Artisan AND Beltsman conveyor training belts 2018

MATLA COAL CONVEYOR BELT
TRAINING FOR

ARTISAN & BELTS MAN



Introduction to conveyor belts

Conveyor belts are probably the most efficient means of transporting
bulk materials. However, it are considered dangerous due to the sheer
size of the installation which prevents clear and unobstructed visibility
down the length of the system. Conveyors can be one of the most
hazardous mine or plant equipment installations if safety regulations
are not strictly followed or if the conveyors are not properly cleaned and
maintained

Belt Maintenance Introduction

Proper maintenance and prompt repairs play a major role in the life
expectancy and efficiency of any piece of equipment. Conveyor belts
may be looked upon as low maintenance installations, but careful
attention should be given to the cleanliness and Maintenance of the
system, Methods and frequencies of cleaning and maintenance plays a
major roll to allow for proper inspection and services of a conveyor.

Introduction to conveyor belts (Continues)

A smooth, clean, trouble free running conveyor will not only reduce the
operator’s work-load, but will also give the company the highest return on
investments.

Maintenance personnel is responsible to control / repair/ maintain
conveyor equipment, identify and repair report address problem areas
before they cause major damage to conveyors and associated equipment.

The cleanliness of a conveyor allows for visual inspection to be carried out
at any time by maintenance teams and Operators

Safety Warning:
No maintenance, adjustments or manual cleaning must be done on
the conveyor system while the conveyor is in motion without the
correct Permits and permissions granted. Water hose cleaning may
be done from a safe distance.

Proper inspection should be done daily and the findings reported
to the responsible Supervisor or control room.
The following should be looked at during cleaning or daily inspection
and reported immediately to the Supervisor or responsible artisans:

• Any part of the conveyor or conveyor structure that is
damaged.

• Worn or seized idlers suspect of causing spillage or cutting
and detraining the belt.

• Spillage of material onto the return belt where it can lodged
between the belt and the pulleys.

• Material spillage will not only damage conveyor belt
components, but will also cause the belt to run off center.

• Conveyor belt running on top of spillage
• Heat buildup or a smell of conveyor belt rubbing against

structure

Proper inspection ( Continues) should be done daily and the
findings reported to the responsible Supervisor or control room.
The following should be looked at during cleaning or daily inspection
and reported immediately to the Supervisor or responsible artisans:

• Excessive noise which is not normal for a running
conveyor belt

• Safety guards or barriers that are not replaced or
damaged.

• Lights that are missing, or broken or not working
• Cut/ exposed cables
• Pull keys hanging loose or broken pull wires.
• Walkways that are unsafe to access or damaged.
• Oil leaks on drives
• Scraper condition
• Conveyor tracking
• Leaking chutes or Skirtings
• Inspection doors closed

BEST PRACTICES

Establish policies to ensure employees are trained to safely
remove spillage near moving conv belts.
Before assigning personnel to clean up spillage, have them
identify hazards and demonstrate how they would safely complete
the task. (Following to be used. HIRA )
Lockout the conveyor belt, by isolating all energy sources.

OBJECTIVE OF THE CONVEYOR TRIANING IS:

To ensure the understanding of the risks involved when cleaning/ maintaining conveyor
systems. This includes isolation and lockout of all energy sources in which the unexpected
energization or start up or the release of stored energy could cause injury.

Areas that needs to be focused on is:
Safety equipment and tools required when inspecting and
maintaining a conv belt
Basic positions of conveyor components and functions
HIRA(Hazard identification and Risk assessment)
Isolation and lockout

OBJECTIVE OF THE CONVEYOR TRIANING IS:

A conveyor belt comprises of a rubberized flat belt suspended between pulleys at either
end and is supported along the way by the basic equipment listed in the diagram below:

Pulleys- belt turn around pulleys and drive determines the conveyor speed
Take up and take up weight- tension conveyor
Drive unit- consist of motor and gearbox
Idlers and Structure- to ensure conveyor can overcome resistance and be
ridged to transport product
Scrapers- to clean conveyors
Chutes – to feed or discharge material
Chute Skirting – to guide coal as well as prevent spillage
Dust Suppression- to ensure dust is controlled
Guarding- to ensure separation between people and machinery
Electrical safety systems like- pull keys/ level controllers/ sequence
controllers and misalignment switches



Conveyor Belt System

Conveyor selection and design is determined but not limited by the following factors:

• Type and size of material to be transported
• Physical characteristics of transported goods( density and mass)
• Flow rate tons per hour
• Required load carrying capacity of the System
• Position of chutes and quantity on conveyor
• Distance of conveyor
• Speed of conveyor
• Height differences between head and tail
• Type of structure required( plinth/ hanging or pipe structures)
• Position of drive units ( top of silos and bins or on ground level)
• Electrical power required|(switch gear / cabling and electrical motors)
• Type of take up and take up traveling distance
• Dust suppression requirements
• Environmental needs (dust / spillage / water requirements/ permits etc.)

COP16 FOR THE USE OF CONVEYOR BELT INSTALLATIONS FOR THE
TRANSPORTATION OF MINERALS

Related documents towards the training on the installation and maintenance on conveyor belts

Mine Health and Safety Act 29 of 1996

Minerals Act 50 of 1991

ETP 85 - Change section conveyor tail end bearings
ETP 103 - Lockout conveyor drives underground.
ETP 109 - Splicing of incline conveyors at safely
COP 04 - Emergency preparedness and response
COP 10 - Lock out of machinery and plant
COP 13 - Airborne pollutants
COP 15 - Prevention of flammable gas and coal dust explosions in collieries
COP 21 - Prevention of fires at mines
SP 08 - Emergency preparedness and response
MS 02 - Fire prevention and fire control
MS 15 - Mining standard regarding protective equipment
MP 02 - Fire prevention and fire control
MP 23 - Ventilation arrangements during belt extensions
MP 24 - Dust suppression equipment at surface plant and underground transfer points.
ES 04 - Use of cutting and welding equipment
ES 05 - Engineering standard regarding design, installation, operation, repairs, maintenance and inspection of conveyor belts
EP 03 - Electrical lock out procedure for underground conveyor drives
EP 20 - Lockout for plant areas.
EP 21 - Steel reinforced conveyor belt splicing procedure

COP16 FOR THE USE OF CONVEYOR BELT INSTALLATIONS FOR THE
TRANSPORTATION OF MINERALS

Related documents towards the training on the installation and maintenance on conveyor belts

EP 40 - Lifting and rigging operations
EP 54 - Working in chutes, feeders and on conveyors under plant silo’s
EP 58 - Welding or cutting in a confined space
EP 61 - Laser alignment
EP 67 - Electrical portable grinder
EP 74 - CO2 welding machine
EP 76 - Diesel welding machine
EP 80 - Battery operated grinder
EP 82 - Arc welding machine
MTP 02 - Test for ventilation
MTP 17 - Conveyor belt extensions in a bord and pillar section
MTP 18 - Make conveyor belt (clip) joints
MTP 40 - Removal of belt structure at stage loader
MTP 46 - Making goro conveyor belt joints
MTP 47 - Line leveling belt structure
MTP 52 - Changing of 300m conveyor belt
ETP 17 - Align conveyor gear case
ETP 10 - Lifting and supporting of equipment
ETP 19 - Operate hand tools
ETP 133 - Operate inverter welding machine
ETP 137 - Remove and replace 4A/4B and 6A/6B conveyor gearboxes safely
ETP 162 - Electrical portable grinder
ETP 171- Diesel welding machine
ETP 175 - Battery operated grinder
ETP 177 - Arc welding machine



RISK MANAGEMENT

To comply with the requirements of Section 11 of the MHSA, the associated Health and
Safety risks were determined to which employees may be exposed to while constructing,
operating, maintaining and decommissioning conveyor belts installations. The Mine made
use of a Risk Management process, as per system procedure - SP01, to determine the
associated risks and to comply with the requirements of Section 11(2) and (3) of the
MHSA.
Determine control measures, the hierarchy of controls will be considered which is based
on the following principal

As far as reasonably practicable , attempts will be made to eliminate the risk Thereafter
attempt to minimize the severity of the risk through substitution Thereafter attempt to
minimize the probability of the risk through engineering controls, signage, warnings, and/or
administrative controls And as a last resource PPE will be provided

The effectiveness of the controls and compliance will be monitored through
inspections, audits and by walkabouts, as per System Procedure regarding
performance measurement and monitoring - SP08

BELTS MAN OR ARTISAN

With reference to belt conveyors means a Competent Person who, in his area of
responsibility and pertaining to his specific responsibilities:

has the experience, knowledge, training and skills to safely carry out the installation
-extension-, dismantling-, transporting- and re- installation processes, as well as the
associated commissioning / de- commissioning processes and any repair / maintenance
tasks on such installations; and (b) is fully familiar with

- any applicable OEM specified procedures; and
-all belt conveyor Task Procedures, Standards and Codes of Practice in force on the
mine; and
- all Lockout Procedures applicable to belt conveyor installations; and
-the requirements of the MHSA [Act 29 of 1996] pertaining to belt conveyor
installations; and
-understands the hazards associated with each of the tasks mentioned in above, including
those hazards associated with stored energy in a belt under tension; and

-has been trained to eliminate any stored energy effectively; and Conveyor Belt Installation
mechanical system used for the transportation of minerals, material, or persons on a belt
over a distance

HAZARD

A hazard is a source with the potential to:

Cause harm to the health or safety of employees
Cause damage to property
Cause change to the environment (Positive or negative)
Cause an adverse effect on the organizations product, processes and services

LOCK OUT

To isolate the energy source to equipment at the respective isolation point for
that equipment.

TAGGED

Is certified lifting equipment like slings/ Shackles/ lever hoists/chain
blocks/TirforsTirfor/ Fur pull belt clamp equipment
Solution Is Rima tip top and vigro stick splicing and splice cleaning and bonding
fluids.
Ambient Conditions Any influence of humidity, e.g. formation of condensation
water
(temperature falling below dew point) must be absolutely avoided. Precondition
products to ambient temperature if necessary. Erect a splicing shelter/tent for
protection against sun, dust, wind, rain etc when required.

MAJOR WORK

Includes but is not limited to, all work that necessitate the removal of a guard, splitting the
belt, scraper maintenance, repairs to sprays, advancing the tail-end, work on the take up
winch or the drive unit or any electrical work excluding work on the “Black line” pull wire
system. Also any work deemed to be major by the relevant Supervisor.

MINOR WORK

Includes but is not limited to, any work that does not necessitate the removal of guards e.g.
replacing an idler, cleaning a tail end without removing any guards,
cleaning the top of a drive unit, training the belt, minor adjustments to structure
alignment, work on the “Black Line” pull wire system.

PERSONNEL

Personnel refer to all coal processing employees and contractors. Personnel Protective
Equipment and HygieneIncludes, but not be limited to;

Hearing Protection Mine supplied overall Mine supplied footwear Mine supplied Hard Hat
Mine supplied Dust Mask
Safety gloves Safety golles

POWER SUPPLY

any energy source feeding the drive motor of a conveyor belt installation

RELATED DOCUMENTS.

Mine Health and Safety Act 29 of 1996 Minerals Act 50
of 1991
Cop`s , Standards, Procedures, Task Procedures

GENERAL SAFETY REQUIREMENT FOR CONVEYOR BELT
MAINTENANCE INSTALLATION AND REPAIR.

Prior to any work conducted on a conveyor belt installation where there is a potential of
mechanical, electrical, hydraulic or any source of energy release, a process to identify,
isolate, de-energise, and lock- out at source must be followed as per Isolation, lockout &
testing of Machinery, Plant and Equipment. Examples of such work are the following but not
limited to:

The removal, adjusting or modification to any guard, nip guard, conveyor structure, idler
frame, and roller, Pulley, idler or similar or:

Where it is necessary to barricaded area in or around a conveyor structure, or enter any
guarded or

Where it is necessary to climb on top of or beneath any, or come into contact with any
part of the conveyor belt.

NOTE:

Under no circumstances may any person perform any work on any
part of the return belt of any conveyor belt unless the conveyor belt
is isolated, locked out, tested and tagged as per COP16, and the
tension in the conveyor belt has been released by lowering the
counterweight to ensure the elimination of any form of stored
energy in the conveyor belt AND the winch mechanism used to
lower and raise the counterweight has been isolated, locked out,
tagged and tested at the local field isolator for that specific
winch. The lowering of the counterweight will not be done for
following tasks: Belt scraper maintenance / Idler and idler
frame/skirting replacement. Lockout of Winch station is compulsory
for any task on a conveyor system.



Description of conveyor belt installation(s) used at the Mine
(including relevant information such as the application and technical
specifications)

Types of conveyor belt installations

Overland Conveyors (include Eskom conveyors) In-plant
Conveyors plant
Underground Conveyors (include incline conveyors)

Conveyor applications

Matla Coal conveyor belts serve as a preferred means of bulk material
transportation. The conveyors serve to move coal from the mining areas to the
process operations, in-plant conveyance, and to move products from the process
operations to storage facilities (stockpile) or Eskom

ES 05 - Engineering standard regarding design, installation, operation, repairs,
maintenance and inspection of conveyor belts

CONVEYOR SAFETY RULES TO HELP PREVENT A TRAGEDY

Never walk, ride, sit, or climb on a conveyor not intended for that purpose. Don’t
attempt to service or repair a conveyor without procedures for locking out power.
When working near a conveyor, don’t wear loose clothing, jewelry, or other articles
that might catch.
Do not operate any conveyor without thorough training in its use. Don’t
overload conveying equipment.
To avoids slips, ensure all work areas are clean and grease free. Keep all
body parts away from moving conveyor parts.
Do not operate any conveyor unless all safety guards, covers, and
maintenance panels are in place.
Focus on the Following Key Priorities: Guarding

GUARDING IS TYPICALLY REQUIRED IN LOCATIONS SUCH AS

Power transmission interfaces Nip
points
Shear points (where a moving conveyor part meets or passes near a
stationary point such as a wall)

Spill points (where material could spill from a conveyor)

FOCUS ON THE FOLLOWING KEY PRIORITIES: GUARDING

Guarding is typically required in locations such as:
Power transmission interfaces
Nipoints
Shear points (where a moving conveyor part meets or passes near a
stationary point such as a wall)

Spill points (where material could spill from a conveyor)

FOCUS ON THE FOLLOWING KEY PRIORITIES: LOCKOUT

When it is necessary to open or remove guards, workers must follow lockout
procedures to prevent injury from the conveyor starting.

Lockout procedures EP03 typically involve bringing the machine to a complete
stop and disconnecting all its power source

Blocking is an extra step that must be carried out to prevent the conveyor belt from
moving under its own power due to tension on the belt

Zero energy must be achieved and verified



GUARD AGAINST CONVEYOR INJURIES!

Conveyors are very common in workplaces and may present serious safety
hazards.
Conveyor-related injuries can be life-altering and even fatal.
Preventing such injuries must be in the forefront of every
workplace safety program.

DEFINITION: NIP POINT
"Nip Point" by definition is that point at which an element of the conveyor
machinery moving in a line or rotating meets another element which is either
rotating or moving in a line in such a manner that it is possible to nip, pinch,
squeeze, or entrap objects coming in contact with one of the two elements.
"Pinch Point" terminology is often used to describe nip points.

TYPICAL CONVEYOR HAZARDS OCCUR

Where power is transmitted
At nip points, shear points, pinch points, and spill points
At transfer counterweights and transfer mechanisms
Where workers can walk or drive under the conveyor
When there are special circumstances

DEFINITION OF A NIP POINT

A nip point is the dangerous pinch point which occurs at the line of contact
between the rotating drum or roller and the moving conveyor belt on the in-
running side of the drum or roller. A diagram showing these locations on a

conveyor belt are shown at ANNEX 1, AND ANNEX 2.

In addition, health and safety statute often uses the term ‘as far as is reasonably
practicable’ in this context, nip guards should be fitted where nip hazards are
identified unless it can be shown that this is disproportionate to the risk. The use
of nip point guards in the industry over many years has shown that to fit them is a
reasonably practicable measure, which can be easily achieved and at little cost
compared to the overall cost of the belt conveyor.

NOTE:

A similar point on the out-running side of the drum or roller where the conveyor
belt exits is not the dangerous location, unless the conveyor can be reversed.
This is important because in some cases it is difficult to identify the nip point
side, for example, in some conveyor loop take-up systems.

HAZARD LOCATIONS

Hazardous nip points may occur at the following
locations: Drive drums
Terminal rollers at delivery and return end
locations Bend and snub rollers

Loop take-up rollers
Transition troughed idlers adjacent to main
rollers Carrying and return idlers at convex
curves
Carrying and return idlers beneath feed hoppers, skirt plates and where the lift of the belt
has been restricted

Roller assemblies for conveyor belt tracking
Locations affording access to persons e.g. bridges or underpasses, maintenance /
storage areas, dinting / cleaning areas

NIP GUARDS

Nip guards, are essential safety devices and they need to be maintained in effective
working order. They are an essential safeguard and should be subjected to a suitable
scheme of inspection, examination and maintenance. Each nip guard should be
individually identified in such a scheme to ensure that the location of each guard is clearly
identified and each has its own record of inspection, examination and maintenance



NIP POINT OF CONVEYOR DRUM

Prevention of these types of accidents involve simple guarding solutions. Fixed guards
can cover chain and sprockets easily. Fixed guards can also often be used on head and
tail drums. Fixed guards are the most effective solution to keeping people from being
exposed to the nip points on conveyors.

Fixed, interlocked guards safeguard the nip point effectively.

Some manufacturing processes may not allow safeguarding by fixed guards. In this case,
access to the entire area must be restricted to prevent exposure to the hazard. Fixed
guards will have to be removed for maintenance on the conveyor. Properly interlocked
guards will shut power down to the conveyor when the guard is removed.

Lock-out/Tag-out is a procedure used to prevent maintenance workers from being exposed

to machinery hazards, as well as to prevent accidental activation of machinery while being

maintained. This involves shutting power down to machinery, and using padlocks to

prevent the power from being turned on again inadvertently. OSHA has specific

requirements for lock-out/tag-out procedures.

Exposed shafts are another hazard that can result in serious injury. An exposed shaft that
is rotating can get clothing wrapped around it, after which the rotating shaft will continue to
rotate, pulling the entangled person along with it. Exposed shafts can be minimized in the
design and construction phase, and any remaining hazard can be protected with a fixed
guard that prevents entanglement with the shaft.

Nip guard

Emergency stops

Emergency stops are important safety features in the event of someone becoming entangled or
otherwise injured in a conveyor. Stopping the conveyor quickly could save a worker’s life or minimize
his injuries. For long conveyors where the control panel may be inaccessible or out of sight, an
emergency stop pull cord gives workers the ability to initiate an emergency stop remotely.

Standards require guarding of machine hazards, Machine Guarding Standard, requires employers
to ensure machine hazards are safeguarded. This read “One or more methods of machine
guarding shall be provided to protect the operator and other employees in the machine area from
hazards such as those created by point of operation, ingoing nip points, rotating parts, flying
chips and sparks.”

Standard for Conveyors, requires emergency stop controls at the operator’s station or at the
conveyor motor, and audible warning signals before conveyor is started. This standard also calls for
guarding of conveyors when they pass over work areas, and locking out and tagging power to a
conveyor during repair and maintenance.

Safety Standard for Mechanical Power Transmission Apparatus, states that “All motion hazards
associated with the operation of mechanical power transmission apparatus shall be eliminated by
design of the equipment or protection by a guard, device, safe distance, or safe location.” Typical to
other industry-produced standards, some standards produced by the conveyor industry have no
mention of safety devices or safeguarding of hazardous components.

CONVEYOR INSTALLATION AND MAINTENANCE

CLIP JOINT OF CONVEYOR BELT.
Stop conveyor belt where required for cutting and splicing.
Responsible maintenance supervisor or permit holder or
artisan/belts man to ensure that no other work is performed on the
belt structure while installation pulling in a conveyor belt
(simultaneous operations).

Conduct a mini HIRA to identify all hazards and risk, and put control measures in
place.

Identify, isolate, de-energise, and lock-out all sources of energy as
per COP 10 Isolation, lockout & testing of Plant and Equipment.
Slack the take-up weight fully until it rests on the ground or
reaches the ends stops on a horizontal tensioning system to
release stored energy using a take-up winch/ Screw or hydraulic
tensioner (where applicable). Isolate and lock-out the applicable
tensioning unit and secure take-up carriage with a chain block or
lever hoist to prevent movement while performing task.

Clamp the belt on both sides of the section to be cut using Flexco certified
clamps. The distance from the clamp to the centre of the cut must not be more
than 10 meters on both sides Clamp the belt on both sides of the section to be
cut using certified clamps.

CONVEYOR INSTALLATION AND MAINTENANCE
CLIP JOINT OF CONVEYOR BELT. ( Continues)

Remove idlers and idler brackets (if necessary) where clip joint need to be
done and place splice board on top of the roller frames. Place top and bottom
ends of conveyor belt on splice board and mark the ends of the conveyor belt
with chalk.

Cut the belt with an approved belt knife as per South32 tool standard. The belt
knife must be inspected and confirmed fit for purpose prior use, and the user
must be trained and familiar with the hazards and risks associated with using
such knife. Ensure the belt is cut square with the belt edge to prevent
misalignment

confirmed fit for purpose prior use, and the user must be trained and familiar
with the hazards and risks associated with using such knife. Ensure the belt is
cut square with the belt edge to prevent misalignment

CLIP JOINT OF CONVEYOR BELT(continues)

Note: the method of cutting must be such that the user cuts away from his/her body.

Place the belt board on top of belt structure and insert the belt clip and guiding pin. Install
one end of belt into belt clip ensuring that the belt is fitted squarely and close belt clip with a
hammer.

Insert nail holder into slots and drive the nails through the belt with a nail punch and
hammer. Repeat until all clips have been nailed.

Repeat process on other side of belt. Join the two ends of the belt together with lacing pin.

Remove Splice board and fit idlers. Release the tension on chain blocks. Remove the chain
block as well as the belt clamps. Cancel lockout permit, tension the belt via the take-up
winch and remove the locks and hand over the conveyor belt. Train belt if necessary

.

SPLICE AND SPOT REPAIR ON CONVEYOR BELT.

Maintenance Supervisor must ensure that no work is planned on the belt structure
while installation of new conveyor belt is in progress. No simultaneous operations
permitted.

Identify the splice that needs to be repaired. Stop this section in a safe area to
perform the task. Lock the belt out as per lock out procedure, COP10 Isolation,
lockout & testing of Plant and Equipment. Release the tension from the belt via the
take up winch and isolate. Slack conveyor belt at the take up winch. All employees to
stand clear from conveyor belt when slacking.

Conveyor belt repair shall be done in such a manner that belts man or competent
artisan will clean the conveyor, grind the part of the damaged splice and then apply
solution and apply the cover strip while standing on the walkway or ground level. If the
conveyor was cut in the centre, slack the conveyor bel take- up and ensure that there
is no stored energy on the conveyor belt and secure take-up with the chain block

No work shall be done while sitting on the return belt of the conveyor belt

PULLEY LAGGING

Maintenance Supervisor must ensure that no work associated with pulling the belt,
splicing, and scraper maintenance, chute liner repairs/replacement above or below the
pulley planned for lagging takes place simultaneously.. Identify, isolate, de-energise,
and lock-out all sources of energy as per COP 10 Isolation, lockout, tag & testing of
Plant and Equipment

Slack the take-up weight fully until it rests on the ground or reaches the ends
stops on a horizontal tensioning system to release stored energy using a take-up
winch/ Screw or hydraulic tensioner (where applicable). Isolate and lock-out the
applicable tensioning unit and secure take-up carriage with a chain block or lever hoist
to prevent movement while performing task.

Note: All employees to stand away from the conveyor belt during such an
operation

ANATOMY OF A PULLEY

REPLACING CONVEYOR PULLEYS

Maintenance Supervisor must ensure that no work associated with pulling the belt, splicing, and
scraper maintenance, chute liner repairs/replacement above or below the pulley planned for
lagging takes place simultaneously. Employees must conduct a Mini HIRA before any work
commence .

Slack the take-up weight fully until it rests on the ground or reaches the ends stops on
a horizontal tensioning system to release stored energy using a take-up winch/ Screw or
hydraulic tensioner (where applicable). Isolate and lock-out the applicable tensioning unit and
secure take-up carriage with a chain block or lever hoist to prevent movement while performing
task.

Clamp the top and bottom belts to provide slack around the pulley planned for replacement
using a Flexco certified belt clamps

Make use of certified lifting equipment to replace the pulley. Ensure chain blocks and slings are
selected for pulley mass being removed.

When complex lift rigger to be used and lifting plan to be completed for the removal of pulley

To remove the pulley loosen the plumber block bolts and the top adjusters, do not remove
the bottom adjuster bolts. This will assist in alignment when fitted.

One pulley is fitted the pulley alignment must be check with a level to ensure pulley is in correct
position, all shims removes should be fitted again in position before plumber block is tightened.



REPLACEMENT OF CONVEYOR PULLEY BEARINGS

Conveyor needs to be slacked off and isolated as per COP 16
Ensure mini HIRA is conducted looking at the following:

Position of bearing to be replaced
Slack requirement or must conveyor be split
Lifting requirements
Hydraulic nut requirements like space to fit nut (Nip points)
Material handling

Conveyor needs to be properly clamped on load bearing and return side of the conveyor to
be able to pull slack for the pulley to be pulled back

Check for alignment when fitting new bearing

Ensure bearing clearance is correct to prevent bearing gliding and rollers not turning

Once completed and conveyor running check temperature and conveyor belt tracking

REPLACING IDLERS

Conduct a mini HIRA to identify all hazards and risk, and put control measures in place

Identify, isolate, de-energise, and lock-out all sources of energy as per COP 10 Isolation
lockout & testing of Plant and Equipment. Ensure the take-up/tensioning system is also
logged out.

Note: slagging of conveyor belt take-up is only necessary when replacing idlers next to tail
pulleys where the belt tension makes it impractical to replace idlers

When replacing troughing idlers (top belt) use a 1.5 or 3 ton nylon sling (depending
of the belt width) attached to a 3 ton lever hoists on both sides of the conveyor structure to
lift the conveyor belt from the idler brackets.
Ensure the lever hoist is attached to a stable beam of the conveyor structure. Lifting
equipment must be inspected, tagged and issued from the lifting store.

Troughing and return idlers

The troughing idlers are design to ensure that the conveyor belt forms a ‘u’ thus allowing the
optimum amount of rock to be moved with the least amount of spillage. The return idlers are
installed to support the return belt.

REPLACING IDLERS (continues)

When replacing impact idlers (at loading points) it necessary to replace idler frames and
skirtings to create working clearance. Use 1.5 - 3 ton lever hoist attached to a stable beam
to pull out idler frames. Take note of nip points and stored energy hazards and risks.

When replacing return idlers, use a 1.5 or 3 ton nylon sling (depending of the belt width)
attached to a 3 ton lever hoists on both sides of the conveyor structure to lift the conveyor
belt from the idler brackets.

Where there is no idler replacement platform, a minimum of 2 people are required to
change idler and a safety harnesses must be used.
For stacker boom belts and inclined conveyors where there is no provision for idler
replacement platforms, a cherry picker or scaffold must be provided for access and
working platform.

Remove clamps and lever hoists, dismantle scaffold (where applicable), and remove all
locks and handover to production team.

Impact idlers

Rubber hi-impact idlers are used directly under the loading point to break the impact of large
lumps of rock onto the conveyor belt.