Part 1: Installation Process and Precautions for Overflow Screw Conveyor -- Pre - Installation Preparation & Core Component Installation

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Installation Process and Precautions for Overflow Screw Conveyor

The installation quality of an overflow screw conveyor directly affects its operational stability, conveying efficiency,and service life. It is essential to follow a standardized process and avoid critical risk points. Below is a detailed installation procedure along with corresponding precautions and key risk alerts:

 

Ⅰ Pre - Installation Preparation

1.Equipment and Accessories Inventory Check

Process Steps:

  1. • Compare the equipment delivery list to verify that the main unit (screw blades, casing, drive unit), accessories (bearing housing, seals, connecting bolts, gaskets), and spare parts are all present and accounted for, with no missing or wrong items.
  2. • Inspect the appearance of key components: Check if the screw blades are deformed, worn, or have cracked welds; ensure the inner wall of the casing is smooth without dents; verify that the drive motor and reducer have no oil leaks, damaged casings, and confirm that the motor model and power match the design drawings.
  3. • Check precision components: Ensure the bearings in the bearing housing are free - moving without jamming, and that seals (such as packing seals, mechanical seals) are intact and not aged.

Precautions:

  1. • If deformations are found (e.g., bent screw blades), they must be corrected using professional tools (such as hydraulic correction) before installation. Forcing installation can lead to jamming and excessive noise during operation.
  2. • Seals should be stored separately in a dry, clean environment to prevent contamination with dust or oil, which could cause seal failure and material leakage after installation.

 

2.Installation Site Planning and Foundation Treatment

Process Steps:

  1. • According to the design drawings, mark the centerline of the conveyor, the positioning points of the supports, and the installation location of the drive unit at the installation site. Ensure that the dimensional errors in connection with upstream and downstream equipment (such as feed hoppers, discharge outlets) are ≤± 5mm.
  2. • Clean the site:Remove debris and standing water. If the ground is a concrete foundation, check its flatness (measure with a level, with a flatness error of ≤3mm per meter). If there are cracks or depressions in the foundation, repair them with high-strength cement mortar and allow the foundation to cure until it reaches the required strength (typically 7 days or more).
  3. • Secure the support precast parts (if any) according to the drawings, ensuring that the position deviation is ≤±2mm and that they are firmly connected to the foundation (check by tapping to ensure no looseness).

Precautions:

  1. • Sufficient operating space must be reserved: At least 800mm of space should be left on both sides and above the conveyor for future maintenance (such as bearing replacement, casing cleaning). A space of over 1.2m should be reserved near the drive unit for the inspection of the motor and reducer.
  2. • If the installation environment contains dust (such as in mining or building materials industries), the installation position of the dust collection device should be planned in advance to prevent dust accumulation from affecting equipment heat dissipation or sealing performance.

 

II.Core Component Installation

1.Casing and Support Installation (Key: Ensure Straightness and Levelness)

Process Steps:

  1. • Lift the segmented casing onto the supports (use soft lifting straps during lifting to avoid scratching the inner wall of the casing). First, align the flange interfaces of adjacent casings to ensure that the flange surfaces are in contact without gaps (if there are gaps, thin shims should be used for adjustment; do not forcibly tighten the bolts).
  2. • Measure the levelness of the entire length of the casing with a level: the longitudinal (conveying direction) levelness error should be ≤1mm/m, and the transverse (perpendicular to the conveying direction) levelness error should be ≤0.5mm/m. If the tilt exceeds the standard, adjust the height of the supports (add adjustment shims under the supports) until it meets the criteria.
  3. • Tighten the casing flange connection bolts (use a diagonal step-by-step tightening method to prevent flange deformation). The bolt tightening torque must comply with the equipment manual requirements (usually, the torque for M16 bolts is 80-100N·m; the specific value should follow the manufacturer’s specifications).

Precautions:

  1. • After the casing sections are joined, check the “straightness”: measure using the string method, with the total length straightness error ≤L/1000 (L is the total length of the conveyor). Otherwise, it will cause friction between the screw shaft and the inner wall of the casing during operation, accelerating wear.
  2. • The supports must be securely fixed to the foundation: use expansion bolts or anchor bolts for connection. After the bolts are tightened, they should be spot-welded to prevent loosening (if in a vibrating environment, add spring washers to prevent the supports from shifting during operation).

 

2.Screw Shaft and Drive Unit Installation (Key: Coaxiality and Sealing)

Process Steps:

  1. • Lift the screw shaft: Slowly insert the screw shaft into the casing, taking care to avoid collisions between the screw blades and the inner wall of the casing. If the screw shaft is segmented, first connect the shaft sections (through a coupling). When connecting, ensure the coaxiality of the two shafts: radial runout ≤0.1mm, face runout ≤0.05mm (measure with a dial indicator).
  2. • Install the bearing housing: Secure the bearing housing to the supports at both ends of the casing. Install the bearings into the bearing housing (before installation, lubricating grease should be added to the bearings, and the grease type should comply with the manual requirements, such as Lithium Grease No.2). Then, insert the shaft necks at both ends of the screw shaft into the bearings, ensuring that the inner ring of the bearing fits snugly with the shaft neck without any looseness.
  3. • Install the drive unit (motor+reducer):

• First, connect the reducer output shaft to the input end of the screw shaft through a coupling (if it is an elastic coupling, an axial clearance of 2-3mm should be reserved to prevent jamming due to thermal expansion and contraction).

• Measure the coaxiality of the coupling with a dial indicator:radial deviation ≤0.1mm, angular deviation ≤0.5°. If it exceeds the standard, adjust the shims under the reducer base (increase or decrease the thickness of the shims) until the coaxiality meets the criteria.

• Secure the reducer and motor base, tighten the anchor bolts, and ensure that the bolt torque complies with the manual requirement

4. • Install the sealing device:Install the seals in the gaps between the ends of the casing and the screw shaft (for packing seals, insert graphite packing;for mechanical seals, ensure the dynamic and static rings are in contact). After the seals are installed, adjust the tightness (too loose will cause leakage, too tight will increase wear, and it is appropriate to manually rotate the screw shaft without significant resistance).

Precautions:

  1. • After the screw shaft is installed, manually rotate the shaft:turn the screw shaft in the conveying direction, there should be no jamming or abnormal noise, and the gap between the screw blade and the inner wall of the casing should be uniform (the gap value is usually 5-10mm, the specific value depends on the equipment model). If the gap is uneven, the coaxiality of the screw shaft should be readjusted.
  2. • The wiring of the drive unit must comply with electrical standards:the wiring in the motor junction box should be secure, and the grounding resistance should be ≤4Ω. If it is a variable-frequency motor, ensure the compatibility between the inverter and the motor (such as power, voltage level) to prevent motor overload and burnout.

 

3. Hopper and Discharge Port Installation (Key: Leak-Free Connection)

Process Steps:

  1. • Install the hopper: Align the hopper with the inlet flange of the casing, adjust the position so that the centerline of the hopper coincides with the centerline of the casing (deviation ≤3mm), then connect the flanges with bolts. A wear-resistant rubber gasket (3-5mm thick) should be installed between the flanges to prevent material leakage.
  2. • Install the discharge port: Adjust the angle of the discharge port according to the conveying direction (horizontal/inclined) to ensure smooth discharge without accumulation. If it is inclined installation, a baffle should be added to the discharge port to prevent material splash.

Precautions: 

  1. • The area below the hopper should have a “smooth transition” with the casing inlet to avoid steps or dead corners, which would otherwise cause material accumulation and blockage of the inlet.
  2. • If conveying sticky materials (such as sludge, coal powder), install wear-resistant liners (such as polyurethane liners) on the inner walls of the hopper to reduce material adhesion.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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