than the field produced by a piece of tramp iron. Therefore, the detector can
distinguish the two fields from each other by their decay time as shown by figure 11.
Figure 11: Decay of Magnetic Field Strength

7.1.5
The metal detector takes advantage of the difference in the decay times by reading the
output signal of the receiver coil only after the magnetic field of the iron ore has decayed and before
the magnetic field of the tramp irons decay has ended. Figure 12 shows the correct measuring
period (measuring window) of the detector.
Figure 12: Correct Measuring Window of Metal Detector

Page No:26

7.1.6
To cater for different conductivity characteristics of different ores, the metal detector
allows for the selection of eight different measuring windows. So, when setting up a metal detector,
you can choose the placement of the measuring window so that the measurement of the receiver
signal strength takes place neither too early nor too late. If the measurement takes place too early,
the detector will signal the control system purely by measuring the iron ore magnetic field. On the
other hand, if the measurement takes place too late, the detector will not detect some of the smaller
pieces of tramp iron. Figure 13 shows the positioning of the available measuring windows for
selection.
Figure 13: Available Measuring Windows for Selection

7.1.7
As well as the placement of the measuring window, you can adjust the signal sensitivity of
the detector. This sets the signal strength below which the detector will not respond. So, because
you can adjust the signal sensitivity and placement of the measuring window, you can set up a
metal detector for optimal performance. This means that the detector will neither give you a false
trip nor allow a piece of tramp metal to go undetected.
7 .2
Components of Metal Detector
7.2.1
Figure 14 shows the main components of a downstream metal detector. An upstream
metal detector is similar, but without a marker. A support structure holds the transmitter coil on top
and the receiver coil at the bottom. It is located so that the conveyor belt runs through the frame in
between the two coils. The transmitter coil can swing in the direction in which the belt travels.
This allows the coil to swing out of the way when hit by a high pile of iron ore on the belt and then
return back to its original position when the high pile has passed through. Such a swing protects the
coil and its support structure from being damaged by oversized material.
7.2.2
A short distance upstream of the coil support structure, a clip detector continuously
monitors the conveyor belt for metallic splices or repair clips. When the detector senses the
passage of a clip, it momentarily reduces the sensitivity of the metal detector while the clip passes
Page No:27
through the detection zone. However, at this momentary low sensitivity, the metal detector is still
able to detect and respond to large pieces of tramp iron.
Figure 14: Main Components of a Metal Detector

7.2.3
Downstream of the coil support structure, there is a frame that holds a flag marker above
the conveyor belt. The function of the flag marker is to drop a flag on the exact spot where a piece
of tramp iron has been detected. This allows you to know where the tramp iron is so that you can
easily find and remove it. For the flag marker to work accurately, the control unit of the metal
detector must have the correct time (in seconds) that it takes for the detected tramp iron to get to the
marker from the detector coil. You can calculate this delay time as follows:
Delay Time (in seconds) = Distance between the coil and marker (in metres) Belt Speed (in m/s)
7.2.4
When a downstream metal detector detects a piece of tramp iron, it allows the conveyor to
run until the detected tramp iron reaches the flag marker. It then:
Drops the flag on the conveyor belt.
Signals the control system to trip the conveyor and warn the control room operator.
Raises local alarms that consist of a flashing red beacon and an undulating sound of a horn.
During the time between detection and marking, the metal detector continues to operate and is able
to detect up to 10 other pieces of tramp iron that may pass through during this delay period. The
detector shows the number of detected pieces of iron during the delay period on a counter located
on its local control panel.
Page No:28

7.2.5
Local to the metal detector is a control unit that controls the operation of the detector and
interfaces with the process control system. The operator can interface with the metal detector from
a control panel on the front face of this local control unit. The panel contains:
six touch keys;

five indicator lights;
an 8-character alphanumeric display window; and
a 3-digit counter window.
Figure 15 shows the main features of the metal detector local control panel.
Figure 15: Main Features of Metal Detector Local Control Panel

7.2.6
The metal detector has two modes of operation:

run mode; and
set-up/calibration mode.
In the run mode, the detector operates normally for detecting tramp metals. In this mode, the touch
keys of the detectors local control panel are inoperative while the panel indicators and display
windows operate normally. In the set-up/calibration mode, the detector allows you to make
Page No:29
changes in its set-up as well as to calibrate it for proper detection of tramp metal. In this mode, all
features of the detectors local control panel, including the six touch keys, are operational.
7.2.7
When the metal detector is in run mode, the NORMAL green indicator light is on, the
display window shows the word COUNT, and the counter window shows the total count of detected
metal so far. Except the bar graph on the right of the window, all other indicator lights will be off.
The bar graph consists of 20 light-emitting diodes (LEDs) that indicate the signal strength of the
receiver coil, which is normally the strength of the magnetic field generated by the tramp iron at the
time of measurement. The more LEDs that are lit from the bottom up, the stronger the signal will
be. The bar graph is also used for balancing the coils when calibrating the detector. However, this
training module will not discuss the calibration methods.
7.2.8
If the detector detects a tramp metal while in its run mode, the NORMAL indicator light
goes out and the ALARM red indicator light comes on. At the same time, the display window
changes to show the word METAL or LONG BAR, and the counter window changes to show the
number of pieces of tramp metal detected since the system tripped. This number on the counter
window is referred to as the coast count.
7.2.9
The ALARM indicator will also come on and the NORMAL indicator will go out if a fault
develops in the metal detector. When a fault develops in a metal detector, the control system will
trip the conveyor to which the detector belongs if the conveyor is running in automatic mode.
7.2.10 Whenever the ALARM indicator comes on, the RESET touch key becomes active to allow
you to reset the alarm. In the case of a tramp metal detection, you can reset the detector by:
(a)
Finding and removing the detected tramp metal from the conveyor load.
(b)
Inserting the flag correctly in the flag marker.
(c)
Pressing the RESET touch key on the detector local control panel.
This resets the control panel to normal running condition and allows the conveyor to restart in
automatic mode.
If the alarm condition is because of a fault in the detector, then you need to rectify the fault before
pressing the RESET touch key for returning the detector to normal running condition.
7.2.11 Two switches inside the detector control unit determine the operational mode of the metal
detector. If you turn these two switches to their BYPASS positions, one of them bypasses the
detector control electronics and the other bypasses its alarm relay. As a result, the detector goes to
its set-up/ calibration mode and will no longer communicate with the process control system, but it
will continue to detect tramp metal. When you turn the two switches to NORMAL positions, the
detector returns to its run mode of operation.
If you put the metal detector into set-up/calibration mode while its conveyor is running in automatic
or remote manual mode, the control system brings up an urgent alarm to warn the operator.
7.2.12 When the detector mode of operation changes from run to set-up/calibration, the NORMAL
indicator light of the local control panel goes off and the following panel indicator lights come on:
The BYPASS yellow indicator light comes on to show that the metal detector no longer is
communicating with the process control system.
The CALIB. red indicator light comes on to show that the touch keys of the control panel are
operational for calibrating and setting up the detector.
Page No:30

7.2.13 When the detector is in set-up/calibration mode, the display window initially show PSWD
which means that you need to use the touch keys to enter the correct password for the panel to
allow you to calibrate and/or set up the detector.
Y,
In the set-up/calibration mode, the counter window is initially blank. It will show the numerical
value of set points and other variables when you start to calibrate and/or set up the detector.
7.2.14 Since you may not be involved in calibrating or setting up a metal detector, this training
module will not provide you with further details about the operation of the local control panel.
Page No:31
8.
Shuttle Assembly
8.0.1
When a conveyor is designed to have more than one discharge point, it will have a shuttle
to move its discharge head to the discharge chute that sends the conveyor product to its correct
destination through the route selected by the operator. The logic under which a shuttle operates will
be discussed in other training modules. Our aim here is to familiarise you with the major
components and functions of a shuttle assembly.
8.0.2
Figure 16 shows major components of a typical shuttle. The shuttle consists of:
a drive motor;
a planetary reduction gearbox;
a pair of sprockets that mesh with two rows of drive chains; and
a rail mounted carriage that carries the conveyor discharge pulley.
Figure 16: Major Components of a Typical Shuttle Assembly

Page No:32

8.0.3
The shuttle drive is an electric motor that incorporates an electro-magnetic brake and can
run in forward and reverse directions. When the power is supplied to the motor for the shuttle to
run, the power supply also energises a magnet to pull the brake pads away from the brake disc for
releasing the brake. When the shuttle stops, the control system removes the power from the electromagnet to de-energise it so that a set of strong springs pushes the brake pads hard against the brake
disc to engage the brake. The motor has a brake handle that is for use for maintenance purposes
only. You can use the brake handle to mechanically release the brake by forcing the brake pads
away from the brake disc against the force of the springs.
8.0.4
The output shaft of the motor turns a drive pinion inside the planetary gearbox. In turn, the
output shaft of the gearbox turns a pair of sprockets that each mesh with a row of drive chains
attached to underside of the shuttle carriage. A torque arm at the output side of the gearbox ensures
that the applied torque is totally transferred to the output shaft of the gearbox rather than turning the
gearbox casing.
8.0.5
The gearbox has an air breather that contains an air filter. The air breather stands well
above the normal oil level and maintains the pressure in the gearbox at atmospheric. The gearbox
has also a dipstick tube for measuring the oil level in the gearbox. The dipstick tube also provides
the space within which the oil can expand when its temperature rises. At the bottom of the dipstick
tube is an oil sight glass. When the motor is stopped and the gearbox oil is at atmospheric
temperature, the oil level should be in the middle of the oil level sight glass.
8.0.6
When the shuttle drive motor runs, the sprockets drive the chains and consequently move
the rail-mounted shuttle carriage. This moves the conveyor discharge head towards its selected
destination, which is normally a discharge chute.
Page No:33
9.
Questions on Conveyor Auxiliaries
Can you now:
Describe functions of a conveyor monitoring and measuring instruments?
Identify and describe functions of major components in:
A typical conveyor take-up unit?

Any one of the three types of conveyor belt cleaners?
A conveyor tramp iron magnet?
A conveyor metal detector?
A shuttle assembly?
The following questions will help you find out. When you finish answering the questions, go to
section 10 to find the correct answers and compare them with yours.
Q.9.1
If a person pulls the trip wire of a conveyor pull-wire switch, the switch:
(a)
Stops the conveyor only if the conveyor is running in automatic mode;
(b)
Stops the conveyor if the conveyor is running in automatic or remote manual mode;
(c)
Stops the conveyor if the conveyor is running in local manual mode; or
(d)
Stops the conveyor if the conveyor is running in any mode.
Q.9.2
If a belt drift switch detects a drift in the belt of its conveyor, the switch:
(a)
Causes the control system to provide the operator with an urgent alarm;
(b)
Stops the conveyor if the conveyor is running in automatic or remote manual

mode;
(c)
Stops the conveyor if the conveyor is running in local manual mode; or
(d)
Stops the conveyor if the conveyor is running in any mode.
Q.9.3
If a tear in a conveyor belt causes the conveyor wire-type rip detector to trip the
conveyor, you can reset the detector by:
(a)
Removing the ore that fell through the tear onto the rip detector tray;
(b)
Replacing the broken wire line;
(c)
Resetting the trip from the control room monitor; or
(d)
Restarting the conveyor for the detector to reset itself automatically.
Q.9.4
If a tear in a conveyor belt causes the conveyor pan-type rip detector to trip the
conveyor, you can reset the detector by:
(a)
Removing the ore that fell through the tear onto the rip detector tray;
(b)
Replacing the broken nylon fishing wire;
(c)
Resetting the trip from the control room; or
(d)
Restarting the conveyor for the detector to reset itself automatically.
Page No:34

Q.9.5
In the port ore handling plant, the blockage of a chute is detected by:
(a)
An ultrasonic level detector;
(b)
A radar-type level detector;
(c)
A tilt switch; or
(d)
Photoelectric cells.
Q.9.6
If an under-speed switch trips a conveyor when the conveyor is under automatic
control, you can restart the conveyor:
(a)
Immediately after the trip as the under-speed switch requires no resetting;
(b)
After resetting the switch locally;
(c)
After resetting the switch through the control system; or
(d)
After resetting the switch by running the conveyor in local manual mode for a
short time.
Q.9.7
To measure the instantaneous carrying capacity of a conveyor, normally in tonnes per
day, the system uses:
(a)
A belt weigher only;
(b)
The combination of a belt weigher and a tachometer;
(c)
The combination of a belt weigher and an under-speed switch; or
(d)
The combination of a tachometer and load profile measuring instrument.
Q.9.8
In a festoon-type take-up unit, the take-up pulley of the conveyor:
(a)
Hangs freely within a take-up tower, being pulled down by a mass;
(b)
Is in a horizontal position, being pulled by a hanging mass through a system of

sheaves and wire ropes;
(c)
Hangs in a take-up tower, being pulled down by a winch; or
(d)
Is in a horizontal position, being pushed back by a hydraulic ram.
Q.9.9
A primary belt cleaner:
(a)
Rides on the backside of the belt for moving and dropping the fugitive material
off the sides of the belt;
(b)
Cleans the load-bearing surface of the belt at just below the horizontal centre line
of the conveyor head pulley;
(c)
Cleans the load-bearing surface of the belt from normally under the head pulley;
or
(d)
Cleans the load-bearing surface of the belt at just below the horizontal centre line
of the conveyor drive pulley.
Page No:35
Q.9.10
In a trolley-type take-up unit, when the temperature rises and everything else
remaining the same:
(a)
The take-up mass rises;
(b)
The take-up mass falls;
(c)
The take-up mass neither rises nor falls; or
(d)
The belt tension increases.
Q.9.11
You use the winch to adjust the position of the take-up mass in:
(a)
Both the festoon-type and trolley-type of take-up units;
(b)
Neither the festoon-type nor the trolley-type of take up units;
(c)
The festoon-type of take-up units; or
(d)
The trolley-type of take-up units.
Q.9.12
If the scraper tips of a secondary belt cleaner have lost contact with the belt, the
adjustment involves:
(a)
Using the adjustment nut to rotate the main shaft of the cleaner towards the belt;
(b)
Using the adjustment nut to rotate the main shaft of the cleaner away from the
belt;
(c)
Using the adjustment nut to raise the main shaft of the cleaner; or
(d)
Using the adjustment nut to lower the main shaft of the cleaner.
Q.9.13
To maintain a high cleaning efficiency of belt cleaners, you need to perform a routine
inspection at about once every:
(a)
Day;
(b)
Week;
(c)
Two weeks; or
(d)
Month.
Q.9.14
When the magnet is isolated and cold, you can check the magnets oil level
(a)
With the use of its oil dipstick;
(b)
With use of its oil sight glass;
(c)
Through the oil fill opening after removing the oil fill plug; or
(d)
Through the oil level opening after removing the oil level plug.
Page No:36

Q.9.15
If the oil temperature of a running magnet at the inlet to the oil cooler rises above
90C, the magnets temperature switch:
(a)
Raises and alarm to warn the operator;
(b)
Trips the magnet;
(c)
Causes the magnet to de-energise while its oil cooling circuit keeps running; or
(d)
Causes the magnet to go to its dump position before the magnet de-energises.
Q.9.16
If the metal detector downstream of the magnet detects a tramp iron, it causes:
(a)
The conveyor to trip;
(b)
The magnet to switch to its high-level energisation;
(c)
A warning alarm to come on to warn the operator; or
(d)
The magnet to trip.
Q.9.17
When the magnet is under remote manual control, it energises at:

(a)
Low level only;
(b)
Medium level only;
(c)
High level only; or
(d)
Either low or high level, depending on whether or not the upstream metal detector
detects a tramp iron.
Q.9.18
On the magnets local control panel, the MODE LOCAL indicator light is on and the
magnet is its dump position. If you now press the TROLLEY OUT push-button:
(a)
The magnet moves to its upper operating position and then stops;
(b)
The magnet moves up and then travels to its upper operating position before
stopping;
(c)
Nothing happens; or
(d)
The magnet moves down and then travels to its correct operating position before
stopping.
Q.9.19
When a running magnet is going through its automatic dump operation and has been
in its dump position for about 60 seconds, you expect its local control panel to show:
(a)
All indicator lights on;
(b)
All indicator light on except the LOCAL, OPERATING POSITION and TOP indicator
lights;
(c)
All indicator lights on except the LOCAL, OPERATING POSITION and BOTTOM
indicator lights; or
(d)
All indicator lights on except the LOCAL, OPERATING POSITION, BOTTOM and
MAGNEt indicator lights.
Page No:37
Q.9.20
A magnet is running normally in automatic mode over its running conveyor when the
upstream metal detector detects two tramp irons 120 seconds apart. In such a case:
(a)
The magnet switches to high energisation level for a continuous period of 240 s;
(b)
The magnet switches to high energisation level for a continuous period of 125 s
and then trips;
(c)
The magnet switches to high energisation level for a continuous period of 120 s
only; or
(d)
The magnet switches to high energisation level for 120 seconds, returns to low
energisation level for 20 seconds before switching back to high energisation level
for another 120 seconds.
Q.9.21
If a downstream metal detector detects a piece of metal, it marks the exact spot where
the metal was detected:
(a)
With a white paint sprayed from the paint marker;
(b)
With a beam of light directed at the spot;
(c)
With a flag dropped from the flag marker; or
(d)
By displaying the exact distance of the spot from the detector support structure on
its local control panel.
Q.9.22
A metal detector has two coils:
(a)
A transmitter coil and receiver coil that are both above the conveyor load-bearing
belt;
(b)
A transmitter coil and receiver coils that are both below the conveyor loadbearing belt;
(c)
A transmitter coil above the load-bearing belt and a receiver coil below the loadbearing belt; or
(d)
A transmitter coil below the load-bearing belt and a receiver coil above the loadbearing belt.
Q.9.23
A metal detectors secondary magnetic fields are produced by:

(a)
The transmitter coil;
(b)
The receiver coil;
(c)
The eddy currents in the tramp metal only; or
(d)
The eddy currents in both the tramp metal and iron ore.
Q.9.24
When a tramp iron passes through a metal detector, the magnetic field that decays
relatively quickly is produced by:
(a)
The piece of metal;
(b)
The iron ore;
(c)
The transmitter coil; or
(d)
The receiver coil.
Page No:38

Q.9.25
A metal detector reads the output signal of its receiver coil when:
(a)
The primary magnetic field is on;
(b)
The magnetic field of the iron ore has decayed and before the magnetic field of
the tramp iron has decayed;
(c)
The magnetic field of the tramp iron has decayed and before the magnetic field of
the iron ore has decayed; or
(d)
The magnetic fields of both the tramp metal and iron ore have decayed.
Q.9.26
Which one of the shown measuring windows do
you consider the correct one for a metal detector:
(a)
Window 1;
(b)
Window 2;
(c)
Window 3; or
(d)
Window 4.
Q.9.27
When the clip detector of a metal detector detects a clip, it:

(a)
Causes the conveyor to trip;
(b)
Momentarily switches the metal detector off;
(c)
Momentarily inhibits the metal detector from generating alarms; or
(d)
Momentarily reduces the sensitivity of the metal detector.
Q.9.28
When the metal detector is in its set-up/calibration mode of operation, the indicator
lights on its local control panel are as follows :
(a)
NORMAl, ALARM
(b)
NORMAL, ALARM
(c)
ALARM
(d)
All indicator lights are on.
and BYPASS lights are out and CALIB. light is on;

lights are out while BYPASS and CALIB. lights are on;
light is out while NORMAL, BYPASS and CALIB. lights are on; or
Q.9.29
A typical shuttle assembly has a motor that drives a reduction gearbox. The gearbox
output shaft then drives the shuttle carriage:
(a)
Through a rack and pinion;
(b)
Through a pair of sprockets and chains; or
(c)
By directly driving the carriage wheels.
Page No:39
How well did you do? You should have answered at least 25 of the questions correctly. If you
did, you are ready to go to your appointed tutor for a written test. Your tutor will give a test paper
that contains questions identical to those in this training module. So, if you have correctly
answered at least 25 of the questions in here, you will have no problem in passing the written test.
If you did not answer at least 25 of the questions correctly, go back and read sections 4, 5, 6, 7 and
8 again. If you feel that you need some help in understanding some of the information, do not
hesitate to seek help from your appointed tutor.
Page No:40

8.
Answers to Questions
Question
Number
Correct Reference
Answer Section
Q.9.1
(d)
4.1.2
Q.9.2
(b)
4.1.3
Q.9.3
(b)
4.1.4
Q.9.4
(a)
4.1.5
Q.9.5
(c)
4.1.6
Q.9.6
(a)
4.1.7
Q.9.7
(b)
4.1.8
Q.9.8
(a)
4.2.2
Q.9.9
(b)
5.0.1
Q.9.10
(b)
4.2.3 & 4.2.7
Q.9.11
(d)
4.2.7
Q.9.12
(c)
5.2.4
Q.9.13
(b)
5.1.2
Q.9.14
(d)
6.1.7 & 6.1.8
Q.9.15
(a)
6.1.6
Q.9.16
(a)
6.1.10
Q.9.17
(b)
6.1.11
Q.9.18
(c)
6.2.6
Q.9.19
(d)
6.2.6
Q.9.20
(d)
6.1.11
Q.9.21
(c)
7.1.1
Q.9.22
(c)
7.1.2
Q.9.23
(d)
7.1.3 & 7.1.4
Q.9.24
(b)
7.1.4
Q.9.25
(b)
7.1.5
Q.9.26
(c)
7.1.6
Q.9.27
(d)
7.2.2
Q.9.28
(b)
7.2.12
Q.9.29
(b)
8.2
Number
Answer Reference
Section
Page No:41
Use this page for your notes
Page No:42

Page No:43
Page No:44

Page No:45
Page No:46

Conveyor Auxiliaries - WP

Diunggah oleh

Informasi Dokumen

Deskripsi Asli:

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

Conveyor Auxiliaries - WP

Diunggah oleh

Hak Cipta:

Format Tersedia

Document Number: 515P-02004-TR-CM-0001

Operator Training Module

Learning Outcome ................................................................................. 5

Assessment Criteria ............................................................................... 5

Conveyor Auxiliaries ............................................................................ 6

Belt Cleaners ....................................................................................... 13

Tramp Iron Magnet ............................................................................. 17

Metal Detector ..................................................................................... 25

Questions on Conveyor Auxiliaries .................................................... 34

Answers to Questions .......................................................................... 41

Document No: 515P-02004-TR-CM-0001 : Rev 0

Operator Training Module

Identify and describe functions of major components in:

A typical conveyor take-up unit;

Functions of any one of the conveyor monitoring and measuring instruments;

Identification and functions of major components in:

A typical conveyor take-up unit;

The Conveyor Drive Unit training module, numbered 515P-02004-TR-CN-0002.

Document No: 515P-02004-TR-CM-0001 : Rev 0

Monitoring and measuring instruments;

Tramp iron magnet;

Metal detectors; and

Monitoring and Measuring Instruments

Operator Training Module

Operator Training Module

Conveyor Take-up Unit

gravity take-up; and

There are also two types of gravity take-up:

Figure 1: Main Features of a Typical Festoon-Type Gravity Take-up

Operator Training Module

Figure 2: Main Features of Trolley-Type Gravity Take-up

Document No: 515P-02004-TR-CM-0001 : Rev 0

Figure 3: Main Features of a Typical Hydraulic Take-up Unit

Operator Training Module

Primary Belt Cleaner

Figure 4: Main Features of a Primary Belt Cleaner

In your weekly routine inspection of a primary cleaner, you should do as follows:

Stop and isolate the conveyor.

Secondary Belt Cleaner

In your weekly routine inspection of a secondary belt cleaner, do as follows:

Operator Training Module

Figure 5: Main Features of a Secondary Belt Cleaner

Return Belt Cleaner (Belt Plough)

Document No: 515P-02004-TR-CM-0001 : Rev 0

Figure 6: Main Features of a Return Belt Cleaner (Belt Plough)

Operator Training Module

Tramp Iron Magnet

Components and Functions

Figure 7: Main Features of a Tramp Iron Magnet

Document No: 515P-02004-TR-CM-0001 : Rev 0

Figure 8: Magnets Oil Cooling Circuit Schematic Diagram

An oil isolation valve being closed or partially closed.

Operator Training Module

Follow the site isolation procedure to isolate the magnet.

Allow the magnet to cool down.

Ensure that all oil isolation valves are fully open.

Document No: 515P-02004-TR-CM-0001 : Rev 0

The magnet can energise at three different levels:

Operator Training Module

If the magnet is not over the conveyor:

A siren sounds for 10 seconds.

The magnet moves to its elevated operating position.

The magnets oil pump starts running.