Equipment Condition Assessment for Screw Conveyors

We conduct screw conveyor assessments during planned shutdowns with the conveyor emptied and access covers removed. Flight assessment includes diameter measurement using calipers or go/no-go gauges at defined stations (typically every 3 to 5 flight pitches), flight edge condition evaluation for wear, chipping, and bending, and weld inspection at flight-to-shaft connections for cracking. Trough assessment includes liner thickness measurement at defined circumferential and longitudinal positions using ultrasonic thickness gauges, liner surface condition evaluation for scoring and perforation, and trough shell condition behind the liner. Hanger bearing assessment includes radial clearance measurement at each bearing position, bearing surface condition evaluation, lubrication status, and bearing housing integrity. Shaft assessment includes visual inspection for corrosion and wear at bearing and seal locations, straightness assessment through runout measurement, and coupling condition at the drive end. End bearing assessment includes radial and axial play measurement, seal condition evaluation, and evidence of material leakage past the seal. Drive assessment includes motor, gearbox, and coupling condition evaluation. Each conveyor receives a wear map showing flight diameter by station, liner thickness profile, bearing condition by position, and overall condition grade with remaining useful life estimate based on current wear rates and capacity requirements.