Artisan AND Beltsman conveyor training belts 2018

BELT TENSIONING DEVICE

In order to drive a conveyor belt with a full load, the belt must be under optimum tension to prevent it from slipping on the drive pulley. The ideal
tensioning device should possess the following features:

a) It must be capable of applying equal tension across the width of the belting.
b) It should apply tension gradually.
c) In the event of the load on the belt varying, the applied tension should be capable of correspondingly increasing or decreasing.
d) The actual value of the applied tension should be known, thus preventing overstressing of the belting.
e) It should automatically take up any slack or stretch in the belting.

An automatic gravity take-up tensioning device is the only tensioning device which has all the desirable features mentioned above. This device
consists of a weighted loose pulley introduced into the return side of the conveyor belt at some point. The best position for this device is
immediately behind the driving drum

Two examples of gravity take up devices are shown below:

A)

Horizontal gravity take-up Tensioning carriage

b) Vertical gravity take up

Discharged onto
conveyor

Chutes

The side of the feed chute onto the conveyor is provided with skirt plates to prevent rock
spillage and to centralise the load onto the centre of the belt.

Skirt plates

REPLACING IDLER FRAMES

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 lowered and logged out.

When replacing troughing idlers frames (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.

Loosen the idler frame bolts and slide the frame off its position. Repeat this step if more than one frame is
replaced.

A minimum of 2 people are required to safely replace an idler frame.

When replacing return idler frame, 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 frame 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.

REPLACING SKIRTINGS.

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 Cop10
Isolation, lockout & testing of Plant and Equipment. Ensure the take-up/tensioning system is
also logged out.

Verify that no work is conducted on the chute above you and chute clean without hang-ups, if
there’s work follow the task procedure.

On some conveyors work might require employees to go inside chute, is such cases that chute
must be assessed whether it is a confined space as part of a risk assessment.

When using hammers and spanners caution must be taken for nip points and ergonomics.
Minimum of 2 people must be assigned to the job.

SCRAPER MAINTENANCE

No person is allowed to maintain a scraper if the conveyor belt
installation is not locked out as per lock out procedure,
Isolation, lockout & testing of Plant and Equipment. Conveyor
needs to be tensioned correctly before scraper can be set
correctly.

All scrapers must be adjustable from the side of a conveyor
without endangering the person while adjusting the scraper.
The scraper can only be adjusted when the belt is under tension
and locked out as per lock out procedure, COP10 Isolation,
lockout & testing of Plant and Equipment.

BELT CLEANING DEVICES

RUBBER SCRAPERS

Belt scrapers are normally mounted adjacent to the head pulley and consists of a rubber blade. Pivoted
with a counterweight to maintain pressure between the blade and the belt. The bolts are most of the time
be adjusted on belt scraper by artisan. Care should be taken that the scraper blade is held against the belt
surface with only sufficient pressure to remove the material

Scraper

RUBBER SCRAPERS

Rubber scraper

Counterweight

TRAINING OF CONVEYOR BELT

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

All personnel working on conveyors needs to be trained in conveyor Safety. No person to work
alone on a conveyor system except for inspection purposes

Trained artisans/ belts man may train a belt that is running skew under supervision of a
maintenance supervisor, live work permit to be completed

Inspect the conveyor belt while running for any loose pieces of belt that may cause injury or
damage to equipment.

Inspect all splices and clip joints visually for protruding metal or belt that may cause an injury
when the belt is moving.

Care must be taken not to come into contact with any moving parts. JSA must be completed
before starting with a task. Beware of loose clothing.

TRAINING OF CONVEYOR BELT(continues)

A belt shall only be trained subsequent to it being stopped and locked out when
training on pulleys is required.

If an idler/ idler frame has to be lifted in order to be repositioned, then the belt must be
stopped and locked out before doing so.

If a bolt is required to be loosened before any idler/ idler frame can be moved, then the belt
must be stopped and locked out before doing so.

Check if the belt is running skew when empty of on full, as this will help with fault finding
Best practice is to check training with 33% load on conveyor

When training a conveyor, first assess exactly where the conveyor is starting to run skew. Look
amongst other for the following:

Load being discharged not in the centre of the belt.
Tail end skew
Idler frames bend or loose
Damaged or missing idlers
Lagging on pulleys damaged or off
Self-training idlers stuck
Train belt by adjusting one idler at a time where the problem starts using the bicycle rule.
If the bias plough scraper is used on return conveyor it is not over tensioned
Self-training idlers/ frames is not stuck
Assess the success of the adjustment prior to making another adjustment



WORKING IN CHUTES, BINS AND CRUSHERS

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

No person are allowed to work inside a chute if the conveyor belt installation that is throwing
into the chute and the belt drawing from the chute is not isolated, locked out
as per lock out procedure, COP10 Isolation, lockout & testing of Plant and Equipment.

In the case where work needs to be done inside the ROM Tip, barricades will be placed at
the entrance and exit points on the haul road as well as in front of the tipping point to
prevent haul trucks from dumping coal into the bin. In addition to this the robot to be
changed to red preventing the haul trucks to enter the tip area,

Maintenance Supervisor to ensure that no work is planned on the belt structure while
installation of new conveyor belt is in progress. When simultaneous operations is required
to be performed there must be a PTO in place

No person may work inside a chute or bin if there is a risk of falling material that may cause
injury to a person. All bins/tips and chutes to be cleaned and inspected before any work is
preformed inside.

WORKING IN CHUTES, BINS AND CRUSHERS

Precautions shall be taken to ensure that all screens, chain feeders, vibrating screens and
conveyor belt installations that throw into a crusher is lock out as per lock out procedure,
COP10 Isolation, lockout & testing of Plant and Equipment before entering such equipment

When welding or gas cutting operations takes place, care must be taken to ensure that there is
enough ventilation so that there is no risk of suffocation due to welding fumes inside. Conveyor
belt needs to be removed/ protected if welding or gas cutting is performed in close
proximity of the conveyor belting or flammable lubricants like oil and grease.

No person may work inside a crusher if the crusher is not locked out as per lock out
procedure, COP10 Isolation, lockout & testing of Plant and Equipment. The Crushers and rotary
breakers must be disabled from moving by means of two 3 ton or bigger chain. There must be
no chance for the crusher to move when a person works inside the crusher or rotary breaker or
on the conveyor feed chute below.

REPLACEMENT OF CONVEYOR DRIVES AND MOTORS

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

Conveyor belt tension does not need to be released on conveyor when the following is in
place

When incline conveyor there must be a anti run back (hold back) to ensure no uncontrolled
movement.

Flat conveyors will normally not have any hold back to keep conveyor from
uncontrolled movement except

Isolate conveyor as per COP10

Ensure there is enough support blocks to support the floating drive train when slow speed
couplings is loosened.

Grid/ fluid drive couplings to be loosened before drive or motor bolts is removed
Once removed loosen the drives and lift the units making use of Manitou or mobile crane
When new unit is fitted motor/ fluid drive or Drive then laser alignment must be done before
slow speed coupling can be connected.

Once completed remove blocks ensure units is lubricated cancel lockout and run
equipment.

HOLD BACK REPLACEMENT

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

Lockout needs to be performed as per COP10
Conveyor needs to slacked before lockout and clamping can commence
Conveyor clamping needs to be done on the load bearing side of the conveyor to prevent roll back or
uncontrolled movement of the
Once clamped secure torque arm with chain block to remove hold down bracket
Follow stripping fitment procedure
Once completed tension conveyor and hand back to operations

PULL KEY SYSTEM (CT SYSTEMS) AND TACHO METERS

Lockout to be taken for palisaded areas to enter for testing purposes

Test each CT system pulley keys 2 weekly as per notifications in the
maintenance plans

Test Head cue unit for operation and feedback to SCADA

Test sirens on CT system pulley key unit along the length of the conveyor

CT systems are not allowed to be bypassed at any stage.

Speed tacho/ sequence deco
• Inspect tacho wheel for wear
• Lubricate tacho wheel bearing

PULL KEY SYSTEM (CT SYSTEMS) AND TACHO METERS

Lockout to be taken for palisaded areas to enter for testing purposes

Test each CT system pulley keys 2 weekly as per notifications in the
maintenance plans

Test Head cue unit for operation and feedback to SCADA

Test sirens on CT system pulley key unit along the length of the conveyor

CT systems are not allowed to be bypassed at any stage.

Speed tacho/ sequence deco
• Inspect tacho wheel for wear
• Lubricate tacho wheel bearing

MAGNET CONVEYORS

Magnet conveyors core function is to remove steel coming through on conveyor belts
It is important that the magnet is operational and self-cleaning conveyor tracking is in the
center
When work is required on the magnet the conveyor which it is installed on needs to be
locked out as well.
Be aware of WAH risks
Be aware of Material handling risks

METAL DETECTOR

A metal detector is a device that will locate tramp iron, even if it is buried under ore or other materials, or through a
conveyor. The metal detector consists of metal frame mounted on the conveyor frame under the loaded conveyor.
When tramp metal passes over the metal detector, it will stop the conveyor and activate the powder marker and siren
so as to alert the attendant. The attendant will then locate the metal and remove it from the conveyor. He will then
restart the conveyor belt. Only found at plant conveyor systems.

A metal detector is situated under the belt.

FIRE RISK

Fire have been caused by coal, flammable dust, and flammable gas, accumulated Lubricants, or
accumulations of combustible material (e.g. belt fabric, rags) being exposed to an ignition
source such as flame, high temperatures, sparks or static discharge. These Conditions have
arisen (without limitation) in the following circumstances

A brake overheats. This could be due to the brakes not fully releasing when the belt conveyor is
running or a brake failing to stop a conveyor

Brake or anti-runback failure

Expelled lubricant accumulates where it can cause belt slip or be ignited itself directly

Fluid couplings or torque converters overheat because they are overloaded or filled to the wrong level

A conveyor idler fails, seizes-up or collapses

The conveyor belt runs out of alignment and rubs on a fixed object such as the belt structure, the
structure of a loading or transfer point, guards, a jammed belt scraper, seized.

Misalignment can even occur when fines build up on the tension pulley or return roller.

There is excessive belt slippage on a drive pulley.

Combustible material (e.g. coal) has accumulated to such an extent that the material is a source of
fuel. This unacceptable accumulation can occur when there is

Build-up of spillage/fines under the return conveyor belt



Fire Hydro system

Fire hydro systems are installed over the whole length of the
conveyor system. Any fire can be extinguished by means of this
system

FIRE RISKS (CONTINUES)

Belt conveyor continues to feed onto a stopped conveyor
Poorly designed or misaligned loading or transfer point;
Blocked chute overflowing at a transfer point;
Overload of material being conveyed; and
Inadequate inspection and cleaning
static electrical charge is discharged
Have fire suppression installed on identified conveyors
Ensure systems is operational
Monthly over inspection
Regular testing and inspection of fire protection systems on conveyors.

CONVEYOR WORK-RELATED HAZARDS INCLUDE

Missing guards
Improperly installed guarding Residual
hazardous energy

Performing repetitive actions without rest

CONVEYOR SAFETY

Equipment safety must be designed from the standpoint of workers who are carrying
out their tasks in their workplace.

TASKS
MAINTENANCE : Inspection, cleaning,
unclogging, load unjamming, greasing,
adjustments, repairs or other

.

POWER TRANSMISSION MOVING PART HAZARDS .

Includes: shafts, couplings, pulley belts, chain and sprockets
Dragging, crushing or entanglement on contact with rotating parts or pinch
points can result in serious injuries

GUARDING

GUARDING

WHY IS THIS A BAD GUARD?

Open on top not covered

WHY IS THIS A BETTER GUARD?

Its covered all around

It is open at the back

THIS IS A BETTER GUARD?

Closed all around

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: LOCKOUT

When it is necessary to open or remove guards, workers must
follow lockout procedures to prevent injury from the conveyor
starting. COP 10 - Lock out of machinery and plant

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

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

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.

Conveyor scrapers used at plants

Secondary Scrapers( head pulley) V plough Scraper tail end

Bias plough scraper

Type off idlers used

Trutrack training idler return belt

Trutrack V return training idler

Conv trough and return idlers

Type off idlers used

Typical idler measerments Troughing Belt friendly idler frame

None friendly 3 idler troughing frame

Type off idlers used

Trough and v return idler aranagment on Typical Impact idlers
structure

Impact bed used on conveyors

Guarding and safety devices used on conveyors

Pulley guarding Palisade guarding used at drives tail ends

Conv guarding with pull wire

Guarding and safety devices used on conveyors

Switch preventing the removal of guards Palisade fence gate limit

Limits used on take up counter weight as well as take up carriages

Guarding and safety devices used on conveyors

Start-up alarms Pull wire along conveyor belt

Belt side rip device on steel core conveyor

Guarding and safety devices used on conveyors

Silo or bin level control Block chute detector

Belt tear device with misalignment switch

Conveyor construction types used belt

Fabric or Ply conveyor construction

Ply belt
Fabric plied belt consists of a single or multi-layered series of
synthetic fabric layers interlaced between rubber based shock
absorbent layers. The "top" and "bottom" sides of the belt
consist of hard wearing, abrasion and cut resistant, rubber
covers. These covers protect the belt from damage, especially
at the loading points of the conveyor

STEEL CORE CONVEYOR CONSTRUCTION

STEEL CORE

Steel cable belting consists of steel and rubber only. Sometimes there are fabric
plies involved. Steel cable belts consist of steel cables manufactured from high
tensile steel wire. These steel cables are surrounded by a layer of high grade rubber
to facilitate adhesion to the outer covers and to improve lateral tear resistance. As
with fabric belting the "top" and"bottom" sides of the belt consist of hard wearing,
abrasion and cut resistant, rubber covers.

IMPORTANT SYSTEMS THAT NEEDS TO BE OPERATIONAL

SAFETY DEVICES LEGAL REQUIREMENTS
• Where 2 or more belt conveyors are used in
Interlocking device
If conveyor stops for any reason, provision to be made series. Sequence inter locking shall be provided
for automatically stopping the feed coming onto such which automatically will:
conveyor. • Stop all other conveyors feeding a conveyor that
has stopped
Tripping devices • Prevent a conveyor from starting until the
Overload protection to protect motors and equipment conveyor onto which it feeds is moving
against overload • Every belt conveyor shall be equipped with
Trip wire system ( pull key) installed along the full length effective means for immediately stopping the
of the conveyor on both sides conveyor, from readily accessible points along the
conveyor
Warning bell and sirens
Startup warning sirens/ bells to warn persons of
conveyor starting up, siren/alarm needs to sound for a
set period before conveyor may start.

IMPORTANT SYSTEMS THAT NEEDS TO BE OPERATIONAL

Slip roller required. Access is prevented along belt unless
Machine stops if belt breaks, jams or slips excessively. there is a walkway If not, other means of
walkway must be in place and provided
to do so safely.

Pre-start required
A warning of 10sec minimum. The
function is to let everyone know in the
surrounding of the conveyor that it is
going to start up and that people should
stay clear of the conveyor

IMPORTANT SYSTEMS THAT NEEDS TO BE OPERATIONAL

Install device to prevent belt from running away in the
event of belt failure.
Like anti run back idlers
Hold back unit

Run-back devices required. (hold back)Function is to
control the movement of uphill running conveyors.
It will also prevent spillage from incline conveyors and
bridges when conveyor starts to run back.

Sequence interlocking is provided where two or more
conveyor belt installations are used in series.
This will prevent of 1 conveyor keeps on running and
then overloading the chute resulting in spillage

Conveyor installations must be earthed.

The earthing is essential because of the following reasons.
Earthing provides the safety of the personnel from electric shock. It insures that the non-
currents carrying parts, such as equipment frames are always safe at ground potential even
though the insulation fails.

Earthing is essential for the safety of the equipment and personnel against lightning and
voltage surges, providing the discharge path for surge arrestors, gaps, and other similar
devices.

It provides the ground connections for the ground neutral system.
It provides a means of positively discharging and de-energizing feeders or equipment
before proceeding with maintenance on them.

Lightning protection

Safety Tips And General Information For Working On Conveyor Belts

Know your area of work well and apply the training and experience you have
received in order to stay safe.
Follow all rules and regulations. You are your brother’s keeper.
Be sure you have been inducted in the area

Electrical panels needs to be closed and locked with an electrical lock.
Panels needs to be clearly demarcated what it is Do not take chances, your life
is in your hands

Belt magnets as seen run diagonally above and across the conveyor removing
and discarding all metal objects off the belt.
The metal objects needs to be removed from the chute and discarded.

Take up carriages play a fundamental roll in
keeping the tension on the conveyor belt.
Alignment of conveyors is critical misalignment of conveyor at take up section
will result in conveyor detraining and running into structures.
Take up carriage must not run in return coal spillage

Typical conveyor problems

Pulley lagging damaged Ceramic lagging coming loose Pulley damaged due to wear

Conveyor detraining on pulley Detraining conveyor running into Detraining conveyor running into
structure guarding

Bottom cover being ripped off Belts sides torn by running into structure Belts sides torn by running into structure