Conveyor Safety

AIMS TECHNICAL MANAGEMENT INSTITUTE
ROAD-2, NEAR UNION BANK, GANDHI MAIDAN, AZADNAGAR, MANGO, JSR
TIPS ON CONVEYOR SAFETY
Safety Precautions for Conveyor System:
Belt conveyor system is hazardous area and prone to create unsafe conditions leading to accident
if proper care is not taken. To address this problem, following steps should be taken care of.
1. The local on/off control should be placed at a convenient location near the drive.
2. Conveyor should have pull chord switch and belt sway switch at an appropriate interval
depending on conveyor length.
3. Zero Speed switches must be available to the conveyor to take care of belt snap. Non-contact
type is preferable over contact type.
4. Hooters/Gong should be provided with a time delay to warn the people for starting of
conveyor.
5. There should be sequence operation (While starting the last conveyor of the circuit to be
started first and while stopping the first should stop first) to avoid dumping material to a standstill
conveyor.
6. No body should be allowed to work on a running conveyor.
7. Nobody should be allowed to walk through the narrow side of the gallery while running. It is
advisable to lock the narrow side.
8. Proper illumination should be ensured on conveyor gallery.
9. Proper training on conveyor safety must be given to the people working in the conveyor
system. (Own and contractors employees).
10. Where ever people have to cross over the conveyors, crossover platform with guards to be
provided.
11. In order to prevent people going for lubrication near to the conveyor there should be
centralized lubrication, which can be operated remotely from a safe place.
12. Ensure Coupling guards and tail pulley guards are there always.
13. Any jobs on conveyors (Changing of Idler, pulley, gearbox, deck Plate etc.) Should be done
after getting power cutting clearance.
14. Periodic checking of all the interlock and protective devices (checklist to be developed)
should be done and corrective action should be carried out religiously.
15. Caution board/Caption for safety to be displaced at proper location.
Contact 9234704886,9308289697 Safety Management 1

16. Also one emergency switch should be provided near counter wt. of every conveyor belt, so
that during emergency belt can be stopped.
Conveyor belts. This was the recommendation of general safety committee after fatal accident in
counter wt. area of conveyor.
17.Do not perform service on the conveyor until the motor disconnect is locked out.
18.Use only authorized maintenance personnel for service work.
19. Keep clothing fingers, hair & other parts of the body away from the conveyor.
20. Do not climb, step, sit or ride on the conveyor
21. Do not load the conveyor outside design limits.
22. Do not remove or alter conveyor guards or safety devices
23. Keep all stopping/starting control devices free from obstructions.
24. Keep all personnel clear of the conveyor before starting.
25. Operate conveyors only with trained/personnel .
26. Keep the area avoid conveyors clean of obstructions.
27. Report all unsafe practice to the supervisors.
28. Maintain log book, caption board for do & do nots in conveyor area.
29. In conveyor belts at tail pulley one proximity switch is fixed .one sensor is
welded with tail pulley edge.
Whenever conveyor starts, tail pulley also starts rotating and so each time
sensor comes in front of proximity and it senses it.it gives feedback to the
driving motor that everything is o.k.
Whenever belt stops due to any overload, drive pulley doesn't stop. It starts
slipping because it is not in position to carry the belt along with its heavy
load.
Due to slippage heat is generated between drive pulley and the conveyor which
is in contact with drive pulley. Thus belt can snap into two pieces.
But here proximity comes in picture. As soon as tail pulley stops due to
overload proximity senses it immediately and gives feedback to motor. Motor
stops immediately and thus belt doesn't snaps this overload in conveyor
system is a frequent phenomenon?s, this proximity switch is also a vital safety
switch to take care of.WE must have an inspection schedule for it to save our
conveyor belt.
Safety Devices In Conveyor Belt System:
Conveyor systems are incorporated with electrical safety devices to facilitate protection of
operating personnel as well as to prevent damage to the mechanical portions of conveyors. The
most common safety devices normally used are the following -
(1)Lateral movement limit switch

(2)Zero limit switch
(3)Proximity swich
(4)Pull cord swiches - located along the walk way, during any emergency, it is pulled manually
and belt stop.
(5)Emergency stop switch
(6)Chute level switch - This is intended to operate when the chute becomes nearly plugged and
the belt stops.
(7)Conveyor limit swich - it limits the travel of stopper, shutter, conveyors and stacker.

(8)Warning horns - audible devices used to warn perating people.

(9)Electrical interlocking
(10)Tramp iron magnet
(11)Metal detector.
User:
"ALSO PROVIDE ONE EMERGENCY PUSH BUTTON IN TAKE UP AREA."
"Safety devices and safety rules for working on the conveyors

1.Rotating couplings must be guarded with coupling guard.
2.Tail pulley guard must be provided over the tail pulley so that nip point of the conveyor should
be out of reach of the person.
3. Wiremesh enclosure must be provided just below the counter weight . So that man should not
walk below the hanging counter weight mass.
4. Internal and external belt cleaners must be provided for proper cleaning of belt.
5.Inuilt audible devices containing "Please keep yourself away from the conveyor or group of
conveyor such as cl-1, cl-2, and so on are going to be started ".Men should be warned just after
the siren/hooter blown.
6.All the fastners such as bolts conected with the idler frames and deck and stinger chanels are to
be fixed this fashion that head of the bolts should be on top of the holes. So that in case of loosen
of the nuts bolts would not be fallen to the moving persons underneeth of the conveyor.
7. Mechanical holdback must be provided in the gearbox for any inclind conveyor.
8.Slope of the conveyor should not be greater than the repose angle of the conveying material.
9. Each conveyor is having two sides.One is walkway side and another is non walkway side or
maintenance side. At the entry point of the non walkway side there must be a lockable door to
avoid unauthorisedperson,s entry.
10. Some of the conveyors are having "NMG" Nuclear moisture gaugefor regulating the moisture
percentage.This is a radioactive materials.People should be far away from the NMG
equipment.There should be a suitable cage all around the NMG.
11.Not a single jobs are to be performed on the running conveyors.
12. At the time of conveyor maintenance HRC fuses for the respective conveyors must be
removed from the electric panels and kept in the control room. In no cases persons are to be
permitted to work without "WRITTEN CLEARANCES."
Safety Measures For Conveyors:
1.Conveyors shall be so constructed and installed

as to avoid hazardous points between moving and satationary parts or objects.
2. Whrere workers have to cross over conveyors,
well fenced cross over platform affording safe passage and adequate lighting shall be provided
one at every 50 ft. length of the belt conveyor.
3. Conveyor shall be provided at loading and unloading stations and at other convenient with
devices for stopping the conveyor in an emergency,
such as sway switch and rope switches.
4.When two or more conveyors are operated together ,the controlling device shall be so designed
that no conveyor canfeed on to a stopped conveyor.
5. Where conveyors extend to points not visible from the control statiomn ,they should be
equipped with gongs or signal lights to be used by the operators before starting the machinery so
as to warn workers who might be in position of danger
6. Conveyors shall be provided with automatic and continuous lubrication system or with
lubricating facility so arranged that oiling and greasing can be performed without the oiler

coming into dangerous proximity of the moving parts.
Maintenance of Conveyor Belt:

Poor maintenance increases the risk of accident and fire, regular check should be made in
possible sources of over heating and friction.
Idlers:
Ensure free rotation and check that they are not warn flat by belt friction.
Belt tension:
Avoid slipping between drive drum and conveyor belt. This include ensuring that gravity take-up
units are free and will not bottom out with belt stretch or spillage accumulation.
Belt alignment:
Correct to avoid belt edge friction.
Spillage:
Removed to prevent built up burden or spillage creating frictional contact with belt.
Motors:
Clear accumulation of fine dust which prevent coiling from motors and leading to dangerous over
heating.
Good House Keeping:
1. It is essential to practice good house keeping to minimise, the dust deposit, Oil impregnation,
packing such as card board and paper e.g. discarded packing from replacement electrical lamp
fitting etc.
2. Work permit should be obtained for attending any work on or near the conveyor belt.
How To Start A New Conveyor Belt:

There is a saying ' Well begun is half done'.
It means that if we start a job in right way then it can be well done. When we start a new
conveyor belt we should check the following.
1] The installation, fastening, lubrication is completed.

2] The equipment?s individual trial has been conducted and found satisfactory.
3] The counterweight is free to move and has been lubricated.
4] Depute inspection staff at various locations to see the entire belt should be visible.
5] Ensure the protective devices installed and working well.
6] The belt is started and stopped. This start is for few seconds.
7] Inspection is carried out to check any obstruction on the way of belt travel.
8] Again the belt is started after giving siren. The belt is kept under watch .If the belt shift side
wise too much it should be stopped at once by pulling pull cord, otherwise it may strike some

structure.
9] If the belt runs aligned its o.k. otherwise move an idler forward after which the belt becomes
misalign.
10] Check movement of Take-up pully and its freeness.
11] Note the current drawn by motor.
12] Check for gear box, fluid coupling and other devices i.e. tripper.
13] Test all protective devices one by one for proper functioning.
14] Safety should be of prime importance during all the activity.
Checking Of Conveyor Before Starting:

Assuming that the operator is a well-trained person and is authorised to operate the belt
conveyors and the conveyor itself is ready for operation,he should make a through check of the
conveyor before starting it. It is as stated below.
1)Men are cleared from the belt. During maintenance as well as a breakdown, men are working
with line cleances.But,after completion of work, the persons engaged as well as the tools
etc.should be cleared.
2)Ensure electric supply is the line.If the supply was switched off for maintenance or repair work,
switch on the supply after taking all safety precautions.
3)Check and ensurethat all the drums and rollers are free to rotate.
4)Check the oil levels in the gearboxes and if necessary,top up to the required level.
5)Ensure that the belt is in proper tension and in position.
6)Ensure the peceding conveyor,if any,is running.
7)See that all the guards in the drive head and tail end station are in position.
8)Give sufficient warning signals like hooter,light,whistles etc. before starting the belt.
9)Then start the conveyor and watch carefully for a few minutes to ensure that things are normal.
REMINDER - Conveyor Belt Safety:
 EMERGENCY STOP MUST BE OPERATIVE ALL THE TIME.
 GUARDS TO BE PROVIDED ON ALL MOVING PARTS.
 PROPER CROSS OVER TO BE PROVIDED.
 CLEARENCE PROCEDURE / PERMIT TO WORK SYSTEM.
 WALKWAYS SHOULD HAVE HANDRAILS TO PROVIDE PROPER GRIP.
 ILLUMINATION SHOLD BE SUFFICIENT.
 NO WORK ON RUNNING CONVEYOR.
 NO NEW WORKER TO BE PUT ON THE WORK ALONE.
 NOBODY SHOULD WEAR LOOSE CLOTHING WHILE WORKING NEAR
CONVEYOR.
 NOBODY SHOULD PICKUP ANYTHING FROM RUNNING CONVEYOR.
 PULL CORDS MUST BE PROVIDED ON BOTH SIDES OF THE CONVEYOR BELT.
 HOOTER SHOULD BE PROVIDED SO THAT BEFORE THE CONVEYOR BELT

STARTS, HOOTER SHOULD BLOW.
 ENNUNCIATION SYSTEM ALONG THE CONVEYOR CIRCUIT.
 SPECIFIC SAFETY TRAINING FOR CONVEYOR SAFETY.

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AIMS TECHNICAL MANAGEMENT INSTITUTE

ROAD-2, NEAR UNION BANK, GANDHI MAIDAN, AZADNAGAR, MANGO, JSR

TIPS ON CONVEYOR SAFETY

Safety Precautions for Conveyor System:

6. No body should be allowed to work on a running conveyor.

8. Proper illumination should be ensured on conveyor gallery.

15. Caution board/Caption for safety to be displaced at proper location.

Contact 9234704886,9308289697 Safety Management 1

Safety Devices In Conveyor Belt System:

(1)Lateral movement limit switch

Contact 9234704886,9308289697 Safety Management 2

(8)Warning horns - audible devices used to warn perating people.

"Safety devices and safety rules for working on the conveyors

Safety Measures For Conveyors:

1.Conveyors shall be so constructed and installed

Contact 9234704886,9308289697 Safety Management 3

coming into dangerous proximity of the moving parts.

Maintenance of Conveyor Belt:

Correct to avoid belt edge friction.

Good House Keeping:

How To Start A New Conveyor Belt:

1] The installation, fastening, lubrication is completed.

Contact 9234704886,9308289697 Safety Management 4

Checking Of Conveyor Before Starting:

 PULL CORDS MUST BE PROVIDED ON BOTH SIDES OF THE CONVEYOR BELT.

 HOOTER SHOULD BE PROVIDED SO THAT BEFORE THE CONVEYOR BELT

 ENNUNCIATION SYSTEM ALONG THE CONVEYOR CIRCUIT.

 SPECIFIC SAFETY TRAINING FOR CONVEYOR SAFETY.

Contact 9234704886,9308289697 Safety Management 5

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