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SCREW CONVEYOR CATALOG & ENGINEERING MANUAL Phone: (308) 324-7591 Fax: (308) 324-7549 [email protected] TOLL FREE: www.conveyusa.com 1-877-664-2687 CEMA Document: SC 2004-01 WARNING AND SAFETY REMINDERS FOR SCREW , DRAG , AND BUCKET ELEVATOR CONVEYORS APPROVED FOR DISTRIBUTION BY THE SCREW CON...

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SCREW CONVEYOR CATALOG & ENGINEERING MANUAL

Phone: (308) 324-7591 [email protected]

TOLL FREE: 1-877-664-2687

Fax: (308) 324-7549 www.conveyusa.com

CEMA Document: SC 2004-01

WARNING AND SAFETY REMINDERS FOR SCREW , DRAG , AND BUCKET ELEVATOR CONVEYORS APPROVED FOR DISTRIBUTION BY THE SCREW CONVEYOR SECTION OF THE CONVEYOR EQUIPMENT MANUFACTURERS ASSOCIATION (CEMA) It is the responsibility of the contractor, installer, owner and user to install, maintain and operate the conveyor, components and, conveyor assemblies in such a manner as to comply with the Williams-Steiger Occupational Safety and Health Act and with all state and local laws and ordinances and the American National Standards Institute (ANSI) B20.1 Safety Code. In order to avoid an unsafe or hazardous condition, the assemblies or parts must be installed and operated in accordance with the following minimum provisions. 1. Conveyors shall not be operated unless all covers and/or guards for the conveyor and drive unit are in place. If the conveyor is to be opened for inspection cleaning, maintenance or observation, the electric power to the motor driving the conveyor must be LOCKED OUT in such a manner that the conveyor cannot be restarted by anyone; however remote from the area, until conveyor cover or guards and drive guards have been properly replaced. 2. If the conveyor must have an open housing as a condition of its use and application, the entire conveyor is then to be guarded by a railing or fence in accordance with ANSI standard B20.1.(Request current edition and addenda) 3. Feed openings for shovel, front loaders or other manual or mechanical equipment shall be constructed in such a way that the conveyor opening is covered by a grating. If the nature of the material is such that a grating cannot be used, then the exposed section of the conveyor is to be guarded by a railing or fence and there shall be a warning sign posted. 4. Do not attempt any maintenance or repairs of the conveyor until power has been LOCKED OUT. 5. Always operate conveyor in accordance with these instructions and those contained on the caution labels affixed to the equipment.

6. Do not place hands, feet, or any part of your body, in the conveyor. 7. Never walk on conveyor covers, grating or guards. 8. Do not use conveyor for any purpose other than that for which it was intended. 9. Do not poke or prod material into the conveyor with a bar or stick inserted through the openings. 10. Keep area around conveyor drive and control station free of debris and obstacles. 11. Eliminate all sources of stored energy (materials or devices that could cause conveyor components to move without power applied) before opening the conveyor

12. Do not attempt to clear a jammed conveyor until power has been LOCKED OUT. 13. Do not attempt field modification of conveyor or components. 14. Conveyors are not normally manufactured or designed to handle materials that are hazardous to personnel. These materials which are hazardous include those that are explosive, flammable, toxic or otherwise dangerous to personnel. Conveyors may be designed to handle these materials. Conveyors are not manufactured or designed to comply with local, state or federal codes for unfired pressure vessels. If hazardous materials are to be conveyed or if the conveyor is to be subjected to internal or external pressure, manufacturer should be consulted prior to any modifications. CEMA insists that disconnecting and locking out the power to the motor driving the unit provides the only real protection against injury. Secondary safety devices are available; however, the decision as to their need and the type required must be made by the owner-assembler as we have

no information regarding plant wiring, plant environment, the interlocking of the screw conveyor with other equipment, extent of plant automation, etc. Other devices should not be used as a substitute for locking out the power prior to removing guards or covers. We caution that use of the secondary devices may cause employees to develop a false sense of security and fail to lock out power before removing covers or guards. This could result in a serious injury should the secondary device fail or malfunction. There are many kinds of electrical devices for interlocking of conveyors and conveyor systems such that if one conveyor in a system or process is stopped other equipment feeding it, or following it can also be automatically stopped. Electrical controls, machinery guards, railings, walkways, arrangement of installation, training of personnel, etc., are necessary ingredients for a safe working place. It is the responsibility of the contractor, installer, owner and user to supplement the materials and services furnished with these necessary items to make the conveyor installation comply with the law and accepted standards. Conveyor inlet and discharge openings are designed to connect to other equipment or machinery so that the flow of material into and out of the conveyor is completely enclosed. One or more warning labels should be visible on conveyor housings, conveyor covers and elevator housings. If the labels attached to the equipment become illegible, please order replacement warning labels from the OEM or CEMA. The Conveyor Equipment Manufacturers Association (CEMA) has produced an audio-visual presentation entitled “Safe Operation of Screw Conveyors, Drag Conveyors, and Bucket Elevators.” CEMA encourages acquisition and use of this source of safety information to supplement your safety program. SEE OTHER SIDE FOR SAFETY LABELS

NOTICE: This document is provided by CEMA as a service to the industry in the interest of promoting safety. It is advisory only and it is not a substitute for a thorough safety program. Users should consult with qualified engineers and other safety professionals. CEMA makes no representations or warranties, either expressed or implied, and the users of this document assume full responsibility for the safe design and operation of equipment.

CEMA Document: SC 2004-01

CEMA Safety Labels The CEMA safety labels shown below should be used on screw conveyors, drag conveyors, and bucket elevators. Safety labels should be placed on inlets, discharges, troughs, covers, inspection doors & drive guards. See CEMA Safety Label Placement Guidelines on CEMA Web Site: http://www.cemanet.org/safety/guidelines.html

Exposed moving parts can cause severe injury

CHR930001

LOCK OUT POWER before removing guard

Walking or standing on conveyor covers or gratings can cause severe injury STAY OFF CHS991026

WARNING Exposed screw and moving parts can cause severe injury

CHR930011

CVS930010

CVS930012

Exposed conveyors and moving parts can cause severe injury

Exposed buckets and moving parts can cause severe injury

LOCK OUT POWER before removing cover or servicing

LOCK OUT POWER before removing cover or servicing

LOCK OUT POWER before removing cover or servicing

PROMINENTLY DISPLAY THESE SAFETY LABELS ON INSTALLED EQUIPMENT SEE OTHER SIDE FOR SAFETY REMINDERS

CVS930011

Exposed screw and moving parts can cause severe injury LOCK OUT POWER before removing cover or servicing

Note: Labels alone do not substitute for a thorough inplant safety training program centered on the hazards associated with operating your installed equipment. Contact CEMA or Your Equipment Manufacturer for Replacement Labels CONVEYOR EQUIPMENT MANUFACTURERS ASSOCIATION 6724 Lone Oak Blvd., Naples, Florida 34109 239-514-3441

Table of Contents Materials Classification Code Chart Materials Characteristics Capacity Table Lump Size Table Horsepower Calculation Horsepower Nomograph Screw Conveyor Deflection Torque Rating Torque Nomograph Stainless Steel Torque Nomograph Carbon Steel Screw Flights with Cuts and Folds Weld Finishes Thermal Expansion Descriptive Part Numbers Component Selection Part Two – Conveyor Components Conveyor Layout Hanger Bearings Replacement Flighting Sectional Screws Sectional Flights Sectional Screw Ribbons Troughs Discharges Bulkheads End Flanges Clamps Seals Shrouds Feet Saddles Shafts Coupling Bolts, Internal Collars, End Lugs Trough Ends Trough End Bearings Hanger Bearings Hangers Gates Inlets Hanger Pockets Covers Cover Clamps

Page 2 Page 3-14 Page 15-17 Page 18 Page 19-21 Page 22-23 Page 24 Page 25 Page 26 Page 27 Page 28 Page 29 Page 30 Page 31 Page 32 Page 33 Page 34-35 Page 36 Page 37 Page 38-39 Page 40 Page 41 Page 42-48 Page 49 Page 50 Page 51 Page 52 Page 53-54 Page 55 Page 56 Page 57 Page 58-60 Page 61 Page 62-65 Page 66-67 Page 68 Page 69-73 Page 74-79 Page 80 Page 81 Page 82-83 Page 84

Page 1

Material Classification Code Chart Major Class

Material Characteristics Included

Code Designation

Density

Bulk Density, Loose

Actual Lbs/cu. ft.

Very Fine Fine Size

Granular

*Lumpy Irregular

Flowability

No. 200 Sieve (.0029”) And Under No. 100 Sieve (.0059”) And Under No. 40 Sieve (.016”) And Under

A200 A100 A40

No.

B6

6 Sieve (.132”) And Under

½” And Under 3” And Under 7” And Under

C½ D3 D7

16 “ And Under Over 16” To Be Specified X = Actual Maximum Size

D16

Stringy, Fibrous, Cylindrical, Slabs, Etc.

E

Very Free Flowing – Flow Function > 10 Free Flowing – Flow Function > 4 But < 10 Average Flowability – Flow Function > 2 But < 4 Sluggish – Flow Function < 2

DX

1 2 3 4

Mildly Abrasive – Index 1-17 5 Moderately Abrasive – Index 18-67 6 Extremely Abrasive – Index 68-416 7 Builds Up and Hardens F Generates Static Electricity G Decomposes --- Deteriorates in Storage H Flammability J Becomes Plastic or Tends to Soften K Very Dusty L Aerates and Becomes Fluid M Miscellaneous Explosiveness N Stickiness-Adhesion O Properties Contaminable, Affecting Use P Or Degradable, Affecting Use Q Gives Off Harmful or Toxic Gas or Fumes R Hazards Highly Corrosive S Mildly Corrosive T Hygroscopic U Interlocks, Mats or Agglomerates V Oils Present W Packs Under Pressure X Very Light and Fluffy – May Be Windswept Y Elevated Temperature Z HOW TO READ THE MATERIAL CODE FROM MATERIAL CHARACTERISTICS TABLE. MATERIAL: CHIPS, PULPWOOD Abrasiveness

Page 2

Material Characteristics

Material Acetylenogen (See Calcium Carbide) Adipic Acid Alfalfa Meal Alfalfa Pellets Alfalfa Seeds Almonds, Broken Almonds, Whole Shelled Alum, Fine Alum, Lumpy Alumina Alumina, Fines Alumina, Seed or Briquette Aluminate Gel (Aluminate Hydroxide) Aluminum Chips, Dry Aluminum Chips, Oily Aluminum Hydrate Aluminum Ore (See Bauxite) Aluminum Oxide Aluminum Silicate Aluminum Sulfate Amianthus (See Asbestos-Shredded) Ammonium Chloride, Crystalline Ammonium Nitrate Ammonium Sulfate Andalvsite (Aluminum Silicate) Antimony Powder Apple Pomace, Dry Arsenate of Lead (See Lead Arsenate) Arsenic Oxide (Arsenolite) Arsenic Pulverized Asbestos-Rock (Ore) Asbestos-Shredded Ash, Black, Ground Ashes, Coal - Dry - ½ Ashes, Coal - Dry - 3 Ashes, Coal - Wet - ½ Ashes, Coal - Wet - 3 Asphalt, Crushed - ½ Bagasse, Dry Bakelite, Fine Baking Powder Baking Soda (Sodium Bicarbonate) Barite (Barium Sulfate) + ½ - 3 Barite, Powder Barium Carbonate Bark, Wood, Refuse

Weight Lbs per Cu. Ft.

Material Code

% Trough Loading

Mat’l Factor FM

Comp. Series

45 14-22 41-33 10-15 27-30 28-30 45-50 50-60 55-65 35 65 45 7-15 7-15 13-20

45A100 35 18B645WY 42C½25 13B615N 29C½35Q 29C½35Q 48B635U 55B625 58B627MY 35A10027MY 65D337 45B635 11E45V 11E45V 17C½35

30A 30A 45 30B 30B 30B 30A 30A 15 15 15 30B 30A 30A 30A

0.8 0.6 0.5 0.4 0.9 0.9 0.6 1.4 1.8 1.6 2.0 1.7 1.2 0.8 1.4

2B 2D 2D 1A-8-C 2D 2D 1A-B-C 2A-B 3D 3D 3D 2D 2D 2D 1A-B-C

60-120 49 45-58

90A10017M 49C½35S 52C½25

15 45 30A

1.8 0.8 1.0

3D 3A-B 1A-B-C

45-52 45-62 45-58 49 15

49A10045FRS 54A4035NTU 52C½35FOTU 49C½35 A10035 15C½45Y

30A 30A 30A 45 30B 30B

0.7 1.3 1.0 0.8 1.6 1.0

3A-B 3D 1A-B-C 3A-B 2D 2D

100-120 30 81 20-40 105 35-45 35-40 45-50 45-50 45 7-10 30-45 40-55 40-55 120-180 120-180 72 10-20

110A10035R 30A10025R 81D337R 30E46XY 105B635 40C½46TY 38D346T 48C½46T 48D346T 45C½45 9E45R/XY 38B625 48A10035 48A10025 150D336 150A10035X 72A10045R 15E45TYY

45 15 30B 30A 30B 15 30B 15 30A 30A 30A 30A 30A 15 30B 30B 30B

0.8 1.2 1.0 2.0 3.0 2.5 3.0 4.0 2.0 1.5 1.4 0.6 1.0 2.6 2.0 2.0 2.0

2D 3D 2D 1A-B-C 3D 3D 3D 3D 1A-B-C 2A-B-C 1A-B-C 1B 1B 3D 2D 3D 3D

Page 3

Material Characteristics Material

Barley, Fine Ground Barley, Malted Barley, Meal Barley, Whole Baryte (See Barite) Basalt Bauxite, Dry, Ground Bauxite, Crushed – 3” Beans, Castor Beans, Castor, Meal Beans, Navy – Dry Beans, Navy – Steeped Beans, Soy (See Soybeans) Beet Pulp – Dry Beet Pulp – Wet Bentonite, Crude Bentonite, -100 Mesh Benzene Hexachloride Bicarbonate of Soda Blood, Dried Blood, Ground, Dried Bluestone (See Copper Sulfate) Bone Ash (Tricalcium Phosphate) Bone Black Bone Char Bones, Crushed Bones, Ground Bones, Whole Bonemeal Borate of Lime Borax, Fine Borax, Screening- ½ Borax, 1 ½ - 2 Lump Borax, 2-3 Lump Boric Acid, Fine Boron Bran, Rice-Rye-Wheat Braunite (Manganese Oxide) Bread Crumbs Brewer’s Grain, Spent – Dry Brewer’s Grain, Spent – Wet Brick, Ground- 1/8 Bronze Chips

Page 4

Weight Lbs per Cu. Ft.

Material Code

% Trough Loading

Mat’l Factor FM

Comp. Series

24-38 31 28 36-48

31B635 31C½35 28C½35 42B625N

45 30A 30A 45

0.4 0.4 0.4 0.5

1A-B-C 1A-B-C 1A-B-C 1A-B-C

80-105 68 75-80 36 35-40 48 60

93B627 68B625 80D336 36C½15W 38B635W 48C½15 60C½25

15 45 15 30A 30A 45 45

1.8 1.8 2.5 0.8 0.8 0.5 0.8

3D 1A-B-C 3D 1A-B-C 1A-B-C 1A-B-C 1A-B-C

11-16 25-45 34-40 50-60 56 40-45 35-45 30

37D345X 55A10025MXY 56A10045R 45A20025Y 30A10035U

30B 30B 30A 30A 30A 30A

1.2 0.7 0.6 0.6 2.0 1.0

2D 2D 1A-B-C 1A-B-C 2D 1A-B

40-50 20-25 27-40 35-50 50 35-50 50-60 60 45-55 55-60 55-60 60-70 55 75 16-20 120 20-25 14-30 55-60 100-120 30-50

45A10045 23A10025Y 34B635 43D335 50B645 43E45V 55B635 60A10035 50B625T 58C½35 58D335 65D335 55B625T 75A10037 18B635NY 120A10036 23B35PQ 22C½45 58C½45T 110B637 40B625N

30A 30B 30B 30B 30B 30A 30B 30A 30B 30B 30B 30B 30A 15 30A 30B 30A 30A 30A 15 15

1.6 1.5 1.6 2.0 1.7 3.0 1.7 0.6 0.7 1.5 1.8 2.0 0.8 1.0 0.5 2.0 0.6 0.5 0.8-4.0 2.2 2.0

1A-B 1A-B 1A-B 2D 2D D2 2D 1A-B-C 3D 2D 2D 2D 3D 2D 1A-B-C 2D 1A-B-C 1A-B-C 2A-B 3D 2D

40D345U

Material Characteristics Material

Weight Lbs per Cu. Ft.

Buckwheat 37-42 Calcine, Flour 75-85 Calcium Carbide 70-90 Calcium Carbonate (See Limestone) Calcium Fluoride (See Fluospar) Calcium Hydrate (See Lime Hydrated) Calcium Hydroxide (See Lime Hydrated) Calcium Lactate 26-29 Calcium Magnesium Carbonate 90-100 Calcium Oxide (See Lime, Unflaked) Calcium Phosphate 40-50 Calcium Sulfate (See Gypsum) Carbon, Activated - Dry 8-20 Carbon Black – Fine 4-6 Carbon Black – Pelleted 20-40 Carborundum 100 Casein 36 Cashew Nuts 32-37 Cast Iron, Chips 130-200 Caustic Soda 88 Caustic Soda, Flakes 47 Celite (Diatomaceous Earth) 11-17 Cement, Clinker 75-95 Cement, Mortar 133 Cement, Portland 94 Cement, Aerated (Portland) 60-75 Cerrusite (See Lead Carbonate) Chalk, Crushed 75-95 67-75 Chalk, Pulverized 18-28 Charcoal, Ground Charcoal, Lumps 18-28 Chips, Pulpwood 12-25 Chocolate, Cake Pressed 40-45 Chrome Ore 125-140 Cinders, Blast Furnace 57 Cinders, Coal 40 Clay, Ceramic – Dry 60-80 Clay, Calcined 80-100 Clay, Brick – Dry, Fine 100-120 Clay – Dry, Lumpy 60-75 Clinker, Cement (See Cement, Clinker)

Material Code

% Trough Loading

Mat’l Factor FM

Comp. Series

40B625N 80A10035 80D325N

45 30A 30B

0.4 0.7 2.0

1A-B-C 1A-B-C 2D

28D345QTR

30A 30B

0.6 2.0

2A-B 2D

45A10045

30A

1.6

1A-B-C

14A200 5A200

30B 30A

1.2 0.4

2D 1A-B-C

100D327 36B635 35C½45 165C½45 88B635RSU

15 30B 30A 30B 30B 30A 15 15 30A 30B 30B

3.0 1.6 0.7 4.0 1.8 1.5 1.6 1.8 3.0 1.4 1.4

2D 3D 2D 2D 2D 3D 2D 3D 3D 2D 2D

30B 30B 30B 30B 30A 30A 15 15 15 30A 30B 30B 30A

1.9 1.4 1.2 1.4 1.0 1.5 2.5 1.9 1.8 1.5 2.4 2.0 1.8

2D 2D 2D 2D 2B 2B 3D 3D 3D 1A-B-C 3D 3D 2D

47C½45RSUX 14A4036Y 85D336 133B635Q 94A10026M 68A10016M

85D325 71A10025MXY 23A10045 23D345Q

19C½45T 45D325 133D336 57D336T 40D336T 70A10035P 90B636

110C½36 68D335

Page 5

Material Characteristics Material

Coal, Anthracite (River & Culm) Coal, Anthracite, - ½ Coal, Bituminous Mined Coal, Bituminous, Mined, Sized Coal, Bituminous, Mined, Slack Coal, Lignite Cocoa, Beans Cocoa Nibs Cocoa, Powdered Coconut, Shredded Coffee, Chaff Coffee, Green Bean Coffee, Ground Dry Coffee, Ground Net Coffee, Roasted Bean Coffee, Soluble Coke, Breeze Coke, Loose Coke, Calcined Compost Concrete, Pre Mix Dry Copper Ore Copper Ore, Crushed Copper Sulphate (Bluestone) Copperas (See Ferrous Sulfate) Copra Cake Ground Copra, Cake Lumpy Copra, Lumpy Copra, Meal Cork, Ground Fine Cork, Granulated Corn, Cracked Corn Cobs, Ground Corn Cobs, Whole Corn Ear Corn Germ Corn/Grits Cornmeal Corn Oil, Cake Corn Seed

Page 6

Weight Lbs per Cu. Ft.

Material Code

% Trough Loading

Mat’l Factor FM

Comp. Series

1.0 1.0 0.9 1.0 0.9 1.0 0.5 0.5 0.9 1.5 1.0 0.5 0.6 0.6 0.4 0.8 1.2 1.2 1.3 1.0 3.0 4.0 4.0 1.0

2A-B 2A-B 1A-B 1A-B 2A-B 2D 1A-B 1A-B 1A-B 2B 1A-B 1A-B 1A-B 1A-B 1B 1B 3D 3D 3D 3A-B 3D 3D 3D 2A-B-C

0.7 0.8 1.0 0.7 0.5 0.5 0.7 0.6

1A-B-C 2A-B-C 2A-B-C 2D 1A-B-C 1A-B-C 1A-B-C 1A-B-C 2A-B 2A-B 1A-B-C 1A-B-C 1A-B 1A-B 1A-B-C

55-61 49-61 40-60 45-50 43-50 37-45 30-45 35 30-35 20-22 20 25-32 25 35-45 20-30 19 25-35 23-35 35-45 30-50 85-120 120-150 100-150 60-70

60B635TY 55C½25 50D335LNXY 48D335QV

135Cx36 125D336 65C½35

30A 30A 30A 30A 30A 30A 30A 30A 30A 30A 30A 30A 30A 30A 45 15 15 15 15 30A 30B 15 15 30A

40-45 25-30 22

43B645HW 28D335HW 22E35HW 42B635HW 10B635JNY 14C½35JY 45B625P 17C½25Y 14E35 56E35 21B635PY 43B635P 43B635P 25D745HW 45C½25PQ

30A 30A 30A 30A 30A 30A 30A 30A 30A 30A 30A 30A 30A 30A 45

40-45 5-15

12-15 40-50 17 12-15 56 21 40-45 32-40 25 45

47C½45T 41D335T 38C½25Q 35C½25 33A10045XY 21E45 20B625MY

29C½25PQ 25A4035P 40A4045X

25C½PQ 19A4035PUY 30C½37 30D737 40D737 40D745TV

103C½36V

0.4 0.5 0.5 0.6 0.4

Material Characteristics Material

Weight Lbs per Cu. Ft.

Corn, Shelled 45 Corn Sugar 30-35 Cottonseed, Cake, Crushed 40-45 Cottonseed, Cake, Lumpy 40-45 Cottonseed – Dry, Delinted 22-40 Cottonseed – Dry, Undelinted 18-25 Cottonseed, Flakes 20-25 Cottonseed, Hulls 12 Cottonseed, Meal, Expeller 25-30 Cottonseed, Meal, Extracted 35-40 Cottonseed, Meats – Dry 40 Cottonseed, Meats – Rolled 35-40 Cracklings, Crushed 40-50 Cryolite, Dust 75-90 Cryolite, Lumpy 90-110 Cullet, ...