Commissioning a conveyor system for the first time is a critical process that ensures smooth operation, safety, and long equipment life.
The following step-by-step procedure covers checks before start-up, individual drive trials, and no-load and load trials of the conveyor system.
Checks Before Start-Up
Before running the conveyor, perform these checks carefully to confirm that all systems are ready.
1. Visual Inspection
Inspect the entire conveyor length, especially the lower belt strand. Remove any tools, nuts, bolts, or foreign materials. These can get trapped between the belt and pulleys and cause serious damage.
2. Conveyor Structure and Alignment
Check that the conveyor frame is straight and properly aligned. Correct any transverse tilting or uneven supports.
3. Counterweight and Take-Up System
Verify the counter weight frame has the correct number of slabs or weights as per design. Ensure smooth and free movement of the take-up pulley.
4. Idlers and Pulleys
Make sure all idler rolls and pulleys are clean and rotate freely. Reinstall any dismantled idlers after splicing or vulcanizing work. Clean the return belt using brushes if necessary.
5. Belt and Safety Devices
Ensure the belt joint is complete and properly spliced. Check all safety devices such as:
- Pull-cord emergency switches
- Belt sway switches
- Zero-speed and interlock systems
Confirm that electrical and mechanical interlocks are functional before any trial.
6. Area Clearance and Communication
Confirm that no one is working on or near the conveyor. Get clearance from erection, maintenance, and commissioning teams. Arrange proper communication using walkie-talkies or visual signals between field observers and control room.
Individual Trial of Drive Units (Before No-Load Trial)
Before running the conveyor belt, carry out individual trials of drive components step by step.
1. Solo Motor Trial
- Run each motor individually (solo run) without coupling.
- Check for motor vibration, noise, and direction of rotation.
- Ensure bearing temperatures and ampere readings are within limits.
2. Trial with Coupling and Gearbox
- Couple the motor with the gearbox and run the drive again.
- Check for abnormal vibration, noise, or misalignment at coupling points.
- Observe oil levels, leakages, and temperature rise in the gearbox.
Note important parameters such as:
- Motor current and voltage
- Bearing and gearbox temperatures
- Vibration level
- Noise and smoothness of operation
3. Interlock Verification
Before every trial, check all electrical and mechanical interlocks for correct functioning.
Ensure that:
- The conveyor cannot start without permission signals.
- Emergency stop devices operate correctly.
- Sequential start logic between conveyors is working properly.
Once the drive units pass all individual trials, proceed to no-load conveyor trial.
Checks During Start-Up (No-Load and Load Trials)
1. No-Load Trial Run
Start the conveyor for 10–50 meters first. Observe belt behavior — it should run centrally on idlers without side drift. Stop immediately if the belt runs off-center or rubs against the structure. Adjust idlers or pulleys as needed. Repeat short trial runs until smooth and centered movement is achieved.
2. Observation by Field Personnel
Deploy observers along the conveyor length, especially at head, tail, and transfer points. Maintain communication with the control room through walkie-talkies or flags.
If any problem occurs, use the pull-cord emergency switch to stop immediately.
3. Load Trial
After successful empty runs, feed small quantities of material. Observe for side run-out or material spillage. Clean any spilled material from idlers and structure immediately. Gradually increase the feed to full load while monitoring all parameters.
4. Monitoring During Operation
- Check for smooth belt running, noise, and vibration.
- Monitor motor load, bearing temperatures, oil level, and belt tracking.
- Maintain uniform loading at feed points to prevent spillage and uneven wear.
Instruments Used During Conveyor Commissioning
During commissioning, several instruments are used to measure critical parameters of motors, gearboxes, pulleys, and conveyor components. These readings ensure that all equipment operates within safe and recommended limits.
1. Vibration Meter
📘 Function:
Vibration meter measures the vibration velocity of motors, gearboxes, and couplings to detect unbalance, misalignment, or bearing faults.
✅ Allowable Vibration Limit (As per ISO 10816 / ISO 20816):
-
Take readings in horizontal, vertical, and axial directions at motor and gearbox bearing housings.
-
Record values during solo run, coupled trial, and load trial.
-
If vibration falls into Zone C or D, check for misalignment, looseness, or unbalance
2. Infrared Temperature Gun
📘 Function:
Infrared temperature gun is used to measure surface temperature of motors, gearboxes, bearings, and pulleys without direct contact.
✅ Allowable Limits:
Practical Temperature Guidelines (Summary)
| Component | Normal Range | Alarm Level | Typical Rule |
|---|---|---|---|
| Motor Body | ≤ 80 °C | > 90 °C | Ambient + 45 °C |
| Gearbox Casing | ≤ 70 °C | > 80 °C | Ambient + 40 °C |
| Bearing Housing | ≤ 60 °C | > 70 °C | Ambient + 30 °C |
| Coupling Surface | ≤ 60 °C | > 70 °C | Ambient + 30 °C |
📝 Note — General Temperature Monitoring Practice:
It is standard field practice to consider “Ambient temperature + 45 °C” as a safe surface temperature for rotating equipment.
Example: At 35 °C ambient, 80 °C is acceptable.
Ensure the temperature rise is uniform, with no hot spots or abnormal smells.
If exceeded, check for misalignment, bearing failure, or lubrication issues.
3. Sound Level Meter
📘 Function:
Sound level meter monitors noise from motors, gearboxes, and conveyor drives to identify gear wear, loose components, or imbalance.
✅ Allowable Limits (As per OSHA / ISO 9612):
| Location / Equipment | Acceptable Noise Level |
|---|---|
| Conveyor drive area | ≤ 85 dB(A) |
| Near gearbox or motor | ≤ 90 dB(A) |
| Operator area (8-hour exposure) | ≤ 85 dB(A) |
4. Digital Tachometer
📘 Function:
Digital tachometer measures rotational speed (RPM) of motor, gearbox, and drive pulley to confirm design speed.
✅ Allowable Limits:
| Component | Designed RPM | Acceptable Deviation |
|---|---|---|
| Motor Shaft | As per nameplate | ± 5% |
| Gearbox Output | As per gear ratio | ± 5% |
| Drive Pulley | As per GA drawing | ± 5% |
5. Clamp Meter
📘 Function:
Clamp meter measures current and voltage drawn by the motor during trials to detect overloading or imbalance.
✅ Allowable Limits:
| Parameter | Normal Range | Action Required |
|---|---|---|
| Motor Current | ±10% of rated FLC | Investigate if >110% |
| Phase Current Imbalance | ≤ 5% | Check if >5% |
| Voltage Variation | ± 5% | Adjust if outside range |
6. Shaft Alignment Tool
📘 Function:
Ensures precise shaft alignment between motor, coupling, and gearbox.
✅ Allowable Limits:
| Misalignment Type | Acceptable Limit |
|---|---|
| Angular Misalignment | ≤ 0.05 mm / 100 mm |
| Parallel Misalignment | ≤ 0.05 mm |
| Offset Deviation | ≤ 0.03 mm |
7. Thermal Camera (Optional)
📘 Function:
Provides a thermal image of the equipment to detect hidden hot spots or insulation breakdown.
Frequently Ask Questions
Conveyor commissioning is the final stage of installation where the complete system is inspected, tested, and operated to verify its performance before handing over for regular use.
The purpose is to ensure:
a. All components are properly installed and aligned.
b. Motors, gearboxes, and pulleys perform as per design.
c. Safety interlocks and emergency systems work correctly.
d. Belt runs centrally without spillage or side tracking.
A well-executed commissioning process guarantees safe operation, longer equipment life, and reduced maintenance issues.
The conveyor commissioning process involves the following major steps:
Pre-start inspection – checking the structure, idlers, pulleys, and safety switches.
Individual drive trials – solo motor run, motor–gearbox coupled run, and full drive trial.
No-load trial – testing the empty belt for smooth running and correct tracking.
Load trial – running with material to observe performance under load.
Instrument readings – recording vibration, temperature, current, and sound levels.
Final adjustments – alignment correction, belt tensioning, and recording baseline data.
Each step ensures the conveyor meets both mechanical and operational safety standards.
A solo motor trial verifies that the motor operates correctly before connecting it to the gearbox or conveyor.
It helps to:
a. Confirm the direction of rotation matches conveyor design.
b. Detect any vibration or bearing noise early.
c. Check current and voltage under no-load conditions.
d. Ensure winding insulation and temperature rise are within limits.
Running the motor solo prevents possible damage to gearboxes or couplings if alignment or wiring is incorrect.
Proper belt tensioning is essential to:
a. Transmit drive power effectively from pulley to belt.
b. Prevent belt slippage and surface wear.
c. Avoid excessive sagging and material spillage.
Incorrect tension can lead to premature belt failure or pulley lagging damage.
The required tension values are always specified in the conveyor GA drawings or data sheets.
A sound level meter measures noise intensity during conveyor operation.
Normal conveyor drive noise is typically below 85 dB(A).
Higher noise levels can indicate:
a. Loose fasteners or guards
b. Gearbox wear or improper lubrication
c. Belt misalignment or idler bearing failure
Maintaining acceptable noise levels protects both equipment and personnel hearing.
Measurements should be taken at each trial stage:
Solo Motor Trial – record current, voltage, vibration, and temperature.
Motor + Gearbox Trial – record temperature and oil pressure (if applicable).
Full Drive Trial with Belt – record all readings every 15 minutes for at least 1 hour.
Load Trial – record once system reaches stable operation.
Maintain all readings in a commissioning logbook to establish baseline data for future maintenance.
Typical issues identified during start-up include:
a. Belt running off-track
b. Excessive noise or vibration
c. Uneven material flow at transfer points
d. Motor overcurrent
e. Hot bearings or gearbox casing
f. Belt slippage at drive pulley
These problems usually arise from improper alignment, insufficient tension, or poor cleaning of the return side.
a. Ensure pull-cord switches and emergency stops are functional.
b. Use lockout/tagout (LOTO) procedures before working on the conveyor.
c. Keep the area free of loose materials.
d. Only trained personnel should operate or observe during trials.
e. Never stand on or lean over the conveyor during start-up.
Safety is the first priority during every commissioning step.
In a multiple-conveyor system (like in a coal handling plant), follow a reverse sequence during commissioning:
a. Start from the last conveyor (discharge end).
b. Proceed backward toward the first conveyor (feeder end).
This ensures each downstream conveyor is ready to receive material, preventing overloading and spillage during testing.
After successful commissioning, detailed documentation is prepared and submitted to confirm that the conveyor has been tested, inspected, and is ready for operation.
Essential Documents Include:
Commissioning Checklist – showing all inspection points, test results, and remarks.
Parameter Log Sheet – recorded values of temperature, vibration, noise, and current.
Alignment & Tension Report – details of pulley and idler alignment readings.
Safety Device Test Report – verification of all pull-cord, belt sway, and zero-speed switches.
Load Trial Report – observations during material flow and performance evaluation.
Handover Certificate – signed document confirming the system is ready for operation.
Maintaining these documents helps in future troubleshooting, audits, and warranty claims, and serves as an official record of commissioning completion.
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