The bulk material handling equipment employed in any operation, be it frac sand processing, potash mining, or other industrial endeavor, is a critical part of operational efficiency. Troughed belt conveyors serve to move material around a facility in seamless fluidity for maximum efficiency. But what happens when an operation will be shut down for an extended period of time, such as in the case of seasonal operations, or when a plant is temporarily closed? In order to maintain equipment during storage, conveyors require proper storage accommodations and interim maintenance.
Proper belt conveyor storage not only helps to keep equipment in its original working condition, but it also allows for a faster, more seamless start-up when operations resume.
Note: This is not a comprehensive storage and maintenance list, but rather a general guide. Always consult your original equipment manual to ensure all necessary maintenance and storage guidelines are followed. The recommendations listed here are not intended for storage beyond two years. Maintenance and storage procedures should always be carried out by a trained professional. FEECO does not make any representations or warranties (implied or otherwise) regarding the accuracy and completeness of this guide and shall in no event be liable for any loss of profit or any commercial damage, including but not limited to special, incidental, consequential, or other damage.
General Recommendations for Long-Term Troughed Belt Conveyor Storage
While the requirements for storing conveyors on a long-term basis are largely dependent on the storage environment, there are a few general guidelines to follow in any setting to ensure optimal equipment condition is maintained…
Troughed belt conveyors and other support equipment should be thoroughly cleaned prior to storage. Methods such as pressure washing are recommended where applicable. Not only will this promote an easier and faster restart, but it also helps to protect equipment, especially when dealing with difficult materials. For example, potash is hygroscopic, meaning it will absorb moisture from the air. This characteristic amplifies potash’s already corrosive nature, and can cause excessive wear if allowed to sit in equipment for extended periods of time. Furthermore, in most cases, the longer any buildup is allowed to sit, the more difficult it will be to remove. It may seem trivial, but thoroughly cleaning the equipment prior to storage saves a lot of time and money in the long run.
Additional guidelines include:
- Motor heaters (if applicable), will require a power source during storage, regardless of how long they will be stored for.
- Motor breather and drains must be operable in order to minimize condensation and drain any condensation that might occur.
- Reducers should be drained at six month intervals. Suitable vapor inhibiting oil should be added and the reducer re-sealed. **See note for further recommendations in uncontrolled and outside storage environments below.
- Reducer bearings will require re-greasing at six month intervals.
- Motor shafts should be rotated at least three to four times every 30 days. This will rotate all drive components, which is very beneficial. This may be accomplished by “bumping” the motor at these intervals if power is readily available.
- It is best to run a conveyor a minimum of 1 hour per month to keep all moving parts loose and prevent the belt from “setting” in between idlers.
It’s also recommended to keep a detailed log of the storage and maintenance procedures. Many manufacturers may require this log to show that equipment has been properly stored in the event of an issue. This helps to avoid nullified warranties when equipment is cared for properly, and can be a helpful starting point in the event of a problem.
Indoor Storage
Indoor Conveyor Storage in a Controlled Environment
Ideally, belt conveyors should be stored in a dry, temperature controlled area. Maintaining the proper humidity and temperature of the storage environment will help to prevent unwanted condensation or humidity, which has the potential to cause rust and other degradation. This is most practical when the conveyor being “mothballed” already is installed in this environment.
In general, atmospheric humidity in the storage environment should be no higher than 40% relative humidity. As such, areas of high humidity may require extra steps to maintain the atmosphere. This might include the use of trays or renewable desiccants such as silica gel, or the installation of dehumidifiers.
Indoor Conveyor Storage in an Uncontrolled Environment
While a controlled environment is ideal, this may not be an option in all settings. For long-term, indoor storage where the environment can’t be controlled, some additional measures must be taken.
- The gear reducer should be examined at the start of the “mothball” period to make sure it is filled to its normal oil level and to check for any contamination. If needed, a mixture of the recommended vapor inhibiting oil and lubricated oil specified by the OEM may be added.
- If practical, wrap all motors securely in plastic with desiccant bags inside. Replace desiccant bags on a monthly basis, while also remembering to “bump” motors or rotate manually as described previously.
- It is best to run a conveyor a minimum of 1 hour per month to keep all moving parts loose and prevent the belt from “setting” in between idlers.
**At a minimum of six month intervals, drain and replace +\-10% of oil volume with a mixture consisting of vapor inhibitor and lubricating oil.
Outdoor Storage
Outdoor storage is never recommended, but sometimes it remains the only option. In cases where the conveyors will be stored outside, additional precautions should be taken to minimize degradation of the equipment.
- The gear reducer should be examined at the start of the “mothball” period to make sure it is filled to its normal oil level and to check for any contamination. If needed, a mixture of the recommended vapor inhibiting oil and lubricated oil specified by the OEM may be added. Ensure equipment is not sitting directly on the ground. Units should be raised, skidded, and protected with a tarpaulin (or equivalent) waterproof covering. This is recommended even if the units will be stored in their operating position.
- **Every 90 days, drain and replace 10% of oil volume (or two quarts – whichever is greater) with a mixture consisting of vapor inhibitor and lubricating oil. At the same time, inspect the equipment for rust.
- As with uncontrolled indoor storage, if practical, wrap motors in plastic with desiccant bags inside, replacing desiccant regularly, while also remembering to “bump” motors or rotate manually as described previously.
- At a minimum, motor and drive system should be tarped to protect against weather.
- It is best to run a conveyor a minimum of 1 hour per month to keep all moving parts loose and prevent the belt from “setting” in between idlers.
Preparing Stored Conveyors for Restart
Once the operation is ready for restart, conveyors coming out of storage will require some work before they are ready to go back online.
- Conveyors and all components (bearings, shafts, etc.) should be checked for rust. Depending on the seriousness of the rust, it may be handled by a spray-on rust inhibitor or by replacing the component as required.
- Drain the oil out of the reducers and fill to the proper level with the type of lubricant specified by the OEM.
- Check bearings and idlers; add grease until it is visible at the seals. Rotate the shafts to distribute the grease.
- Start belt conveyor with proper personnel observing in suitable locations for any issues that may arise, during belt training most notably.
Now is also a good time to take advantage of the downtime; conduct any necessary repairs, replace worn parts, etc. This will help to avoid downtime in the future for repairs that could have been carried out during shutdown.Additionally, having an experienced technician come out to assess the equipment prior to re-start is also valuable. In addition to inspecting and repairing equipment, OEM technicians can help to ensure start-up goes smoothly. FEECO Customer Service Engineers can also assist in re-positioning and aligning equipment components through the use of our laser alignment system. This ensures proper alignment and accurate installs.
Conclusion
Conveyors are a critical component to an operation’s efficiency and uptime; the breakdown or malfunction of a single conveyor holds the potential to put the entire plant at a standstill. For seasonal operations, or those in the midst of a temporary shutdown, proper storage procedures are essential to keeping the equipment in its original condition and ensuring an easier, faster restart.
FEECO is a leading manufacturer of troughed belt conveyors and custom bulk material handling equipment. Our Customer Service Engineers can assist in storage procedure consulting, as well as inspections, repairs, and even start-up support. To learn how we can assist you in your conveyor needs, contact us today!