Commissioning Procedures for Conveyors (Typical)

1. Purpose & Scope

The purpose of this paper is to suggest procedures and guidelines to erectors for the
commissioning of conveyors and conveyor systems
2. Responsibilities and Authorities
It is the responsibility of the commission manager to ensure that the procedure as
defined below are implemented and adhere to.
3. Procedure
Unless otherwise specified it is a requirement that the erectors will have the
conveying system prepared for commissioning following their laid down procedures.
The commissioning procedure for conveyors will then proceed according to the
following steps.
3.1 Pre-Start Checks
3.1.1 Ensure that all the belt splices are intact.
3.1.2

Ensure that all temporary construction struts, stays and steelwork are
removed and that the belt path is clear and free from obstructions

3.1.3

Check that all additional steelwork, plate work and attachments over the
conveyor are secure and that no loose members can contact the belt.

3.1.4

Check that all guarding requirements are met and that all the guards are
in place and securely fastened.
Check that belt travel (both carry and return side) is clear from any sharp
edges on the conveyor structure which may cause belt damage when
tracking conveyor belt.
Ensure that all the idlers are properly aligned and securely bolted and
that they can rotate freely, on both the carrying and return strands.
Check that all safety devices have been installed and commissioning
prior to start-up. In particular, check that speed sensing devices are
correctly installed.
Check that all over-travel devices are correctly located and are
operational.
Check that all pulleys are securely fastened and aligned.
Check that all bearings are correctly greased.
Check that the motors rotate in the right direction.
Check that the power packs are securely fastened down and that the
reducers are properly lubricated with the correct grade filling oil.
Where the reducer is fitted with a holdback, check that the unit rotation
is in the correct sense.

3.1.5
3.1.6
3.1.7
3.1.8
3.1.9
3.1.10
3.1.11
3.1.12
3.1.13

3.1.14 Check that external holdbacks are correctly fitted and that their rotation
is in the correct sense.
3.1.15 Check that the holdback is correctly lubricated.
3.1.16 Check that all couplings are correctly aligned and that their transmission
systems ( such as driving pins, grids, etc ) are in place.
3.1.17 Check that the coupling all lubrication requirements are met, for both
high speed and low speed locations.
3.1.18 Check that all coupling covers and guard covers are in place.
3.1.19 Check the counter-weight. In particular check that the counterweight is
correctly fitted with the design mass and that the position of the
counterweight is in accordance with the design.
3.1.20 Check the condition of counterweight carriage and take-up carriage.
3.2 Running Checks
3.2.1
3.2.2
3.2.3

Place observers within the reach of the trip wire along the length of the belt.
Under local control start the belt empty.
Check the system during start-up ( acceleration ) and observe behavior of each
belt.
3.2.4 Check the belt speed and the start-up time.
3.2.5 Monitor movement of the counter weight in the tower and the take-up
carriage.
3.2.6 Check the location of over-travel switches and sensors.
3.2.7 Check for misalignment along the line of the belt and at the terminals, and
correct as required.
3.2.8 Check controlled performance of safety devices.
3.2.9 Check reducer empty running temperature.
3.2.10 Check fluid coupling empty running temperature where fitted
3.3 Intermediate Checks
3.3.1
3.3.2
3.3.3
3.3.4
3.3.5

3.3.6
3.3.7

After running the system for a minimum of 3 hours or 10 full cycles, shut the
system down and observe the behavior.
Re-Check reducer oil level and top up to indicator as shown on reducer
housing.
Run the system with material, up to the specified capacity.
Stop the system under load and observe any dynamic behavior which may
occur.
Start the system under load and observe any dynamic behavior which may
occur. It is necessary to run the system for at least 10 hours to allow the
belting to settle down, to identify and correct any misalignment and identify
mortality of idlers and bearings.
Check reducer full load running temperature.
Check idler seals for leaks.

4. RECORDS
The signed checklists, punch lists and commissioning certificates are classified as
quality records and should be maintained as per the requirements of the operating
division.