SOP: Conveyor System Installation
1. Objective
This SOP outlines the standardized, safety-compliant procedure for installing conveyor systems in industrial and logistics environments. It ensures precise mechanical assembly, safe electrical connections, and readiness for commissioning—aligned with ISO 5048 and OSHA 1926 standards.
2. Tools and Materials Required
Category | Tools & Materials |
---|---|
Mechanical Tools | Spirit level, torque wrench, laser alignment tool |
Electrical | Wiring kit, multimeter, grounding straps |
Installation | Power drills, spanners, cranes, hoists |
Conveyor Parts | Belt, rollers, frame, pulleys, motor, gearbox |
Safety Gear | Gloves, helmet, goggles, LOTO kit |
Pro Tip: Use a laser alignment tool for pulleys over 2 meters long to prevent future belt drift issues.
3. Pre-Installation Requirements
- Verify foundation integrity and utility availability.
- Cross-check conveyor layout with the latest manufacturer’s installation drawings.
- Ensure component inspection for damage during transport.
- Confirm electrical compatibility with motor and VFD ratings.
- Conduct a toolbox safety talk and issue LOTO permits.
4. Mechanical Installation Steps
4.1 Frame and Support Assembly
- Level and secure base frames using spirit level and bolts.
- Erect support legs and cross-members according to the layout drawing.
- Confirm structure rigidity before mounting further components.
4.2 Roller & Pulley Mounting
- Fit head, tail, and snub pulleys using laser alignment.
- Install carry and return rollers at manufacturer-specified intervals.
- Check for parallelism to ensure straight belt tracking.
4.3 Belt Installation
- Carefully place belt over pulleys and rollers.
- Apply correct tension and track alignment using tensioning devices.
- Avoid twisting or sharp bends.
4.4 Drive Motor & Gearbox Installation
- Align gearbox shaft to motor and secure coupling.
- Bolt down using anti-vibration mounts.
- Confirm manufacturer torque specs (e.g., 80 Nm for M12 bolts).
5. Electrical Installation
- Mount control panel on a vibration-free location.
- Route cables through cable trays or steel conduits.
- Wire VFDs or DOL starters per IEC wiring codes.
- Connect proximity sensors, belt misalignment switches, and emergency stops.
- Perform proper grounding for all electrical elements.
6. Testing & Commissioning
6.1 Pre-Start Checklist
- All hardware torqued to spec.
- Belt tension/alignment validated.
- Guards, covers, and warning signs in place.
- Area cleared of debris.
6.2 Dry Run Test
- Run motor without load.
- Verify direction of rotation.
- Observe belt tracking, noise, and vibration.
6.3 Load Testing
- Feed test material to check throughput and flow control.
- Validate sensor response, e-stop functionality, and discharge accuracy.
- Confirm operational safety and record anomalies.
7. Safety Measures
- Apply Lockout/Tagout (LOTO) before all electrical work.
- Never operate with removed guards.
- Clearly label danger zones with high-visibility signage.
- Avoid overloading or standing on the conveyor.
8. Documentation and Handover
Create a commissioning report including:
- Drive system specifications (motor/Gearbox RPM, rating)
- Belt make/model, tension/track data
- Test logs (dry run, load trial, sensor response)
- Photos of installed setup and safety guards
- Client sign-off on completion
Bonus: Provide a downloadable PDF checklist for future audits.