ESCO Kwik-Lok Wear Protection Application Guide for Crushing and Conveying P6001UWS01L0312
Safety www.escocorp.com General Safety Information The safety practices described in this manual are meant as guidelines for safe operation under most conditions and are meant to supplement any safety rules and/or laws that may be in force in your area. Your safety and the safety of others results from putting into practice your knowledge of the correct operating procedures. Signal Words Throughout this manual are statements preceded by a special attention symbol:. The symbol is used with the following signal words to attract your attention to information of special priority. Read the paragraphs carefully and make sure you understand their significance, especially the possible causes of injury. WARNING: A statement preceded by WARNING is information that should be acted upon to prevent serious injury. CAUTION: A statement preceded by CAUTION is information that should be acted upon to prevent machine damage. Additional signal words that are not preceded by the attention symbol are: IMPORTANT: A statement preceded by the word IMPORTANT is information that possesses special significance. Tip: A statement preceded by Tip is information that is handy to know and may make your job easier. Personal Safety WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. Always wear hard hat, gloves, safety shoes, eye protection, hearing protection and fall protection per regional, national and site requirements (e.g. OSHA, MSHA) when performing maintenance work. To avoid injury to others, keep bystanders well out of the way. 2
Kwik-Lok Wear Protection Application Guide for Crushing and Conveying ESCO offers a choice of 2 styles of Kwik-Lok wear protection. Kwik-Lok Wear Protection The original Kwik-Lok system has been used extensively in fixed plant applications. Where gravity and or material flow are sufficient, runners may be installed without stops, making the system change-out 100% mechanical. Where some method of runner retention is required, a separate stop block is welded in place to retain the runner. Kwik-Lok System Wear runner Base Weld-on stop Kwik-Lok II Wear Protection Kwik-Lok II system, with its own integral mechanical lock and reversible runner, offers even greater flexibility and benefits. Also featuring the ability to be gravity retained, the mechanical lock allows the runner to be secured in place without additional welding. The reversible runner also ensures you maximize protection and minimize throw-away in areas of uneven wear. Kwik-Lok II System Lock Wear runner Base 3
Some Areas that Benefit from Kwik-Lok Protection Primary Crushing Circuit C. Pan and vibratory feeders A. Earthmovers B. Conveyor head boxes D. Strike plate G. Chutes and screen decks E. Scalping deck or grizzly F. Transfer points under crushers or sides of conveyor A. Earthmoving Equipment This is where Kwik-Lok wear protection was first used. The Kwik-Lok system provides superior wear protection for face shovels, hoes, front end loaders, shovel dippers, draglines, and haul dump trucks. B. Conveyor Head Boxes The most common application for Kwik-Lok runners is at the end of a conveyor where the material strikes a wall opposite the conveyor before traveling down into a crusher, onto a stock pile, onto another conveyor, or sometimes through a chute. Applications exist in the plant and in the pit. The in-pit conveyors often have severe wear problems due to the large size of material coming directly from the bank. C. Pan and Vibratory feeders Pan and vibratory feeders are used to move material at a controlled pace onto the scalping deck and into a crusher. Material falling off of the feeder hits the strike plate. Applications are found on the sides of the pan feeders. In most cases a feeder is located under a grizzly immediately before a primary crusher. The feeder is usually fed by a loader from stock piles or from trucks from the pit. 4 D. Strike Plate This is a very high impact area due to the size and impact energy of the material falling from the feeder. E. Scalping Deck or Grizzlies The chutes under a scalping deck or grizzly are good applications for Kwik-Lok runners. Special wear runners are also used to protect grizzly bars in some applications. F. Transfer Points onto Conveyors In almost all cases the chute or crusher discharging above a conveyor is wider than the belt. Angled plates are used to choke the material down to the width of the belt. G. Chutes & Screen Decks Chutes are used to get material down from a discharge or screen deck to another crusher, storage bin, or another conveyor. Kwik-Lok systems can be spaced out and staggered to provide the most cost effective coverage in these applications.
1) Locking Runners in Place Both the angle of the surface and the relative angle of material flow must be considered when determining whether to use a locking system. A lock or stop is generally not required if the surface being covered is upright at an angle greater than 45 from horizontal and material striking the surface is less than 60 from the surface. However, if material tends to back up into the runners, the surface is located in an area of heavy vibration, or the risk of losing a runner is too great, then the Kwik-Lok II system should be used and a lock should be installed in every runner. For detailed installation instructions, see ESCO Kwik-Lok Installation and Removal. 2) Recommended Runner Spacing Runners should be installed with sufficient clearance in front of each runner to allow it to be individually installed and removed. MA Size 63mm/2.50in. MB Size 38mm/1.50in. MC Size 32mm/1.25in. Minimum removal distance 6mm/0.25in. min. distance between runner and side plate. Runner can be at edge, if no side plate. 13mm/0.50in. min. distance between runners. 45 Must use lock or stop when surface angle is less than 45. 3) Tight Spacing In applications where a tight layout is required a minimum spacing of 6mm/0.25in. can be used between all runners. When spacing is this tight: 1. Runners cannot be individually installed or removed. To remove one runner, all runners in front must be removed first. 2. When installing bases, the installation must be held to very tight tolerances. 3. When using the following base styles and general purpose runners, the end of the bases must be trimmed. 4. When reverse loads are present (loads that could push the runner off the base), the Kwik-Lok II system should be used with a lock installed in each runner. Kwik-Lok bases Material flow 60 Optional lock or stop when material strikes the surface at less than 60. Must use lock or stop. CAUTION: When material backs up against runners or causes reverse loading a lock or stop must be used. WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. Always wear hard hat, gloves, safety shoes, eye protection, hearing protection and fall protection per regional, national and site requirements (e.g. OSHA, MSHA) when performing maintenance work. To avoid injury to others, keep bystanders well out of the way. Burn line is cast in base. Kwik-Lok II bases Burn line is cast in base. 5
4) Layout Creation Process 1. Identify the dimensions of the surface you will protect. 2. Choose the layout pattern that is best for your application. 3. Identify the appropriate system size. 4. Determine whether locks or stops will be necessary. Choose Kwik-Lok or Kwik-Lok II. 5. Select parts and make a layout. The typical steps of creating a layout are: 1. Identify the dimensions of the surface you will protect. Complicated surfaces can be broken into smaller, simpler areas. Multiple surfaces like multiple sides of a chute can be done individually with the recognition that when all sides come together allowance must be made for clearance of runners in the corners. 2. Identify what type of layout is best, in-line, staggered, checker board, etc. The type of layout will depend on the ability of material to deadbed (pack) between runners. In some cases, if the space between runners in an in-line layout is too great, it can force the need for a staggered layout. 3. Identify the system size most appropriate for the load forces that will be encountered in your application. 4. Identify whether locks or stops will be required to hold the runner onto the base. Decide whether to use the Kwik-Lok or Kwik-Lok II system. 5. Select a runner from the specification book. Using minimum spacing and part information provided: create a layout 5) Base Orientation Load forces can come from all directions, but runner assemblies are normally installed such that the primary load force (force of highest magnitude) frontally loads the runner against the base dovetails. Where necessary, side-loading is acceptable, but the assembly should be oriented such that the lowest impact l oads are reverse loads. Base dovetail Primary load Front of runner Back of runner Reverse load (a stop or lock must be used) CAUTION: When reverse loads are present, a weld-on stop or mechanical lock must be used. 6
6) System Size Selection The appropriate system size to use is defined by the angle that material strikes the surface and the size of the material. In most applications with sliding abrasion or where material is striking the runner face at a relatively perpendicular angle, any system size will work. Where material is very large and dropping a long distance, impacts that could generate extreme loads on the runner, dictate the use of a larger system size. See the illustration and chart. Kwik-Lok II Kwik-Lok Material MA AA Any size material Use any system size Material flow See chart 15 Surface Use any system size 30 30 MB AB 305mm/12" and smaller diameter falling up to 3m/10' or less. MC AC, AR 203mm/8" and smaller diameter falling up to 1m/3' or less. AD, AM 51mm/2" and smaller diameter falling 3m/10' or less. 7) Standard Layout Patterns In-Line Layout An in-line layout is the simplest layout to calculate and the easiest to install. Successful use of this layout depends on material packing between columns to eliminate washing between runners. The tendency for material to pack (dead-bed) between runners will depend on the angle of the surface relative to the flow of material, and the consistency of material being processed. Where material does not pack well, or where the side-to-side gap between runners is excessive, a staggered layout may be necessary. In-line layout Typical 0.50-1.50" Material flow WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. Always wear hard hat, gloves, safety shoes, eye protection, hearing protection and fall protection per regional, national and site requirements (e.g. OSHA, MSHA) when performing maintenance work. To avoid injury to others, keep bystanders well out of the way. 7
7) Standard Layout Patterns Cont. Staggered Layout A staggered layout can be used to promote a dead-bed of material between runners. In this layout, runners are offset to create pockets that trap material. This layout eliminates the vertical channels that exist in an in-line layout. Staggered layout www.escocorp.com Material flow Typical 1.00-2.50" Checker Board Layout Where an application will provide a significant dead-bed effect, runners can be staggered to minimize the amount of steel required to protect a surface. This layout relies on material packing between runners. The checker board layout depends on subsequent rows of runners to dead-bed material, so the last (or exit) row should be tightly gapped 12-25mm/0.50-1in. side-to-side. Checker board layout Material flow Tip: The ability for material to dead-bed can often be determined by looking at the application and noting the degree to which material sticks in corners, or backs up behind a change in angle, or is contained in a grid or bar type layout. Typically 1/2 to 1 times runner width Angled Sides Where a chute or bin has angled sides, the layout should be made in such a way that material will pack in the triangular void left between the side of the chute and the first runner in each row. Angled sides Material flow Material dead-bed 8
8) Additional Layout Information Inside Corners Where a layout calls for two or more sides to be covered, corners come into play. Several options exist for corner layouts. To leave room for runner removal in a corner, the spacing must equal the height of the base plus 6mm/0.25in. Inside Corners Option 1 www.escocorp.com Option 2 Option 3 Staggered Layout with Sidewalls In a staggered layout with sidewalls, the corners can be alternated using corner layouts shown above to provide a stagger. Staggered Layout with Sidewalls Sidewall Sidewall Hot Spots If there is a concentrated area of high wear, Kwik-Lok runners can be used to cover only the highest wear areas and alternative materials can be used in the low wear areas. A combination of wear runners and plate can provide best value in some applications. Hot Spots Weld-on plates WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. Always wear hard hat, gloves, safety shoes, eye protection, hearing protection and fall protection per regional, national and site requirements (e.g. OSHA, MSHA) when performing maintenance work. To avoid injury to others, keep bystanders well out of the way. Hot spot of highest wear. 9
8) Additional Layout Information Cont. Concave Surfaces On concave surfaces, the base must be elevated off the mounting surface to provide clearance for the runner. This can be accomplished in two ways: 1. Flat plate strips can be welded to the wear surface to accept flat bases. 2. Special curved bases can be mounted directly to the wear surface. Tip: Curved bases are also available for convex curved surfaces. For more information on curved bases, refer to product specification literature. Flat bases on plate strips Concave Surfaces Special curved bases on wear surface www.escocorp.com Weld-on plates 10
9) Recommended Products Kwik-Lok II Mechanical Runners General purpose runner Long runner H-style runner Kwik-Lok II Bases Flat base Outside radius base Inside radius base (across length) Inside radius base (across width) Kwik-Lok Semi-Mechanical Runners Flat runner Flat runner Chute liner runner Kwik-Lok Bases Curved base Flat base Bi-directional base WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. Always wear hard hat, gloves, safety shoes, eye protection, hearing protection and fall protection per regional, national and site requirements (e.g. OSHA, MSHA) when performing maintenance work. To avoid injury to others, keep bystanders well out of the way. 11
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