STANDARD FOR OPERATION AND MAINTENANCE OF BELT CONVEYORS Issue:

(BSP-TS-12) Rev: 00

ISSUE: 00 Date:

STANDARD FOR OPERATION AND

MAINTENANCE OF BELT CONVEYORS

Rev
Reason for Revision Prepared by Checked by Approved By
No

00

01

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 STANDARD FOR OPERATION AND MAINTENANCE OF BELT CONVEYORS Issue:
(BSP-TS-12) Rev: 00

STANDARD WRITING TEAM – OPEARTION AND MAINTENANCE OF

CONVEYORS

SL . No. NAME SIGNATURE

Shri GA Rao, CGM COCCD

1
Chairman

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CONTENTS

1 PREFACE..................................................................................................................................................4

2 PURPOSE ................................................................................................................................................. 4

3 DEFINITIONS ........................................................................................................................................... 4

4 ABBREVIATIONS ...................................................................................................................................... 5

5 SCOPE .....................................................................................................................................................5

6 EXCLUSIONS ............................................................................................................................................ 5

7 THE MANAGEMENT PROCESS ..................................................................................................................5

7.1 Standard Implementation…………………………………………………………………………………………………...…5

7.2 General…………………………………………………………………………………………………………………………………..…………….5

7.3 Safety precautions for operating personnel ……………………………………………………………….………….5

7.4 Safety precautions for maintenance personnel ………………………………………………………………………….…….….6

7.5 Fire prevention in conveyor galleries……………………………………………………………………………………….……………7

7.6 Safety precautions during maintenance work in conveyor belts……………………………………………….……….….7

7.7 Safety precautions during operation work in conveyor belts ………………………………………………………………10

7.8 Belt Changing job………………………………………………………………………………………………………………………………..13

8 ROLES & RESPONSIBILITIES .................................................................................................................... 17

9 TRAINING .............................................................................................................................................. 18

10 MODIFICATION OF THIS STANDARD....................................................................................................... 18

11 AUDIT OF THIS STANDARD................................................................................................................... 188

12 MEASUREMENT & REVIEW .................................................................................................................... 18

13 DEVIATION PROCESS ............................................................................................................................. 18

14 CONTINUAL IMPROVEMENT .................................................................................................................. 18

15 DOCUMENT CONTROL ........................................................................................................................... 18

16 REFERENCES .......................................................................................................................................... 18

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1 PREFACE
Conveyors form a significant part of transportation of materials in BSP. Ensuring that these conveyors are
operated and maintained safely is critical for sustained productivity and safety performance. This standard
provides the overall framework for operation and maintenance of conveyors and is based on Steel Ministry
Guideline SG –19 and IPSS 1-11-026-16

2 PURPOSE
This Standard has been prepared as a guideline for safe working in conveyor belt system during operation,
maintenance and belt changing activities. This standard is useful in preventing hazards like getting caught /
pressed between objects, injury due to entanglement of clothing, cleaning devices, body parts etc. with running
partsof conveyor system, falling of material from height, falling from height, snapping of belts etc.

3 DEFINITIONS
Conveyor belt: A belt to carry materials and transmit the power required to move the load being conveyed.
Belt sway: A belt is considered to be aligned properly, when under full load or in no load the edges of the running
belt consistently remain within the width of the pulley faces and within the confines of other rolling components,
such as idlers. If the running belt deviates from the above definition of aligned tracking, it is called as ‘belt sway’.
Spillage: The fall of material from the belt conveyor.
Joint preparation: Making of new joint in a belt conveyor/ making ground joint preparation in case of multiple
belt conveyor rolls
Joint repairing: Repairing of a damaged joint.
Pulley lagging: Mounting/ fixing of layer of ceramic or rubber material on the face of a pulley.
Safety: Safety is the continuous process of mitigating the risk of personal injuries and with it the related losses of
property and income through a variety of management, engineering and awareness strategies.
Danger zone: Any area inside or around equipment that presents a hazard to a worker’s health, safety or physical
integrity.
Intervention area: The area in and around equipment and the moving load, including access points and integrated
access ways.
Loading and unloading zones: Areas where loads are picked up or deposited, either manually or automatically,
after conveyance.
Maintenance tasks: Inspection, cleaning, unclogging, load un-jamming, greasing, adjustments, repairs or other
maintenance.
Production operations tasks: Start-up, shut-down and other operations such as loading and unloading, assembly,
fastening, labelling, coding, monitoring, etc.,
Service way: An area around conveyor(s) reserved for access to equipment for operation and maintenance.
Work area: A place at a work site where a worker is, or may be, present during work or during a work break.
Job Safety Analysis (JSA): Job safety analysis is a procedure which helps to integrate accepted safety and health
principles and practices into a particular task or job. In a JSA, for each basic step of the job, it is to identify
potential hazards and to recommend the safest way to do the job.
Hazard: Source or situation with potential for harm, something that can cause body injury /occupational illness or
damage to company property.
Hazard Identification & Risk Assessment (HIRA): Hazard Identification & Risk Assessment is to identify and
evaluate the hazards, risk and put controls measures for safe execution of activities.
Inspection: Checking the work permit controls in practice using a prepared checklist.
Risk: The likelihood (probability) which can lead to potential negative consequences.
Risk Assessment: A systematic and structured process whereby hazards present in a workplace, or arising from
workplace activity, are identified, risks assessed / evaluated, and decisions prioritized in order to reduce risks to
acceptable levels.
Backstop (Hold Back): The backstop is an anti-reverse device installed on the belt conveyor to prevent reverse
movement of the belt and to avoid accidents.

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Responsible Person: means a person appointed by the employer to be responsible for the performance of specific
duty or duties and who has sufficient knowledge and experience and the requisite authority for the proper
performance of such duties.
Danger: means potential of causing bodily injury or danger to health.
Nip point: The point at which a moving conveyor element meets a fixed or moving element.
Pinch point: A pinch point is any location where a person or part of a person’s body can be caught between two or
more moving mechanical parts, or the bulk material and a moving part.
Safety Talk: Safety talk is a brief given to working personnel, typically at beginning of work shift and shall cover
potential hazards like fire /explosion, fume of un-burnt gases etc., All workers shall be given a safety talk by
executing officer or his representative and this shall be recorded by the person in a register.

4 ABBREVIATIONS
PPE: Personal Protective Equipment.
PTW: Permit to Work.

5 SCOPE
This Standard applies to all BSP works and Project Sites where belt conveying systems are in use

6 EXCLUSIONS
There are no exclusions to this standard

7 THE MANAGEMENT PROCESS

7.1 Standard Implementation
This standard shall be implemented in all Departments & Factories of BSP where belt conveyors are in use.
Each department / factory shall prepare Work Instruction(s) wherever required detailing department specific
Hazards & mitigation measures

7.2 General

1. Before starting any activity in a conveyor belt, hazards & associated risks to be identified and addressed. In
all the activities, the worker must wear the necessary PPEs.
2. There must be proper illumination at the working area/ zone in the conveyor belt.
3. All the necessary tools and tackles should be checked prior to use in the job.
4. During working at height, necessary protections should be taken as per the Work at Height Standard BSP-
TS- 04.
5. During working in Gas hazardous area necessary protection should be taken as per the Gas safety standard.
6. Follow all norms of permit to work system as per Standard for Permit to Work BSP-TS-05.

7.3 Safety precautions for operating personnel

The following precautions must be observed:
1. Stop the conveyor before clearing jams or removing foreign objects.
2. Make sure that all personnel are at a safe distance from moving parts before starting the conveyor.
3. Make sure that only authorized, trained personnel operate the conveyor.
4. Do not wear loose clothing or accessories where such clothing may be caught in moving parts of the
conveyor.
5. Do not eat food or drink when operating the conveyor.

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6. Do not smoke when operating the conveyor.

7. Avoid distractions when operating the conveyor.
8. Never place hands in moving parts when the conveyor is operating.
9. Never reach under or in to the conveyor when the belt is running.
10. For planned maintenance, stop the conveyor belt, after emptying its contents.
11. Never stop the belt in load except during emergency.
12. Operation personnel should be alert for hazardous conditions at all times.
13. Never attempt to cross a moving conveyor belt except at designated safe crossings
14. Do not touch, climb, walk or ride on a moving conveyor belt.
15. Know the location of emergency shut-off devices for conveyors and how to use them.
16. Test emergency shut-off devices periodically.
17. Install audible and visible warning systems to signal the start of the conveyor.
18. There must be proper illumination at the working area/zone in the conveyor belt.
19. Ensure that all personnel are equipped with the correct Personal Protection Equipment (PPE) relevant to
the task and work area.
20. Ensure that the belt conveyor is not overfilled to avoid spillage of material

7.4 Safety precautions for maintenance personnel

The following precautions must be observed:
1. Do not perform maintenance while the conveyor is operating.
2. Always take the shutdown before performing any maintenance job in conveyor belts and keep the permit
form after counter signing by authorised personnel with time. Refer to Energy Isolation Standard BSP-TS-
06
3. For belt tracking or listening for bearing noise, never touch a moving belt, roller, pulley, or bearing.
4. Never reach under or into the conveyor when the belt is running.
5. Before normalizing the shutdown of the conveyor, make sure all personnel are at a safe distance and also
all material are removed from the site/moving parts.
6. Maintain good housekeeping in the vicinity of the conveyor at all times.
7. Clean up spilled materials or lubricants promptly.
8. Always replace the safety guards and protective devices before putting the conveyor back in service.
9. Maintenance personnel should be alert for hazardous conditions at all times.
10. Remove sharp edges and protruding objects and replace broken or worn parts promptly.
11. Always stop the conveyor to clear jams or to remove foreign objects.
12. Use the proper tool for each job. Carry tools in a pouch or a tool box. Never carry tools in pockets.
13. Wear goggles while using compressed air.
14. Do not direct the stream of air toward yourself or other workers.
15. Do not use compressed air to clean yourself or your clothing.
16. Do not smoke in conveyor belt galleries & while using solvents.
17. Report all accidents resulting in personal injury or damage to equipment or material, and all irregularities
in equipment operation, promptly to the proper authority.
18. Install audible and visible warning systems to signal the start of the conveyor.
19. There must be proper illumination at the working area/zone in the conveyor belt.
20. All the necessary tools and tackles should be checked prior to use in the job.
21. During working at height, necessary protections should be taken as per the Work at Height Standard
BSP-TS- 04
22. It is necessary to isolate / completely release all stored energy from the system, so that work can be
performed in a safe environment. This can be done by applying clamps to isolate the energy from the
work area or releasing the energy applied by the take-up system.
23. Ensure that all personnel are equipped with the correct Personal Protection Equipment (PPE) relevant to
the task and work area.
24. Risk assessment should be prepared and it should be explained to the all concerns before starting of the
activity.

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25. It should be ensured that before starting the job surrounding area of the work side should be made free
of fire hazard.
26. Employees engaged on working, cutting or heating by gas and gas weldingwork/ other hot jobs should be
trained and capable to use fire equipments in case of any fire emergency.
27. Adequate fire fighting provision to be made available close to each area of cutting and other hot job.

7.5 Fire prevention in conveyor galleries

1. Heat, dust and muck shall be cleaned regularly and worn out parts shall be immediately replaced.
2. There is also a significant fire hazard associated with the conveyor drive unit due to a combination of
brake faults, failure of fluid couplings and overfilling of the drive gearboxes as well as that due to an
overheated motor which has become inadequately cooled in service due to the build-up of coal / raw
material dust.
3. The primary causes of conveyor fires fall into following main areas:
a) Maintenance activities involving the use of electric or gas welding, gas cutting equipment, or similar
activities.
b) Failure of part of the conveyor system (usually an idler or a pulley) can lead to localized overheating
and eventually, to the ignition of the coal dust, conveyor belting or lubricating oil and greases
associated with the plant.
c) Rubbing of a belt (running out of centre) with steel work resulting in localized overheating and
eventually belt catching fire when stopped from the ignition of a quantity of spilt coal dust, either by self
ignition or other causes.
Also ignition of the conveyor belt while transporting hot sinter / hot coke without undergoing proper
quenching.
4. Care must be taken to ensure that hot coal, which may have heated up spontaneously while in storage, is
not loaded on the belt in hot condition & the same does not overload the belt due to wetting (for fire
quenching) of the same.
5. Regular maintenance of the conveyor shall be undertaken to ensure freedom from friction due to the
spillage of belt over the drive or idle roller and/ or its becoming misaligned or slipping off the roller and
becoming jammed.

7.6 Safety Precautions during maintenance work in a conveyor belt

7.6.1 Conveyor drive
1. Stop the conveyor belt, when it is empty. Never stop the belt in load.
2. Ensure permit to work system is followed before starting of work as per Standard for Permit to Work BSP-
TS-05
3. Only designated persons shall operate, repair or service the conveyors.
4. Before changing/ replacing drive drum, idle drum, do the positive isolation of potential energy source (take-
up unit) of the belt by holding it with a pair of suitable chain blocks. Select the chain blocks from table-1. To
hold Gravity Take Up (GTU), lift it by 6-8 inches by chain blocks. It is also desirable (although not a must) to
place the ‘I’ beam/ channel at correct position under the gravity take up. Internal inspection of gearbox
components should be done through the provided inspection cover
5. Before changing/ replacing of any component of the drive (coupling, gearbox or motor) other than drive
drum, de-couple the output shaft & drive drum
6. The oil level in fluid coupling should be maintained as per mentioned quantity in its manual. The slip in fluid
coupling should be less than 3%.
7. In the pin-bush and gear couplings, the minimum gap between the flanges should be maintained as per the
recommended value according to their size as per OEM.
8. All the moving/ rotating components of the drive should be covered by standard safety guards.

7.6.2 Counter weight

Follow steps 1, 2 & 3 of Section 7.6.1
1. Spillage material accumulated on counter weight should be removed on regular interval.

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2. A counterweight and its pulleys suspended above the floor or ground, in an area where an employee
could walk, shall have an enclosure around the area of impact or a catch pan under the counterweight of
such strength and design to hold the counterweight and pulley from dropping to the ground, floor or
platform.
3. The concrete slab type counter weight should be replaced by box type closed counter weight wherever
installed.
4. The rope of the counter weight should be checked at regular intervals for its strands condition and
bulldog grip looseness wherever applicable.
5. When two wire ropes hang the counter weight, the wire ropes should be of opposite lay. This will avoid
twisting of counter weight about its vertical axis.
6. There should be proper gap (minimum 2 mm) clearance between the ‘L’ Shaped guide clamp and the
guideposts of the counter weight.
7. The weight of the GTU should not be increased/ decreased without consulting the designer/ expert
of the conveyor belt.
8. There should be minimum 2.5 m to 3.0 m clearance between the counter weight and ground (wherever
feasible as per design).
9. Area below counter weight should be barricaded properly.

7.6.3 Chute (Receiving or discharge chutes)

Follow steps 1, 2 & 3 of Section 7.6.1

1. Before starting any job in receiving chute, power of the preceding belt or feeding device must be isolated.
Similarly, before starting any job in the discharge chute, power of the succeeding belt must be isolated. In
addition, the chute must be checked for loosely held material inside and cleaned before entering.
2. The side skirt rubber should not be kept in contact with the belt. This may create longitudinal groove on
belt top cover and increase friction also.
3. The inside space between side skirt boards (left and right sides) should be two third of belt width.
4. Never use metal plate as a side skirt(s) as it may damage the belt.
5. An inspection cover/ window should be given in chute at the non impact-wall. The inspection window can
be used for dislodging the jammed material on impact walls or inspection of inside condition of chute.
6. To protect the mother plate of a chute, the hard faced liner or wear resistant liner plate should be fixed at
the impact zone of chute walls.
7. Before executing the welding or gas cutting job in chute, the belt below the chute must be covered by a
fire resistant cloth (Standard Asbestos). For welding or gas cutting work follow the relevant safety
standard IPSS No. 1-11-020-15.
8. There must be proper clearance between the pulley (discharge pulley or tail pulley) end face and the
inside wall of the chute.
9. If the dust content in the material handled is high, a dry fog or Dust Extraction system is preferable to be
installed at the receiving chute.
10. 24 volts hand lamp only should be used for inspections as well as performing any job inside the chute.
11. For performing job inside the chute, all the precautions for confined space work to be taken as per
Standard for Confined Space Entry BSP-TS-02.
12. Loading of material on conveyor should be at centre of the conveyor.

7.6.4 Belt joint (Vulcanized or Mechanical)

Before starting the repairing or preparing of belt joint follow steps Follow steps 1, 2 & 3 of Section 7.6.1
1. Fix the jam angle with deck plate/ stringer at a sufficient free length (3 m to 5 m from the joint), towards
head end of the conveyor belt.
2. To pull the loose belt, it should be clamped with a pair of angles (also called as pulling angles) at a
distance of 3 to 5 m from the joint & towards tail end.
3. Pull the belt from the pulling angles with the help of suitable chain blocks & slings.
4. Clamp the belt with a pair of jam angles and hold it with deck plate/ stringer. This should be at a suitable
distance from the pulling angles & towards tail end of the conveyor belt. Before applying the adhesive the
joint surface must be cleaned thoroughly and the surface should be made free from moisture.
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5. In case of mechanical joints of belt, proper selection of fastener and bolt tightening should be done.
6. If there is pocket formation at joint or the edge of the joint is found uprooted, it should be repaired
immediately.
7. Vulcanized joint should be made with proper matching of edges on both the ends.
8. For more accuracy of joint it is required to align both ends by proper use of right angle and other tools.
9. If the both ends to be joined are not of the same width, then it is required to align the joint with the
centre of both joining ends,
Precautions: In case of short length belt where tilting of belt is not possible, exact lengthof belt to be spliced
to avoid the dressing.

7.6.5 Pulley
1. Pulley should be checked for its lagging condition (if lagging is present), for axial shift and its bearing
condition at regular intervals.
2. Weld-joint condition of the disc with hub and shell of the pulley should be checked in every six month.
3. Before starting the repairing or inspection work, where pulley is required to be touched, the steps
explained in section 7.6.4 must be followed.
4. Entrapment of material between tail pulley and return-side belt should be avoided by fixing an inclined
plough / scrapper on the belt at return-side.
5. If the bearing temperature of the pulley is found above 70 ºC, the grease quality, quantity and radial
clearance of bearing should be checked. Always close the greasing points after completion of greasing.
6. The tail pulley of a conveyor belt should be guarded as per SAFETY CODE / IPSS 1-11-025-15.
7. Ceramic lagging on bend pulley should be avoided as it increases the friction and overall tension in the
belt. If lagging is required, preferences to rubber lagging should be given.
8. Damage or worn-out drum lagging should be replaced with new lagging.

7.6.6 Idlers
1 The jammed or damaged idlers should be replaced immediately, as they have high potential for
damaging the belt and may catch fire (specially the belt joint).
2 The space between two idlers should be maintained as per standards, based on belt width and bulk
density of material. For example, for a belt of width 1,200 mm and carrying material of bulk density 1.2
3
t/m the distance between two troughing idlers should be 1.0 m (max.) and that for return flat idlers
should be 3.0 m. Distance between two idlers below the chute to be 0.5 m to avoid belt sagging (which
should not be more than 2%).
3 The minimum distance between two troughing-trainer idler should be 15m and that for return trainer
should be 30 m.
4 For better control on belt sway, the ‘tru-trac’/ self aligning idlers shall be used. In return side, fix the idler
:
i) At 4.0 m away from the tail pulley. (ii) At about 2.0 m towards head end from the bend pulley of GTU
and (iii) In return side, at 4.0 m away from the head pulley.
5 Always use rubber cushion idlers/ impact idlers below the charging chute.

7.6.7 Deck plate

1. Deck plate must be given below the troughing belt. It protects the entrapment of spillage material
between the rotating pulleys and the belt.
2. The locations where the conveyor gallery is passing over the road or working area, the deck plate below
the return belt must be provided.
3. For repairing or fixing of a deck plate, as per relevant SAFETY CODE / safety standard on welding and gas
cutting should be used.
4. If deck plate is not available or worn-out too much in any conveyor belt then it is necessary to use
diversion plough before the Tail Pulley, to prevent any material to come between the conveyor and
pulley. Cleaning of accumulated material is required which got accumulated due to this diversion.

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7.6.8 Belt safety switches (Zero Speed Switch, belt sway switch, pull cord switch, chute jamming detection
device-(CJD)

1. The ZSS switch should be cleaned thoroughly at regular intervals.

2. The length of lever of ‘belt sway switch’ should be in the range of belt during belt sway.
3. The ‘pull cord switch’ with LED indicator should be used and distance between two pull cord switches to
be maximum 30 mtr. If length of the belt is less than 30 mtr., it should be 15 mtr.
4. The pull chord rope shall be checked and ensured to be in good condition periodically
5. All the belt safety switches should be tested periodically (at suitable frequency) for proper functioning.
6. Before repairing or changing of belt safety switches, the step 1 & 2 of section 7.6.1 should be followed.
7. Emergency switch is required to be installed at drive end to stop the running belt immediately.
8. It is advisable to install ZSS on Tail- end Snub pulley.

7.7 Safety Precautions during operation work in a conveyor belt

7.7.1 Belt sway (Belt Tracking)

1. Keep one skilled person with ‘walky-talky’/ Appropriate Communication system near the pull cord/
emergency switch.
2. Communicate with control room before aligning/ tracking the running belt.
3. Move the trainer idler by pushing/ pulling its frame from the ends only.
4. Do not try to rotate any damaged/ jammed trainer idler manually.

7.7.2 Spillage recovery/ cleaning

Follow steps 1, 2 & 3 of Section 7.6.1
1 Do not stand /walk on the belt.
2 The spillage material accumulated below the return side-belt or on the deck plate should be cleaned by
hand scrappers only.
3 The spillage material should be collected in bucket and it should not be thrown down from conveyor
gallery.
4 Throw the collected spillage material on belt, only from those positions, where the safety guards are
provided on belts.
5 Never heap up the spillage material at the tail end of conveyor.
6 If the spillage material is in large amount (more than one ton), the conveyor should be taken in local
operation mode. Start the belt in empty condition. Keep one person at pull cord.
7 Communicate with control room and start throwing the collected spillage material by bucket on the
running belt from the safety guard positions only or station made for this purpose.
8 Understand that shovelling material onto a moving belt presents a risk:
a) Establish a safe shovel point.
b) Always shovel in the direction of belt travel.
c) Use shovels without a “D” grip (plain, smooth handle).
d) Erect a barrier that prevents the shovel from reaching the edge of the belt, but allows material to pass
over or through.
e) Be careful where material is thrown. Be conscious of the surroundings.
f) Never clean alone—use the buddy system.
9 Do not clean under or near moving equipment when visibility is poor.
10 Workers who clean up spills around conveyors must be trained to follow safe clean-up practices.
11 When cleaning overhead conveyor catwalks, or decking, or doing overhead repair where there is a danger
of falling material, the “fall area”—the area below the overhead structures—should be cordoned off
(Refer Barricading & Use of Signage standard BSP-TS-08) and danger signs are to be placed where hazards
exist. In addition, an observer should be stationed at ground level to warn other personnel to stand clear.
12 Be careful where material is thrown. Be conscious of the surroundings. Watch other workers and mobile
equipment that might move to pinch, confine, or otherwise trap the clean-up crew.

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7.7.3 Safety precautions while cleaning with high pressure hoses

1. Wear safety glasses or goggles.
2. To prevent the hose from whipping, use secure grip, stand on the hose near the nozzle.
3. Use good posture, stand with feet apart, lean forward to brace against pressure. Do not stand with back
toward open walkways or stairs. Do not climb or descend stairs while handling the hose under pressure.
4. Know where the water is going. This is important during cleaning operations, so the spray does not affect
other operations, personnel, or equipment. When the cleaning operation is complete, it is important that the
plant does not have trouble with emissions and releases of contaminated, untreated water.
5. Start from the highest area and work down, washing platforms, walkways, and other areas where there is an
accumulation of material.
6. Watch the spray. Avoid aiming at electrical junction boxes; do not aim nozzle at other workers.

7.7.4 Safety precaution for using skid steer loader for cleaning operation
1. Wear proper personnel protective equipment (PPE).
2. Do not operate the loader in a manner that causes any wheel to leave the ground.
3. Do not overload the Bucket. Two trips are better than one accident.
4. Carry the bucket low when transporting materials.
5. Check for co-workers changing direction. (Especially before going in reverse.)
6. When driving, watch for pedestrians as well as other vehicles.
7. Do not leave the operator seat while the Engine is on.
8. Keep all body parts inside the cab while operating a skid- steer loader.
9. Never permit riders on the speed steer loader, in the bucket or other attachment.
10. Skid steer operator should have sufficient skills to operate the equipment safely.
11. If working with other employees in the vicinity- with a clean-up crew, use the buddy system and have a
dedicated spotter.

7.7.5 Start/stop of belt

1. Ensure proper Pre-start warning/ Alarm system (sound level of at least 120 dB – shall be determined on a
case to case basis depending in ambient noise level) before starting of any conveyor with minimum 30
seconds delay.
2. If a conveyor belt needs stopping, it should never be stopped in loaded condition, except in case of
emergency.
3. If the Silo / Bunker on to which the material is unloaded is about to be filled, sufficient warning / interlock
system is to be provided to allow emptying out the loaded / feeding belt so that it stops in empty
condition only

7.7.6 Basic check list prior to re-starting a conveyor

Ensure that:
1. Nobody is working on the belt.
2. Guards have been re-fitted and that all the safety interlocks are operational.
3. The area is clean and clear of equipment and /or debris or spillages.
4. All the fire fighting/fire suppression devices and equipment are in place and operational.
5. All clamps, safety interlock devices like pull cord are normalised or released.
6. All other spragging devices have been removed.
7. The take-up system is operational.

7.7.7 Inspection:
Inspection of conveyor belt is very important to enhance life of conveyor and its other equipment. The
following chart is to be used for scheduled inspection of conveyors.

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BEL T INSP EC TION SU MM ARY REPO RT

Date of Inspection:
DEPARTMENT :

SECTION :
Belt Name
Belt Length Mtrs. Mtrs.
Belt Specification
Last Belt Changing Date
Belt Condition
a) Top Rubber Good/Burnt / Worn out G ood/Burnt / Worn out
b) Bottom Rubber Good / Worn out G ood / Worn out
c) Ply Good/Burnt / Worn out G ood/Burnt / Worn out
Joint Condition
Vulcanising joint Not O.K. / G ood / Poor N ot O.K. / Good / Poor
Idler Condition
a) TroughingIdler …….N os. Missing /……..Nos. Jam …….Nos. Missing /……..Nos. Jam
b) Return Idler …….N os. M issing /……..Nos. Jam …….Nos. Missing /……..Nos. Jam
Drive Drum Good / Lagging worn-out. G ood / Lagging worn-out.
Tail End Drum Good / Lagging worn-out. G ood / Lagging worn-out.
Drive Snub Pulley Good / Lagging worn-out. G ood / Lagging worn-out.
Take-up Good / Missing / Bad / Worn-out G ood / Missing / Bad / Worn-out
Scrapper Good / Missing / Bad / Worn-out G ood / Missing / Bad / Worn-out
Decking Plate Good / Missing / Bad / Worn-out G ood / Missing / Bad / Worn-out
Charging Chute Good/Non-Center loading/N ot O.K. G ood/N on-Center loading/Not O.K.
Tail end Drum Guard Fixed / Missing Fixed / Missing
House Keeping
a) Head End Clean / Material accumulated Clean / Material accumulated
b) Tail End Clean / Material accumulated Clean / Material accumulated
c) G allery Clean / Material accumulated Clean / Material accumulated
d)Decking Plate Clean / Material accumulated Clean / Material accumulated
Operating Condition
a) Temperature Normal High / Low N ormal High / Low
b) Belt Position Normal/ Swaying Rt. / Lt. N ormal/ Swaying Rt. / Lt.
Electrical Safety Devices
a) Pull Card Exists Exists
b)Zero Speed Limit Switch Exists Exists
c) Emergency Switch Exists Exists
d) Sway switch Exists Exists
Remarks

(Shri ……………………) (Shri …………………………) (Shri …………………………)

Designation …………… Designation ……………… Designation …………………..
Representative of Representative of Representative of
Belt Maint. Group Shop (Mech.) Shop (Opr.)

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 STANDARD FOR OPERATION AND MAINTENANCE OF BELT CONVEYORS Issue:
(BSP-TS-12) Rev: 00

7.8 Belt Changing job

1. When belt changing job is done in an area where there is road/rail movement, concerned agencies like
T&D, Plant garage, Road Safety are to be informed through separate protocol & by co-ordination
through designated persons for preventing haphazard/hazard prone working
2. Ensure provision of suitable Power Outlet at suitable location for facilitating connection to hand lamp,
Grinders, heaters etc,.
3. Ensure suitable fire fighting arrangements like fire extinguishers, Fire Hydrants, Sprinklers etc., at job
site.
4. New belt roll should be put on a fabricated & heavy stand and roll shaft is to be locked from top on
supporting points. The stand should be sufficiently heavy and stable to avoid tilting of stand while the
belt is being dis-mounted from belt roll.
5. Belt changing area should be properly barricaded by safety ribbon and a safety observer should be
deployed throughout the job. (Follow as per barricading & usage of signage standard BSP-TS-08).
6. Follow steps 1, 2 & 3 of Section 7.6.1
7. Belt conveyor should be put under local mode, if running of motor is required for belt changing activity.
The belt is to positioned at a suitable place for joining the belt and then the conveyor belt is to be
stopped.
8. Before starting any activity in conveyor belt, positive isolation of potential energy source (take-up unit)
of the belt is to be done by holding it with suitable chain blocks. Lift the Take-up by 6-8 inches (Refer Fig.
- 1).
9. Take-up must be lifted and held with two numbers of suitable and tested chain blocks. Selection of chain
block is to be done as per the table 1.
10. It is also desirable to place the ‘I’ beam/ channel at correct position under the gravity take up, to avoid
the free fall of take up. (Refer Fig. - 2).
11. The vertical take up / horizontal take up should be secured to immobilise the same to prevent any
unwanted movements that may damage the take up or structure.

12. Before cutting of old belt, it should be clamped properly with conveyor deck plate by 2 nos. of jam angles
(refer Table 2) on both side of the cutting position. (Refer Fig. - 4).

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 STANDARD FOR OPERATION AND MAINTENANCE OF BELT CONVEYORS Issue:
(BSP-TS-12) Rev: 00

13. Before executing the welding or gas cutting job in chute, the belt below the same must be covered by a
fire resistant cloth (Standard Asbestos) . For welding or gas cutting work follow the relevant safety
standard IPSS No. 1-11-020-15.
14. To avoid slip or damage of conveyor belt, a rubber piece should be inserted in between the jam angle &
conveyor belt.
15. One end of new belt should be joined with old belt by plate-fasteners. During jointing, no. of fasteners
should be as per the given table.3.
16. The other end of old belt, which is supposed to be
pulled out, should be clamped with holding T-shape
plates. (Refer Fig. - 5).
17. Do the positive isolation of all the electrical power
sources of conveyor system (including preceding and
succeeding conveyors)
18. Holding plate with D-shackle should be tied with
sling and hooked to the pulling device.
19. Release the jam angles and pull the old belt manually
or by some external pulling device (Like winch or pay
loader). The new belt is to be pulled from reel by
inching drive with local switch. (Refer Sketch-1).

20 The speed of pulling device should be very slow max. 15 meter/ min.

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 STANDARD FOR OPERATION AND MAINTENANCE OF BELT CONVEYORS Issue:
(BSP-TS-12) Rev: 00

21 If belt is longer (more than 250 mtr. and at a height), three persons should co-ordinate through Walky-
Talky. One with belt local switch operator, second with the pulling device and the third along with joint
movement.
22 If belt gallery is at more than 15 m height from ground and when about 5 to 8 m of new belt remains in
the reel, pulling of the belt is to be stopped. Now, wrap the wire rope (used for pulling) with a fixed and
robust structure.(The rope length should be more than the height of gallery from ground)
23 After this, the other end of the new belt should be pulled using ‘T’ shape plates & wire rope to the
required position where joint is to be prepared .
24 Finally, requisite belt tension is to be attained using pay loader/ any suitable pulling device
25 The pulled end is to be clamped with jam angle/ jam device.
26 Both ends of new belt is to be joined with plate fasteners (Refer Fig. - 6)/ vulcanised.
27 If there is excess new belt before cutting, it should be held with rope and other end of rope should be
fixed / anchored with robust structure at upper level. (Refer Fig.-7)
28 After all these activities are performed & belt changing is complete, holding of the belt in gallery is to be
released, power cut-off clearance to be taken and positive isolation locking to be done properly.
29 After vulcanizing, idlers to be set in their position, the take-up is to be released and tension is to be put
on/given to the belt.
30 Once again inspection is to be done to see “Is any jam angle left intact with belt”. If not, Job completion
clearance is to be given.

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 STANDARD FOR OPERATION AND MAINTENANCE OF BELT CONVEYORS Issue:
(BSP-TS-12) Rev: 00

Table – 1: Table for selection of Chain block

Belt width (mm) Belt length (m) Chain Block Size (Ton)

Up to 800 Up to 600 2T+2T

1000 Up to 300 2T+2T

Above 300 – up to 600 3T+3T

Above 600 – up to 1300 5T+5T

1200 - 1600 Up to 300 2T+2T

Above 300 – up to 500 3T+3T

Above 500 – up to 800 5T+5T

Table – 2: Table for selection of Jam Angle

Length of angle Cross section of angle Remarks

1.5 X Belt width (mm) 90 X 90 X 8 (mm) i. Fasteners: Size-M20 grade 8.8,
Quantity: 2 + 2

ii. To avoid slip or damage of

conveyor belt, at the point where
jam angle has to be fixed, a
rubber piece should be inserted in
between the jam angle &
conveyor belt.

Table – 3: Table for selection of Belt fastener

Distance between two clip-

Belt width (mm) Minimum no. of fasteners
fasteners
800 10 Approx. - 75 mm

1000 12 Approx. - 75 mm

1200 16 Approx. - 75 mm

1400 20 Approx. - 75 mm

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 STANDARD FOR OPERATION AND MAINTENANCE OF BELT CONVEYORS Issue:
(BSP-TS-12) Rev: 00

8 ROLES &RESPONSIBILITIES
8.1 Shift In charge (Operations)
a) Authorised operations person of the process plant/ section concerned who drives the preparatory
measures and ensures that necessary shutdown preparation conditions are met as required by executing
agencies
b) Times the shutdown activities in accordance with process priorities & safety of personnel

8.2 Contractual supervisor / Company Supervisor (Operations)

a) Field personnel responsible for executing the activities as required by standard & fulfilling other
necessary conditions required by maintenance personnel
b) Communicating the field condition constantly to Shift In Charge or concerned executive next in the
hierarchy for seeking suitable counsel/guidance to enable smooth and safe job execution

8.3 Permit Authoriser (Maintenance)

c) Ensures hazard identification & mitigation measures for concerned job
d) Keeps track of timing (of beginning, end) of shutdown & its normalisation and communicates the same to
concerned agencies

8.4 Permit issuer

a) Ensures that the required job safety, preparation measures are in place before beginning of the job
b) Gives the necessary clearance for equipment normalisation after successful job execution and
communicates it to all concerned

8.5 Job Co-ordinator

a) Co-ordinates the job including shutdown fulfilment measures, job progression, resource mobilisation
for timely job execution and also oversees the safe execution of job in totality.
b) Keeps in touch with all stakeholders constantly for enabling smooth activities.

8.6 Workmen
a) The field personnel who are actually executing various jobs like: giving/arranging shut downs, doing
power dis-connection, doing site cleaning, preparing belt joints, removing worn-out or damaged belts,
driving pay loaders/ cranes/ hydraulic equipment, doing rigging/welding & cutting/grinding etc.,
b) They are required to work in accordance with all safety regulations, abide by SOPs/SMPs/WIs etc.,
c) Required to give timely feedback about any abnormal incidence/ systemic anomaly to job supervisor/
job co-ordinator/ shift in charge so that safety of workmen or equipment is not at peril and that the
concerned job gets executed in planned time

Foot note:
i) The above roles and responsibilities are only indicative and non-exhaustive. Depending on
site conditions, there may be overlap of roles or variation in the same.
ii) Multiple roles may require to be taken up by single person provided, that there is no conflict
of interest in working between the various roles assumed by the person
iii) Individuals are required to carry out various additional job responsibilities along with the
above

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 STANDARD FOR OPERATION AND MAINTENANCE OF BELT CONVEYORS Issue:
(BSP-TS-12) Rev: 00

9 TRAINING
Awareness training to be provided at all levels of the organisation

10 MODIFICATION OF THIS STANDARD

Modifications to this Standard shall be recommended to the Standards CFT in writing clearly stating the reasons
for the request and any additional risk introduced as well as control measures required in case the modification is
approved. Only the Standards CFT is authorized to approve any modifications to the standard as well as the
training and audit protocol. The modification shall only be implemented after all the revisions are made in the
document

11 AUDIT OF THIS STANDARD

The implementation of this standard shall be Audited using the checklist provided in Appendix . The audit shall be
carried out as per protocol (to be issued later)

12 MEASUREMENT & REVIEW

The implementation of this Standard shall be measured based on audit observations.

13 DEVIATION PROCESS
Deviations from this standard must be authorized in writing by the Director I/C of BSP after consultation with ED
Works and ED SSO, and if required Legal resources. The Deviation shall be considered in detail by the Standards
CFT and recommendation shall be made to ED Works and ED SSO. Deviations must be documented, and
documentation must include the relevant facts supporting the deviation decision. Deviation authorization must be
renewed periodically and no less frequently than every three years.

14 CONTINUAL IMPROVEMENT
This standard shall be reviewed once in 3 years and would be revised as and when found necessary. The review
shall be conducted by selected users from the Factory / Department that used the Standard at high frequency
during the last 3 years. The review team shall consider Learnings From Incidents, Inputs from BI, Audit inputs as
well as feedback from Workforce and Contractors. If similar Standards from other user Industries are available that
may be used as reference for such reviews.
The recommendations from this review team shall be discussed by the Standards CFT and approved or rejected as
the case may be.
15 DOCUMENT CONTROL
All old versions of this standard shall be destroyed by user Factories / Departments. Old version shall be retailed
for record purposes for maximum of 3 years by SED in archive
This Standard shall be owned by Standards CFT

16 REFERENCES
a) IPSS 1-11-026-16 : Operation & Maintenance of conveyor belts.
b) Relevant Indian Standards IS: 7155-1986,

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