Conveyor Operations - Resource Manual

Conveyor
Operations
Resource
Manual
Conveyor Operations
Table of Contents
1 Session Preliminaries.............................................................................................................7
1.1 Purpose of this Resource Manual...............................................................................................7
1.2 Safety Requirements....................................................................................................................7
1.3 Training Requirements...............................................................................................................7
1.4 Assessment Requirements...........................................................................................................7
1.1 Prerequisite..................................................................................................................................7
1.2 Getting Help.................................................................................................................................8
2 Introduction............................................................................................................................9
2.1 Scope.............................................................................................................................................9
2.2 Understanding Conveyors and Conveyor Applications...........................................................9
2.3 Terminology...............................................................................................................................10
3 Operate Conveyor................................................................................................................17
3.1 Operator Responsibilities..........................................................................................................17
3.2 Identifying Safe Operating Practices.......................................................................................18
3.2.1 Operational Safety Requirements......................................................................................18
3.2.2 Additional PPE Requirements...........................................................................................19
3.3 Crusher Operations Environmental Concerns.......................................................................19
3.4 Pre-Start Inspections.................................................................................................................20
3.4.1 Introduction........................................................................................................................ 20
3.4.2 Potential Pre-Start Hazards............................................................................................... 20
3.4.3 Conveyor System Pre-Start Inspection Requirements.......................................................21
3.4.3.1 Introduction................................................................................................................ 21
3.4.3.2 General Conveyor System Inspections.....................................................................21
3.4.3.3 Specific Checks for the Ball Mill Feed Conveyor.......................................................22
3.4.3.4 Specific Checks for the Weightometer.......................................................................22
3.4.3.5 Post Inspection Tasks............................................................................................... 23
3.4.3.6 Pre-Start Sirens......................................................................................................... 23
3.4.4 Common Safety Inspections.............................................................................................. 23
3.5 Conveyor Start Up Procedures................................................................................................25
3.6 Conveyor Shutdown Procedures..............................................................................................27
3.7 Conveyor Types, Components and Specifications..................................................................28
3.7.1 General Description........................................................................................................... 28
3.7.2 Conveyor Types................................................................................................................ 28
3.7.3 Standard Belt Conveyor System........................................................................................ 29
3.7.3.1 Overview.................................................................................................................... 29
Printed copy is UNCONTROLLED. The training web site has the latest version of this document
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Conveyor Operations
3.7.3.2 Conveyor Nip Points.................................................................................................. 30

3.7.3.3 Conveyor Deck.......................................................................................................... 30
3.7.3.4 Conveyor Belt............................................................................................................ 31
3.7.3.5 Drive Motor and Gearbox..........................................................................................31
3.7.3.6 Conveyor Braking...................................................................................................... 32
3.7.3.7 Drive Pulley............................................................................................................... 32
3.7.3.8 Pulleys....................................................................................................................... 33
3.7.3.9 Carry / Troughing Idlers............................................................................................. 37
3.7.3.10 Return Idlers............................................................................................................ 38
3.7.3.11 Impact Idlers............................................................................................................ 39
3.7.3.12 Skirt Assemblies...................................................................................................... 40
3.7.3.13 Vee or Plough and Belt Scrapers............................................................................41
3.7.3.14 Tracking Rollers....................................................................................................... 43
3.7.3.15 Drift Switches........................................................................................................... 44
3.7.3.16 Emergency Stop Devices........................................................................................ 45
3.7.3.17 Chutes..................................................................................................................... 47
3.7.4 Other Conveyor Components and Equipment...................................................................48
3.7.4.1 Introduction................................................................................................................ 48
3.7.4.2 Under-speed Sensors................................................................................................ 48
3.7.4.3 Weightometers.......................................................................................................... 49
3.7.4.4 High Burden Detector................................................................................................ 51
3.7.4.5 Metal Detectors......................................................................................................... 52
3.7.4.6 Tramp Metal Magnet................................................................................................. 53
3.7.4.7 Belt Rip Detectors...................................................................................................... 54
3.7.4.8 Transfer Stations....................................................................................................... 55
3.7.4.9 Local Control Stations............................................................................................... 58
3.7.4.10 Vibrating Feeders / Conveyors................................................................................59
4 Perform Operator Maintenance.........................................................................................61

4.1 Overview.....................................................................................................................................61
4.1.1 Maintenance...................................................................................................................... 61
4.1.2 Preventive Maintenance (PM)...........................................................................................61
4.2 Maintaining Conveyor Components........................................................................................63
4.2.1 Introduction........................................................................................................................ 63
4.2.2 Conveyor Deck.................................................................................................................. 64
4.2.3 Conveyor Belt.................................................................................................................... 64
4.2.3.1 Top Cover Wear or De-Lamination............................................................................65
4.2.3.2 Longitudinal Grooving of Top Cover..........................................................................66
4.2.3.3 Abrasion Loss of Belt Edge Top Cover......................................................................67
4.2.3.4 Excessive Wear to Bottom Cover..............................................................................67
4.2.3.5 Longitudinal Grooving of Bottom Cover.....................................................................68
4.2.3.6 Gouging or Stripping of Bottom Cover.......................................................................68
4.2.3.7 Damage to or Abrasion of Edge Rubber....................................................................69
4.2.3.8 Wavy Abrasion Loss of Top Cover............................................................................69
4.2.3.9 Drive Motor and Gearbox..........................................................................................70
4.2.3.10 Conveyor Brakes..................................................................................................... 70
Conveyor Operations
4.2.3.11 Pulleys..................................................................................................................... 71
4.2.3.12 Idlers........................................................................................................................ 72
4.2.3.13 Skirts....................................................................................................................... 74
4.2.3.14 Belt Scrapers........................................................................................................... 74
4.2.3.15 Belt Ploughs............................................................................................................ 74
4.2.3.16 Tracking Frame....................................................................................................... 75
4.2.3.17 Belt Drift Switches................................................................................................... 76
4.2.3.18 Emergency Stop Devices........................................................................................ 77
4.2.3.19 Under-speed Sensors.............................................................................................. 78
4.2.3.20 Weightometers........................................................................................................ 78
4.2.3.21 High Burden Detectors............................................................................................ 78
4.2.3.22 Metal Detectors....................................................................................................... 78
4.2.3.23 Tramp Metal Magnets.............................................................................................. 79
4.2.3.24 Belt Rip Detectors.................................................................................................... 80
4.2.3.25 Transfer Stations..................................................................................................... 80
4.2.3.26 Local Control Stations............................................................................................. 81
4.2.4 Washing Conveyor Systems.............................................................................................. 81
4.3 Troubleshooting.........................................................................................................................82
4.3.1 Introduction........................................................................................................................ 82
4.3.2 Fault-finding Examples...................................................................................................... 83
5 Activities................................................................................................................................85
5.1 Section 3 Operate Conveyor Activities....................................................................................85
Activity 1..................................................................................................................................... 85
Activity 2..................................................................................................................................... 85
Activity 3..................................................................................................................................... 85
Activity 4..................................................................................................................................... 86
Activity 5..................................................................................................................................... 86
Activity 6..................................................................................................................................... 86
5.2 Section 4 Perform Operator Maintenance Activities.............................................................87
Activity 1..................................................................................................................................... 87
Activity 2..................................................................................................................................... 87
Activity 3..................................................................................................................................... 87
Activity 4..................................................................................................................................... 88
Activity 5..................................................................................................................................... 88
Activity 6..................................................................................................................................... 88
Section 1 Session Preliminaries
1 Session Preliminaries
1.1 Purpose of this Resource Manual

The purpose of this Resource Manual is to provide detailed information and instructional
material for the subject matter of this training module. Where appropriate the content covers the
standards, procedures, safety and operational requirements of for the workplace and tasks
described.
This Resource Manual is a key document in a suite of documents for the learning and
assessment requirements of this module.
1.2 Safety Requirements

If you demonstrate unsafe behaviour or perform a task without the necessary care or
confidence, the Trainer must direct you to cease work and terminate the training immediately.
1.3 Training Requirements

This Training module is conducted in accordance with the Training and Assessment Standard
and will be delivered in a variety of work situations and conditions appropriate to the role or task
to reinforce the required learning and repeated over a suitable time frame.
The Trainer will explain the training format, process and the progression to the assessment
requirements.
The content of this Resource Manual satisfies the training material requirements for this module.
Although you can keep this manual, the Activities at the end of each Section must be completed
and a copy of the Activities given to the Trainer.
1.4 Assessment Requirements

On completion of this training module an assessment will be conducted, which must be
successfully completed to attain an assessment of Competent for the material covered by this
module.
The assessment requirements are:
 A knowledge based test
 Practical demonstrations to establish a satisfactory understanding of the required
task/s and the associated safety requirements
 Workplace evidence completed by the Participant demonstrating competency in all the
required tasks
1.5 Prerequisite
Completing the training for the Generic Health, Safety and Environment Requirements and
being assessed as Competent, is a mandatory prerequisite for attending the training for this
module.
Information covered in the Generic Health, Safety and Environment Requirements Resource
Manual that is also applicable to conveyor operations is not duplicated in this resource manual.
If necessary, review the HSE manual to assist you with the full understanding required for
conveyor operations.
Section 1 Session Preliminaries
1.6 Getting Help

See your Line Manager or Supervisor to obtain further assistance with the subject matter in this
training module.
Section 2 Introduction
2 Introduction
2.1 Scope
This training module is aligned with the requirements of the unit of competency, RIIPEO201A
Conduct conveyor operations.
This Resource Manual discusses conveyor operations for the mining industry. It is to be used in
conjunction with the relevant Original Equipment Manufacturer (OEM) manuals for the conveyor
equipment, fittings and associated systems that you will be operating at your mine site.
The topics include planning and preparing for conveyor operations, operating and maintaining
the conveyor equipment, fittings and associated systems.
There is also relevant information covering the HSE and legislative requirements for the
functions associated with operating mine site conveyors. This safety information is extremely
important and is discussed in detail with all related subject matter, as required, throughout this
manual.
2.2 Understanding Conveyors and Conveyor Applications

Conveying systems, using various rolling methods, have been used for thousands of years as a
means of moving heavy and large quantities of loose items over short distances.
The introduction of powered methods of driving conveyor systems (e.g. internal combustion
engines and electricity) enabled more sophisticated conveyor systems to be developed using a
range of gears, rollers and pulleys for elevated transport and transport over long distances.
Using conveyors to move materials from one location to another is often the most cost effective
method of transport.
Although conveyors are designed for specific purposes and industries (moving both wet and dry
materials), most conveyors have a similar configuration with a central control and body structure
using head and tail pulleys, gearing systems, belts, rollers, safety protections (e.g. barriers and
emergency stop) and limit switches.
Material is placed on the conveyor through a feed system that delivers the material to the
conveyor in a manner that allows the conveyor to accept the material without loss of the product
or damage to the conveyor carrying the material to its required location.
Conveyors can feed stockpiles, elevators or load a truck or ship.
Conveyors have a huge impact on the way we process and move material.
Conveyors are used in all mining operations, e.g. gold, titanium minerals (mineral sands), rare
earths, chromite, tin, iron ore and coal.
Conveyors, as with all electrical and mechanical equipment, can present hazards to the unwary
and present some unusual technical problems when their operating conditions are stressed. So
it is extremely important for you to have a good understanding of conveyor systems, how they
work, the safety precautions and how to maintain them.
Warning : Conveyors are not designed to transport people. You must never ride on a conveyor
because serious injury or death can result from such acts of stupidity.
2.3 Terminology
The following table lists terms and definitions used in this module and conveyor operations.
All personnel operating conveyors must be familiar with the listed terms and their meanings to
ensure a safe and effective operation of the conveyor systems and associated equipment.
Item Definition
Amplitude Maximum extent of vibration or oscillation from the centre, i.e. position of
equilibrium
Assay The percentage of an element in a representative sample, as found by
analytical testing
Attrition Grinding resulting from the constant rubbing of rock against rock and / or
rock against steel
Authorised A person trained in the Permit to Work Procedures and nominated as
Person authorised by the Project Manager to issue the permit
Ball Charge Percentage by volume of steel balls in a ball mill
Ball Mill A large rotating steel drum, lined with steel or rubber that contains a
charge of steel balls used to grind ore
Barrel (pump) Pump drive shaft bearing assembly
Barring Drive An auxiliary drive that is used to slowly turn over the ball mill for
maintenance purposes or to free the ball / ore charge if the mill has been
stopped for any length of time
Belt Scraper Conveyor belt cleaning device that contacts and cleans the belt
Usually located at the head of the conveyor
Bogging Extreme result of sedimentation causing blockages, e.g. in pipes and
tanks
See sedimentation
Bump Start Quick start / stop of a drive
Used to check that rotating equipment (e.g. a pump) is able to turn
Capacity The maximum rate at which equipment can be fed while still maintaining
operational goals
Cascade When the set point of a controller is changed automatically by another
controller, the first is said to be in cascade
Casing The housing of a pump that surrounds the impeller
Centrifuge When material is held to the outside of a mill due to a high charge level or
density
It causes a decrease in power draw and grinding efficiency
Circulating Load The portion of feed that is retained in a closed circuit for retreatment
Clarified Containing no solids
Classification The separation of material into two different size fractions
Usually done by cyclones or screens
Closed Circuit Refers to a circuit where the classifier’s oversize (e.g. cyclone overflow)
returns to the same unit from where it was discharged
See Open Circuit
Comminution The reduction in size of ore particles through various mechanical stages,
e.g. crushing and grinding
Controller Pneumatic or electronic device used for process automation
Counter Weight A heavy weight that is suspended from a pulley carriage and free to move
in a vertical direction to maintain tension on a conveyor belt
Item Definition
Critical Speed The theoretical speed of rotation of a mill in which a ball is held to the
inner surface of the smooth mill liners by centrifugal force
Crushing The process of breaking large ore into smaller pieces by the impact of
crusher surfaces
The action is one of impact rather than attrition
Cyclone A classifying unit in which centrifugal force is used to separate coarse
and fine material
Cyclones can be hydrocyclones (water) or air cyclones
In both cases, coarse material is discharged from the underflow and fine
material is discharged from the overflow
Cyclone Overflow The cyclone product that contains the fine particles
These exit via the vortex finder
Cyclone The cyclone product that contains the coarse particles
Underflow These exit via the cyclone spigot (apex)
Density A measurement of the concentration of solids in a slurry or pulp
Density is expressed as a percentage of solids by weight or as a Specific
Gravity (SG) figure
Density Gauge In stream analysis instrument measuring the density of a slurry stream
Dewater Any process that removes water from a pulp stream
The term includes both thickening and filtering
Discharge Cone The conical section at the bottom of a thickener through which the
underflow discharges
Dispersing Agent A chemical used to promote the removal of slimes from particle surfaces
Distribution Expressed as a percentage passing each standard micron size
Distributor Used to divide / split a stream into a number of equal parts, e.g. a cyclone
feed distributor distributes the flow equally between the operating
cyclones
Drum Scrubber A large rotating steel drum, lined with steel or rubber removing any clays
and slimes attached to the ore
Drum Tipper A device used to tip drums allowing their contents to be removed, e.g.
drums containing steel balls for the ball mill
F80 The size through which 80% of the feed particles will pass
Usually measured in micrometres
Feed The material entering a particular section of the plant, e.g. mill feed,
cyclone feed and thickener feed
Feed Box A box mounted at the start of a circuit or unit into which the feed is
directed
Feed then flows from the feed box into the circuit or unit
Feed boxes are often used to combine several flows before treatment
Feed Rate The rate at which feed is delivered to a section
Usually expressed as Tonnes Per Hour (TPH)
Feed Well The central cylindrical area of a thickener into which feed is introduced
Feeder A vibrating pan drawing material from the bin or stockpile and depositing
it onto a conveyor
Item Definition
Filter A device used for dewatering by extracting water through a porous

membrane
The driving force can be either vacuum, pressure or gravity
Flocculent A chemical reagent that aids settling by forming large flocculent particles
out of a number of fine slow settling particles
Flow Rate The rate of flow of a liquid or slurry
Usually expressed as cubic metres per hour (m3/h) for slurries and litres
per minute (L/m) or millilitres per minute (mLs/m) for reagent flows
Frequency The speed of oscillation / vibration
Gear Reducer A mechanical device containing two or more gears that is used to give a
specific speed change from input to output shafts
Used between a drive motor and a drive load, e.g. conveyor, mill and
pump
Gland The seal on a pump shaft
Sometimes requires a water supply to maintain the seal
Grade Describes the percentage of metal content of a sample or process
stream, e.g. feed grade and concentrate grade
Grate Type of mill liner with slotted openings allowing ground material of the
required size to discharge from the mill regulating the size of material
discharging from the mill
Grind Out The process of emptying a mill by running it with the feed off
Grinding (1) Powdering or pulverising by pressure and abrasion
Grinding (2) The process of size reduction performed in grinding mills
Grinding Media Steel balls and natural ore media of various diameters used in mills
Hardness Measure of the ore’s resistance to communition
Head Pulley The head pulley is a cylindrical drum around which the conveyor belt
passes, located at the discharge end of the conveyor and usually doubles
as the drive pulley
Hoist A lifting device used to raise weights such as steel balls
Hopper A vessel that receives and holds material until it is discharged in
accordance with production requirements
It has the capacity to accommodate surges in material flow
Hydrophobic Fear or hatred of water
A mineral made hydrophobic attached itself to an air bubble in a flotation
extraction processes and is recovered into the flotation concentrate
Idler A roller or set of rollers arranged in such a way that they shape and
support a belt to contain and convey material with a minimum of friction
and sagging
Impeller The rotating part of a pump that is attached to the drive shaft inside the
pump casing designed to push fluid from the centre of the pump to the
casing outlet
Interlock An electrical circuit that is designed to prevent a piece of equipment from
operating, unless the piece of equipment that succeeds it in the process
flow is running
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Item Definition
Jaw Crusher Crushing equipment consisting of one moving and one fixed jaw that is
typically used at the first stage of size reduction
Knife Gate Valve A type of isolation valve used on pump suction lines
Lanyard Emergency shutdown pull wire located along conveyor belts wherever
personnel access is available – also known as a trip wire
Launder A trough in which material may be transported
Level Controller A device regulating the contents of a sump or tank to a set level by
increasing / decreasing the inputs to the sump to match its output
Lifter Bar Mill liner shaped like a bar and normally located on the joining line
between two flat liners
Lifters are raised higher than flat liners to lift the mill load up the side of
the mill assisting with the tumbling action
Linatex A type of soft rubber with good resistance to wear
Used for lining chutes and bandaging pipes
Liner Hard cast piece of steel or rubber attached to the inside of the mill shell,
throat or trunnion to act as a protective wear surface and to help induce
tumbling of the load
Lubrication The use of oils and greases to reduce friction and protect mechanical
parts / gears / bearings
Magnet Used to remove tramp steel from the ore before comminution
Marcy Scale A spring balance used for measuring slurry density
Micrometre One micrometre is equal to one millionth of a metre, i.e. one thousandth
of a millimetre
Commonly known as a micron, its symbol is um, e.g. 250um = 250
micrometres (microns)
Moisture Content A measure of the amount of moisture in ore to calculate dry tonnage
Open Circuit Refers to a circuit through which all material passes without being
returned for further treatment
See Closed Circuit
Overflow (1) Fine product from a cyclone that exits via the vortex finder
Overflow (2) The clear liquid that is discharged via the peripheral launder of a
thickener
P80 The size through which 80% of the product particles will pass – usually
measured in micrometres (microns)
Particle Size A measure of the spread in particle size (grind)
Pegging The term used for screen or grate blockage by ore particles
Permit Holder The person that carries out the job or his / her immediate Supervisor at
the work site and who accepts the conditions on the permit for the defined
scope of the work
Permit to Work A signed statement by the Permit Holder and the Authorising Person that
a job may be carried out under stated precautions
Item Definition
pH The unit of measurement of acidity and alkalinity

The pH can be any number between 1 and 14
A pH value:
 Less than 7 is acidic
 Greater than 7 is alkaline
 Of 7 is neutral
Pinion A gear driving the mill by meshing with and turning the ring gear
Pneumatic Air operated / powered
Power Draw The amount of electrical power (i.e. measure of voltage x amps) being
used to drive a piece of electrical equipment
Power draw increases or decreases depending on the load being placed
on the equipment
Pre-start check A full check of the equipment before starting to ensure it is safe to
operate
Pulp A mixture of ground ore and water – also known as slurry
Pulp Density A measure of the concentration of solids in a pulp usually expressed as
either a percentage of solids or as specific gravity
Rakes Radial arms with ploughs that are attached to the thickener drive shaft
and slowly rotated around the thickener to plough the thickened solids
towards the central discharge cone
Recovery The amount of valuable mineral recovered in a process step usually
expressed as a percentage of the total amount of mineral contained in the
feed to the process
Recycle Refers to the thickener underflow being pumped back to the thickener
(Thickening) feed
Ring Gear The large gear mounted around the periphery of the mill driven by the
pinion gear
ROM Bin The Run Of Mine bin into which ore from the open cut is tipped
Roping Condition of the cyclone underflow resulting from too small a spigot (lack
of capacity) or too great a flow
Recognised by an extremely thick pulp stream of the same diameter as
the spigot with a rope like appearance
Sample A representative fraction taken from the stream for analysis, which is
used to determine plant performance
Sanded When solids have settled out of the slurry and caused a blockage in a
pipeline
Scats Worn pieces of grinding media that are discharged from the mill (trommel
oversize)
Scats can also be large particles of ore that are discharged from the mill
due to mill operating conditions or ore type
Scuttle Operation performed on a pump shutdown to remove slurry from the
pump and suction line to prevent bogging
Sedimentation Describes the settling of solids from a pulp or slurry
Shell The cylindrical section of the mill
Slurry A mixture of ground ore and water – also known as pulp
Item Definition
Snub Pulley Conveyor pulley used to increase the contact area between the drive
pulley and the belt
Spigot The cyclone orifice through which the underflow is discharged –
sometimes referred to as the apex
Sump Collection receiver for spillage – usually equipped with a pump
Tail Pulley Cylindrical drum around which the conveyor belt passes and is located at
the loading end of the conveyor
Tailings Process stream containing waste (gangue) material
Tech Taylor A valve designed so that a slurry stream from either of two pumps can be
Valve directed along a single pipeline automatically
A ball inside the valve moves to seal off the non-duty line
Thickener A large cylindrical tank that is used to dewater slurry by sedimentation
Torque Measure of the fluidity of the pulp bed within a thickener
(Thickener)
Trip Wire Emergency shutdown pull wire located along conveyor belts wherever
personnel access is available – also known as a lanyard
Trommel Screen A cylindrical screen attached to the discharge end of the mill used to
separate scats from the mill discharge to protect the mill discharge pumps
Trunnion End sections of the mill supported by trunnion bearings on which the mill
rotates
Underflow The coarse product of the cyclone that exits via the spigot or apex
(Cyclone)
Underflow The thickened pulp discharged from the thickener via the discharge cone
(Thickener)
Vortex Finder The cylindrical insert through which the cyclone overflow exits the cyclone
Weightometer An instrument used to measure the feed rate of a conveyor
Section 3 Operate Conveyor
3 Operate Conveyor
3.1 Operator Responsibilities

Conveyor operations are a crucial mining function. A good Conveyor Operator, apart from the
primary function of correctly running, monitoring and maintaining the conveyor system, needs to
be constantly aware of his / her surroundings to ensure a safe and productive operation.
Conveyor Operator responsibilities include:
 Knowing what is happening around the conveyor work areas
 Awareness of any person working above, below and near the conveyor work areas
 Not exposing co-workers to unacceptable risks
 Knowing about any work permits in progress in or near the conveyor work areas
 Understanding all the mechanical / electrical aspects of the conveyor system for which
you are responsible to ensure equipment is functioning correctly and within operating
limits
 Being proactive with observing and assessing conveyor operational problems to stop
the conveyor when required to avoid significant damage to the conveyor system
 Ensuring minimal spillage
 Ensuring that the conveyor is not overloaded
 Avoiding double handling
 Checking for slurry build up
 Checking for hydraulic leaks
 Recognising hazards around the conveyor system
 Reporting all safety and environmental incidents to the appropriate people and
according to procedures
 Operating the conveyor system safely and productively, taking care not to reduce its
service life or cause
3.2 Identifying Safe Operating Practices
3.2.1 Operational Safety Requirements

You must be aware of the general hazards and dangerous situations that exist around the
conveyor system equipment in your work area.
Ensure you are familiar with the safety policies and procedure relevant to your work area.
You must take appropriate precautions when working around conveyors. This has been
demonstrated by the number of accidents and incidents that have occurred in the workplace
over the years and which unfortunately continue to occur.
Conveyor operational safety includes:
 Not stepping or riding on any conveyor belt
 Not attempting to remove material from a moving conveyor
 Ensuring that no part of your body projects past the pull wire when cleaning near any
moving conveyor
 Not standing under the conveyor to avoid being hit with falling material
 Not stepping over, or in the case of low level conveyors, climbing under conveyor belts
 Using only purpose-built bridges and walkways when moving around a running
conveyor – it’ll take longer, but avoid serious injury
 Extreme care when walking anywhere near conveyors — materials often fall from
moving conveyors
 Not moving inside any guarded area of a conveyor
 Not removing any guards
 Reporting any missing guards to your Supervisor
 Using only a straight handled shovel when cleaning around any moving conveyors –
Do not use D-handled shovels
 Remembering that conveyors can be started automatically from the Control room –
Unless they are isolated do not work on them
 Never tapping jammed centre idlers while the belt is running
Frames must be tagged and the idlers freed or changed out with the belt stopped and
isolated.
 Taking precautions to keep hair, sleeves, trouser legs and other loose fitting clothing
from being caught on moving parts or controls when performing inspections
 Keeping the emergency stop lanyard in good condition and never using it for any other
purpose other than an emergency stop
Do not attempt to use an emergency stop lanyard as a means to isolate a conveyor.
 Being constantly aware of conveyor energy sources

These are:
 Moving conveyor
 Conveyor pinch points or nip points
 Pressurised fluids
 Heat
 Electricity
 Vibration of belt and other parts
 Radiation sources
3.2.2 Additional PPE Requirements

PPE equipment for conveyor operations in addition to your site’s basic requirements includes:
 Hearing protection
 Skin protection (when required)
 Torch – for use during the hours of darkness
 All tags and personal Isolation lock
 Gloves, face shields and fall protection devices must be worn when carrying out some
tasks
3.3 Crusher Operations Environmental Concerns

Environmental concerns that apply when you are operating crushing equipment that are in
addition to the HSE information covered previously, includes:
 Uncontrolled drainage and run off of contaminated water
 Emissions outside EPA guidelines
 Flora and fauna damage
 Control and clean-up of spills including Hydrocarbons
 Waste management and disposal as per site procedures
 Ensure that the required level of water quality is maintained
3.4 Pre-Start Inspections
3.4.1 Introduction
The primary reasons for pre-start inspections are to identify any maintenance and housekeeping
concerns, before they become serious problems and to identify any potential safety issues
before they become serious hazards.
If a conveyor has been left in an unsafe state or there are some incomplete maintenance items,
a pre-start visual inspection can identify these issues and avoid the potential of creating hazards
to personnel and / or damage and down time to the conveyor.
A pre-start inspection must be completed:
 At each shift changeover
 After a repair or servicing has been performed to check for damage or component
wear
3.4.2 Potential Pre-Start Hazards

Although the conveyor is not running for a pre-start inspection, there are some potential hazards
of which you must be aware.
These include:
 Conveyor movement
 Pinch points
 Slips and falls
 Faulty steps and ladders
 Sharp edges
 Head clearance
 Crushing
 Loose clothing and jewellery
 Pressurised systems
 Falling rocks
 Flammable material build-up
 Air pressure directed at you
If you have any safety concerns before starting or during the inspection process you can stop
and perform an appropriate hazard assessment.
If you are in doubt about anything you can refer to the relevant site policies and procedures, and
if necessary, discuss the concern with your Supervisor.
3.4.3 Conveyor System Pre-Start Inspection Requirements
3.4.3.1 Introduction
A pre-start inspection is performed in, under and around all the conveyor equipment and related
systems.
Use the prescribed checklist for the conveyor system being inspected.
Ensure that you are wearing all the required PPE for conveyor operations.
You must be a competent Operator or be with a competent Operator to perform pre-start
inspections.
3.4.3.2 General Conveyor System Inspections

A comprehensive pre-start inspection includes:
 Checking the area for personnel and ensuring they will not be affected by the
operation of the conveyor
 Checking for evidence of damage or component wear
 Checking affected equipment after repairs and maintenance have been completed
 Checking that the fire extinguisher system has all components available and housed in
their correct place
 Ensuring that safety showers are provided and are in a satisfactory working condition
 Checking all equipment associated with the conveyor is available
 Making sure safety lanyards are reset and working
 Identifying hazards, risks and defects in the work area
 Identifying all emergency stops
 Checking for oil leaks and spills, and manage as per site spill procedures
 Checking conveyor belt is ready for operation
 Checking belt for loose flaps of rubber, exposed wire or cuts
 Checking for wear lines on conveyor outer cover – if they exist assess conveyor
serviceability
 Checking belt for tracking problems – is the belt sitting in the correct position
 Checking for excessive build-up on rollers
 Checking the conveyor is not touching any structure
 Checking that all guards are in place (do not start the conveyor if guard/s are missing)
 Checking if any hatches, covers or doors are missing or left open
 Checking that electrical de-contactors are in place and field isolators are closed
 Checking there is no unfinished maintenance work
 Checking there are no foreign objects on conveyor belt
 Checking for isolation tags and complying with the tags instructions
 Ensuring that all lighting and directional indicators are in working condition – for night
shift operations
 Checking with the Control Room Operator to verify that no faults are displayed on
system consoles
3.4.3.3 Specific Checks for the Ball Mill Feed Conveyor

These checks include:
 Visually checking the position of the belt on tail drum
The belt should be central, but up to 50mm variation side to side is acceptable.
 Checking the security of the tail pulley under-speed switch and associated wiring
 Walking the conveyor and checking:
 That all guards are in place
 The skirting rubber for correct adjustment, trapped rocks / material and wear
 All carry and return idlers for wear, damage, excessive noise etc – attach a tag to
any frame which is carrying noisy idlers
 The return idlers for build-up of material
Warning : Do not attempt to clean any idlers while the conveyor is operating, unless this is done by
hosing down with water from a safe distance.
If manual cleaning is required, you must stop, isolate, lockout and tag the conveyor in
accordance with site isolation procedures.
 That the belt is tracking correctly

Damage to the edge of the belt and obvious rubber marks on the support
structure indicates that the belt has not been tracking centrally
 The security of all drift switches and emergency stop lanyards
 For excessive carry back of material
 Opening the head chute door and checking that the belt is tracking correctly around
the head pulley
 Checking the operation of the primary scraper for wear and correct adjustment – all
blades are to contact the belt evenly
 Checking the condition and security of the rubber impact block on the front face of the
chute
 Inspect the drive for oil leaks, heat build-up (hand touch) or abnormal vibration
If it is too hot to touch for 5-10 seconds, you should record the potential problem for
investigation
3.4.3.4 Specific Checks for the Weightometer

These checks include:
 Checking that the Weightometer is clean and that no ore is jammed in weigh-frame
Ore caught in the weigh frame can result in incorrect readings affecting feed rates.
 Checking the reading on the Weightometer’s local indicator against the DCS value
If the belt is empty, this is to read zero.
3.4.3.5 Post Inspection Tasks

At the completion of all pre-start inspections ensure that you:
 Manage and report all defects to your Supervisor and maintenance
 Identify and manage all active alarms
3.4.3.6 Pre-Start Sirens

Some conveyor systems are fitted with a start-up siren. Each time the conveyor is to be started
by an automatic sequence or local control, the siren sounds.
There is a pre-set interval between the finish of the siren and actual start-up of the conveyor
drive motor. This time delay is to allow any person near the conveyor to move clear.
3.4.4 Common Safety Inspections

When conducting pre-start inspections, operating inspections and during the course of your
assigned tasks, observe the condition of infrastructure and support equipment that you use
every day, but is not necessarily directly associated with the conveyor systems.
These common safety inspections include:
Stair treads for:
 Damage
 Security of treads
 Oil / grease spillages
 Rubbish, tools
 Pegging of the tread mesh
Access ways for:

 Damage to the mesh panels
 Security of panels
 Rubbish, tools
 Pegging of the tread mesh
Safety railings for:

 Damage
 Security
 Dust build up on rails
Hoses for:
 Correct stowage out of walkways
 Fastened with safety clips/fasteners
 Depressurised when not in use
Lighting and fittings for:

 Undamaged
 Secure
 Operating – report all lights that are not working to maintenance
 Providing sufficient light for any task at hand
Electrical Wiring for:

 Damage
 Evidence of arcing
 Security
3.5 Conveyor Start Up Procedures

Conveyor start up can commence when:
 All the pre-start inspections have been completed
 Any problems identified have been resolved,
 The pre-start siren (if fitted) has been sounded
Typical Start Up Sequence

Use the following sequence to start the conveyor.
1. Advise control that conveyor is available for sequence start-up – Automatic
or
Advise control to select manual mode for manual start-up
or
Locate local control station and start conveyor using manual control button
2. Check operation of conveyor including:
 Material is flowing freely throughout system from start to finish
 Load distribution is correct throughout plant
 Conveyors are tracking correctly
 Safety lanyards not fouled and in good condition
 Checking for any seized, collapsed, flat spot and noisy idlers
 Checking drive and tail pulleys are running freely without any rubber lagging lifting,
excessive wear, loose flaps of rubber and build-up of slurry or other material
 Checking belt cleaning equipment is working properly
Automated Starts
Most driven equipment items associated with conveyor systems can be started remotely or
automatically. Such equipment may start with no advanced warning.
Ensure that any equipment you are working on is correctly isolated and that you have attached
your Personal Danger Tag to the appropriate isolation point/s.
Start after Clearing a Blocked Chute

Additionally, to the standard sequence:
 Look for spillage around the conveyor
 Check the chute for damage
Start after a Belt has Tracked Off

Additionally, to the standard sequence:
 Check for damage to the belt
 Ensure that the skirt rubbers are in good condition
 Check the chute for excessive build up
 Call maintenance to track belt
Start after an Ore Surge

Additionally, to the standard sequence, check for ore surges as these increase the weight and
impact on the operation of the conveyor.
Start when there is Slurry on the Belt

Additionally, to the standard sequence check for slurry on the belt as this can cause spillage
from the conveyor.
Continuing Checks
Throughout start-up and operation of the conveyor system you need to continue your checking
and safety vigilance by using all your senses to monitor the conveyor’s performance. This
approach can be summarised as follows.
Look: for unusual occurrences, e.g. leaks, abrasions, obstructions, peeling, missing
guards, abnormal operations, deterioration of components, spillage
Listen: for unusual noises, e.g. bearing failures, strange sounds, warning alarms,
escaping gas
Smell: for burning and overheating, electrical equipment, rubber
Feel: for unusual vibrations, motor, temperature, electrical and hydraulic controls
Operating Conveyor Inspections

Shift handovers on conveyor system operations usually involve taking over a running conveyor.
Any equipment that is operated continuously is subject to wear and equipment failure making it
important for you as part of the new shift to complete a visual walk-around inspection as per
your site’s relevant procedures.
It is important to recognise signs of wear and the potential for component failure before the
problems develop into major equipment failures. Regular inspections and walk-around checks
are a valuable tool with helping to identify potential equipment problems.
Conveyor system Operator’s also conduct a start of shift inspection of all the process equipment
items in the conveyor system. They observe the plant during your normal day-to-day duties so
that any defects or abnormal operating conditions are identified before they cause mechanical
failures or disrupt production.
3.6 Conveyor Shutdown Procedures

Planned Shutdown
Use the following process for a planned and controlled shutdown of the conveyor system.
1. Check with control before automatic shutdown is performed.
2. Check belt is clear before manual shutdown is performed.
Run all feed off before shutting down conveyor.
3. Push the OFF switch for the conveyor
or
Use Lanyard line to turn off conveyor
4. Check:
 Transfer chutes are clear
 Fluid levels are normal
 For excessive spillage and clean up requirements, as necessary
 Conveyor belt components for security and wear
5. Identify and report defects during a post shutdown check.
Emergency Shutdown
Assess the risk of stopping the conveyor and determine if you need to:
 Move conveyor to a safe position
 Push the OFF switch of the conveyor – at a safe position
 Use the emergency stop
 Use the conveyor’s lanyard line pull wire– at a safe position
3.7 Conveyor Types, Components and Specifications
3.7.1 General Description

Mining industry conveyors are typically large and long complex endless flat belt systems that
run almost continuously moving ore and other crushed material over long distances.
The conveyor belt is looped between a head pulley and a tail pulley that are located at either
end of the conveyor. In between these two pulleys the belt is supported by idler rollers. The idler
rollers and the head and tail pulleys are mounted on the conveyor’s support framework.
Power to drive the belt is provided by a drive motor that is normally connected to the head
pulley, although on some conveyor configurations it may be connected to the tail pulley, or to a
drive pulley located along the length of the belt. The belt must be sufficiently tensioned to
prevent slippage on the drive pulley. This is provided by a belt take-up arrangement that is
located at either, the tail pulley or along the length of the conveyor.
Material is generally loaded onto a conveyor by means of a loading chute. This directs the
material down onto the centre of the belt. Rubber impact idlers are normally positioned under
the loading point to help absorb the shock of loading.
3.7.2 Conveyor Types

The types of conveyors being used in mining and other processing environments include:
 Belt Conveyors
 Bucket Elevators
 Vibrating Feeders
 Screw Feeder
 Chain Conveyors
 Enclosed Conveyors
3.7.3 Standard Belt Conveyor System
3.7.3.1 Overview
It is important for you to be able to:
 Identify conveyor components
 Understand the components functions
 Determine if the components are in good condition or will require maintenance in the
near future
The following diagram illustrates the configuration and main components of a typical belt
conveyor system.
The main components of a standard belt conveyor generally include:
Conveyor deck Return idlers

Conveyor belt Impact idlers
Drive motor and gearbox Skirt assemblies
Conveyor braking Belt scrapers
Drive pulley Belt ploughs
Tail pulley Tracking rollers
Snub pulleys Drift switches
Bend pulleys Safety lanyard
Take-up pulleys Emergency stop switch
Take-up assemblies Chutes
Carry / troughing idlers
Each of these components is described on the following pages.
3.7.3.2 Conveyor Nip Points

Due to the large numbers of idlers and rollers that are in contact with the conveyor belt, there
are many nip points on any conveyor system.
If you were to become caught in a nip point, you would find it virtually impossible to free yourself
with serious injury or worse resulting. Personnel in the mining and minerals processing
industries have been seriously injured through being caught in nip points.
Conveyor Nip Points are illustrated in the following diagram.
To restrict access to conveyers, exclusion zones are sometimes used to ensure personnel are
not exposed to the hazards of a moving conveyor belt. Exclusion zones are usually recognised
by a sign on or around the access gate on a conveyor walkway.
Note : Always ensure all conveyor nip points are guarded.

Never allow a conveyor to be operated with any of the guards removed.
3.7.3.3 Conveyor Deck

The steel frame or deck is the basic structure of the conveyor system. The bolted and welded
skeleton structure is the platform for the conveyor belt transport components that roll, i.e. the
rollers and idlers.
3.7.3.4 Conveyor Belt

Conveyor belts are usually constructed of layers or plies of cotton duck or synthetics such as
rayon and nylon, impregnated with rubber or PVC on both sides and edges.
The cotton duck provides the strength in tension, while the rubber or PVC lining provides
protection to the cotton plies from cuts, abrasion or deterioration. The rubber or PVC also
provides the essential bonding of the plies and provides the flexibility by forming an elastic
connection between them.
Many conveyors have a belt made of rubber, sometimes with steel reinforcement. Although
unlikely, there is always the potential for conveyor belts to ignite either through friction or from a
fire close to the conveyor. The ignition of rubber can produce significant heat and toxic smoke.
You need to be aware of the action required (see site procedures) in the event of a conveyor
belt fire.
The strength of the belting depends on the weight and number of plies in relation to the width of
the belt.
Good housekeeping prolongs the life of the belt.
Build-up of material around idler rollers can stop the roller from turning, which will result in the
roller being worn away by the friction of the belt. As the roller wears, it creates sharp edges that
have the potential to damage the belt.
3.7.3.5 Drive Motor and Gearbox

The Drive Motor and Gearbox assembly is known as a head drive, because it drives onto the
head pulley at the discharge end of the conveyor. Tail drives are also used in some installations.
The motor is coupled to the gearbox through a flexible coupling. The gearbox lowers the motor’s
output rpm to a speed suitable for conveyor operation. Decreasing the motor speed means an
increase in the power the motor delivers to the belt.
The type and size of the electric motor used to drive a conveyor is determined by the size and
length of the belt and the material it is designed to carry.
These photographs show a typical electric drive motor and the associated gearbox.
Conveyor Drive Assembly Gearbox Assembly
Where conveyors are on an incline, the gearbox may incorporate mechanical holdbacks. These
engage to stop the conveyor from running backwards under the weight of ore on the belt when
the conveyor is stopped. The holdbacks act as a back up to the conveyor brakes, where fitted.
Very long conveyor systems can be fitted with more than one drive. In a multi-drive assembly,
the current drawn and rotation speed of the drives must be carefully controlled and monitored. If
the drives were not correctly synchronised, the results would be counter-productive and cause
excessive belt wear.
Where required, motors may be of the variable-speed type to facilitate acceleration and
deceleration control. Belt speed can be matched to product flow to maintain optimum running
efficiency.
Additionally, some drive assemblies include flywheels, which significantly increase the inertia of
the drive assembly. The flywheels reduce the take-up travel during acceleration and
deceleration, and prevent excessive belt sag during a coasting stop.
The coupling from the gearbox to the pulley drive shaft may be rigid or in some circumstances
(e.g. where 3.3kV motors are used) a fluid coupling or a rotor resistance starter is used to
reduce starting shocks.
3.7.3.6 Conveyor Braking

Disc brakes, which may operate at a high or low speed, are fitted to conveyor drives in some
conveyor installations. Where fitted, they can be coupled between the electric motor and the
gearbox. The brake calliper is mounted on a common base plate.
3.7.3.7 Drive Pulley

Drive pulleys provide the moving force for the conveyor belt, which passes over them. In most
instances, the drive pulley also doubles as the head pulley. Drive power is supplied by an
electric motor / reduction gearbox assembly that is coupled to the pulley.
The surface of the pulley is usually covered in a lagging to increase the friction between the
pulley and the belt providing a more efficient drive.
This photograph shows an example of pulley lagging.
In some instances, drive snub pulleys are also used to improve the efficiency of the drive. These
are placed close to the drive pulley to allow more belt contact with the drive pulley than would
otherwise occur.
Pulley bearings can be fitted to the conveyor frame on adaptor sleeves and can have manual or
automatic grease lines for lubrication.
3.7.3.8 Pulleys
Although the physical design of the various types of pulleys is similar (i e. the tail, snub, bend
and take up pulleys) all serve different purposes within a conveyor system.
3.7.3.8.1 Tail Pulley

The tail pulley is located at the tail (feed end) of the conveyor. In some conveyor systems, the
tail pulley is also the drive pulley.
The tail pulley is mounted to the conveyor support frame, or take-up arrangement, via plummer
blocks and bearings.
If the conveyor is designed with a screw-adjusted take-up assembly, it is also generally added
at the tail pulley. In some cases, a tail pulley may incorporate a disc brake.
3.7.3.8.2 Snub Pulley

The snub pulley is located in close proximity to a head drive pulley. Its purpose is to cause more
of the belt to wrap around the drive pulley thus increasing the area of belt in contact with the
drive pulley.
This increases the friction between the belt and the drive pulley reducing the possibility of belt
slippage, as shown in the diagram.
3.7.3.8.3 Bend Pulley

Bend pulleys are normally used when a conveyor system is fitted with a gravity take-up system.
The bend pulley is used to change the direction of the belt from the horizontal or near horizontal
to the vertical.
A second bend pulley is then required to change the belt back from the vertical to the horizontal
or near horizontal.
3.7.3.8.4 Take-Up Pulleys
Take-Up Pulley
The take-up pulley transfers the downward force of the take-up weight to the belt. This
maintains a constant pressure on the belt so that it is correctly tensioned at all times.
The pulley is effectively located on the belt between two take-up bend pulleys and the take-up
weight is attached to the pulley’s spindle.
Take-Up Bend Pulley

Take-up bend pulleys are simple pulleys that the belt passes over to drop down and pass under
the take-up pulley.
3.7.3.8.5 Take-Up or Belt tensioning Systems
Three Types of Take-Up

The purpose of a take-up system is to absorb variations in the belt length due to:
 Belt stretch
 Dynamic load variation
 Slack side tension generated during start up
 Braked stops
Essentially, there are three types of take up functions that are available to maintain the tension
on a conveyor belt.
These are:
 Screw take-up
 Horizontal gravity take-up
 Vertical gravity take-up
These take-up assemblies are illustrated in the diagrams below.
In the horizontal and vertical take-ups, the counter-weight maintains belt tension.
Screw Take-Up
Screw take-up systems are used on the tail pulleys of short conveyors where only a small
take-up capability is required.
This type of system has an adjuster that slides the tail pulley in or out on guides to increase or
decrease belt tension. Adjustment is achieved by turning adjusting nuts.
Care must be taken to ensure that both sides are adjusted equally to keep the pulley at right
angles to the belt. If the pulley is out of alignment, the belt is tighter on one side and tends to run
off centre.
The drum scrubber feed conveyor is an example of a screw take up system.
The screw take-up system is used when:
 The weight of the belt and its load can be easily managed with a screw take-up
 Relatively little stretch of the belt is expected
 There is insufficient space to allow any kind of gravity take-up arrangement
Horizontal Gravity Take-Up

A horizontal gravity take-up system uses a rail-mounted tail pulley that is connected to the
suspended weight by wire rope and pulley blocks.
The primary screen feed conveyor is an example of a horizontal take-up configuration.
The horizontal gravity take-up system is used when the following five criteria apply.
1. The belt is long enough to warrant a gravity take-up.
2. The belt is heavy (wide) enough to warrant a gravity take-up.
3. The belt carries enough load to warrant a gravity take-up.
4. The belt may stretch significantly over time.
5. The conveyor does not have sufficient clearance above the ground to allow a vertical
gravity take–up to be used.
Vertical Gravity Take-Up

A vertical gravity take-up system uses a weighted take-up pulley that is suspended between two
take-up bend pulleys on the return side of the belt.
The secondary screen feed conveyor is an example of a vertical gravity take-up configuration.
The vertical gravity take-up system is used where the following five criteria apply.
1. The belt is long enough to warrant a gravity take-up.
2. The belt is heavy (wide) enough to warrant a gravity take-up.
3. The belt carries enough load to warrant a gravity take-up.
4. The belt is expected to stretch significantly over time.
5. The conveyor has sufficient clearance above the ground to allow a vertical gravity take-up
to be used.
This photograph shows an example of a vertical take-up suspended in a take-up tower.
This photograph shows a common variation of the horizontal take-up running the vertical ropes
from the tensioned pulley (located on a rail-mounted take-up trolley) through a sheave
arrangement to the counter-weight suspended in the tower.
3.7.3.9 Carry / Troughing Idlers

Carry idlers support the upper or working run of the conveyor.
These idlers are configured to form the belt into a trough to help prevent spillage. They consist
of a central idler that supports the loaded part of the belt and two inclined idlers that turn up
each edge of the belt. All three idlers in the set are mounted on a support bracket attached to
the conveyor support frame.
The weight of the belt and the load, forces the belt into a trough shape along its length.
The aim of this is to prevent the conveyor’s load from falling off during operations. In some
cases, troughing idlers are mounted on a frame that has the ability to swivel, assisting with
alignment and belt tracking.
Carry / troughing idlers are closely spaced along the load-bearing length of the conveyor.
Depending on the particular system, three or four idlers may be used to maintain the trough
shape. In some systems, there may be transition systems that transform the belt from the
troughed position on the troughing idlers to a flat attitude at the head pulley.
This photograph shows that some troughing idlers have a tracking role, i.e. they are pivoted at
the centre of the support so that they will swing and bring the conveyor back into alignment if
the belt travels sideways.
Long-distance conveyors may be designed with larger diameter idlers (to reduce power demand
and required belt strength) and the centre roller of a set may have heavier duty bearings.
3.7.3.10 Return Idlers

Return idlers are in place on the underside (i.e. the non-load-bearing side) of the conveyor and
support the lower or return run of the conveyor belt. As they only carry the weight of the belt
they are spaced further apart than the carry idlers.
Return idlers may have full-width, flat surface contact with the belt or make contact only at
intervals across the width of the belt. There is no need for the belt to be troughed on the return
side.
This photograph shows the return idlers as described above.
As with troughing idlers, some return idlers have a tracking role, i.e. they are pivoted at the
centre of the support so that they will swing and bring the conveyor back into alignment if the
belt tracks to one side.
This photograph shows a typical idler arrangement.
3.7.3.11 Impact Idlers

Impact idlers are used at the point where material is loaded onto the conveyor.
Impact idlers are made partly of rubber and are designed to absorb as much energy as possible
when the material hits the belt at transfer points. If left unprotected at these points, the belt
would soon wear through.
Therefore, impact idlers are used in sections where transfer chutes feed onto the belt and the
spaces between sets of impact rollers are generally shorter than for other types of idlers.
Depending on the design of the conveyor system, impact rollers may be an expendable item.
This photograph shows three types of Impact Idlers.
3.7.3.12 Skirt Assemblies

A skirt and skirting board assemblies are attached to the bottom of transfer or discharge chutes
where they load onto a conveyor.
The purpose of skirt assemblies are to:
 Confine material within the loading point impact areas
 Centralise the load as it is carried away by the belt
 Prevent any spillage of material as it feeds onto the conveyor
 Help minimise dust
Skirts are rubber strips that are attached to the skirting board via an adjustable clamping
arrangement. Skirting boards must not be allowed to come in contact with the conveyor belt.
They should be set at least 25mm above the conveyor belt and the gap closed by the rubber
skirt.
Additionally, any gap between the skirting rubber and the conveyor belt should increase in the
direction of belt travel to allow any material that becomes lodged under the skirt to be freed.
It is critical that skirt gaps (the gap between the bottom of the skirt and the surface of the belt)
are correctly set.
This diagram illustrates a cross-sectional view of a skirt assembly.
3.7.3.13 Vee or Plough and Belt Scrapers

One of the main problems associated with the transport of material on a conveyor is that a small
amount of the material tends to stick to the belt and get carried back on the return run. This is
especially prevalent if the material is wet.
This material can then be deposited onto the idlers and pulleys, causing accelerated wear and /
or tracking problems. To prevent this, belt scrapers are fitted to remove material from the carry
and return side of the belt.
These diagrams illustrate the two types of belt scrapers.
1. Vee or Plough Assemblies

Belt ploughs are designed to remove spillage or wet, sticky material from the underside
(non-carrying side) of conveyor belts. Their action prevents belt wear and damage to, or
jamming of, idlers and rollers. By removing material build up, belt ploughs also help to
maximise the belt’s traction over the drive pulley.
Ploughs are usually Vee-shaped and located as close as practical to the tail pulley and
have rubber inserts that make contact with the belt. They may also be located ahead of a
take-up pulley in some installations.
Where the belt is reversible, an H-type scraper is used to remove most of the residue from
the belt surface.
2. Belt Scrapers
This type of scraper is fitted at the head pulley to remove material clinging to the working
side of the belt. This ensures that the belt is not dropping material as it makes its return to
the tail of the system. It also helps to minimise belt wear.
Belt Scrapers are held against the belt by a pneumatic or spring device to maintain
constant contact with the belt.
To be effective, the scraper must be making contact with the belt across its full width.
However, it must not be forced against the belt hard enough to cause excessive wear.
Correct pressure of the belt scraper is maintained by a tensioning arrangement, as
illustrated in the photograph below.
Both Scrapers
Wear occurs on both types of scrapers.
When you are conducting walk around checks on the conveyor, ensure that the scrapers are
correctly adjusted and that any rubber inserts are not worn to the point where there is a danger
of the metal frame contacting the belt.
3.7.3.14 Tracking Rollers

Tracking rollers on each side of the conveyor belt help compensate for variations in the belt’s
load and ensure that the belt tracks correctly along its entire length at all times.
If the load is not correctly centred on the belt, there is a tendency for the belt to track to one side
or the other or from side to side depending on the loading caused by the material on the belt.
When variations in tracking occur, the belt comes in contact with the tracking rollers causing
them to swivel forward forcing the belt to track back towards the centre.
Your main task with regard to belt tracking is ensuring that the belt conveyor framework is
correctly aligned and that the belt is correctly spliced.
This photograph shows the tracking rollers near the edge of a conveyor belt.
3.7.3.15 Drift Switches

Belt Drift Limit Switches, also known as side-travel switches, are installed to ensure that any
damage is minimised if the belt begins to track off line. The switches are usually attached to
small rollers located on each side of the belt at strategic locations, e.g. the head of the conveyor
on the upper side, the tail on the return side or where the belt is snubbed.
If the belt starts tracking off line, it contacts the small roller and activates the limit switch. This
trips the conveyor (and any interlocked equipment items) and raises an alarm on the DCS.
A belt drift switch by-pass switch is located on the local control station so that the belt can be
restarted to correct tracking.
The belt cannot be restarted until the drift switch has been manually reset. In order to reset the
belt, a drift switch override system may need to be operated.
There are typically two types of drift limit switches used on mining conveyor systems.
1. Proximity switches (green)
These activate when the electrical circuit within the switch registers the steel wire running
through the conveyor.
2. Mercury tilt switches
These activate when tilted more than 15° from the vertical roller arm drift switch (as shown
in the photo below). When the arm is moved more than a set distance away from the
vertical, the switch trips and stops the conveyor.
Once set, a belt drift switch must not be moved or adjusted, as it will fail to activate.
3.7.3.16 Emergency Stop Devices

Two types of emergency stop devices are typically used on the conveyor systems.
1. Conveyor lanyards
2. Emergency stop buttons
The activation of either of these devices immediately stops the equipment item associated with
the emergency stop and any other interlocked equipment.
Note : Emergency stop devices must not be used as an alternative to an isolation procedure
when conducting maintenance tasks.
To prevent personal injury and effectively isolating equipment, you must stop, isolate,
lockout and tag the equipment in accordance with site isolation procedures.
3.7.3.16.1 Safety Lanyards

Conveyor lanyards are plastic-coated wires that run along the side of a conveyor. The wires are
connected to a safety stop switch that is generally located at the midpoint of the conveyor. The
stop switches are activated stopping the conveyor by an increase or decrease in wire tension,
e.g. by somebody pulling the lanyard.
This ensures that:
 In an emergency situation, the conveyor can be stopped from anywhere along its
length by pulling on the lanyard
 If the lanyard breaks or comes loose from its fastenings, the conveyor stops and
cannot be restarted until the problem is rectified
This action also prevents an undue amount of slack developing in the lanyard making
activating the switch difficult,especially if you are trying to activate the switch with your
clothing caught in the conveyor.
When activated, the stop switch sounds an alarm in the control room and must be reset before
the conveyor can be restart. To reset the stop switch, press the reset button located on the
underside of the stop switch.
This photograph shows a Dongrif type Safety Lanyard Switch
One switch controls a length of the conveyor system, typically of 200–300m. The switches are
designed to trip if the lanyard is pulled or if the tension on the switch is released, e.g. the
lanyard is broken.
The state of the switch can be identified by either:
 A button on top of the switch – if the button is raised, the switch has been activated, or
 The position of the rotary activator – if it is at the 11 o’clock position, the switch has
been activated
This photograph shows an AVH type Safety Lanyard Switch
When the switch is activated, all equipment up to that point in the production chain is stopped.
All affected equipment, including the safety lanyard switch must be manually reset before the
conveyor can be restarted.
Note : Do not hesitate pulling a lanyard switch if you consider there is any danger to you or a
co-workers safety or to equipment.
Warning : Identify the cause of the fault before resetting the pull wire switch.
The switch may have been activating accidently by:

 Rocks hitting the lanyard
 A cold morning may contract the lanyard cable if it is too taut
 Edge damage to the conveyor belt
3.7.3.16.2 Emergency Stop Buttons

Emergency stop buttons are located on the Local Control Station (LCS) for each driven
equipment item and are coloured red for easy identification.
Emergency stop buttons are activated by firmly pushing inwards on the button face.
If an emergency stop button is activated, it must be reset before the equipment item can be
restarted. To reset an emergency stop button, pull the button firmly outwards.
Some local control stations incorporate an emergency stop switch that if pressed has the same
effect as pulling a lanyard safety switch, i.e. an alarm is raised and all equipment up to that point
in the production chain is stopped.
The emergency stop button must be reset before the conveyor can re-start.
3.7.3.17 Chutes
Chutes are located where material is loaded onto a conveyor.
Their function is to transfer the material onto the centre of the belt and help prevent spillage that
would otherwise be caused by material bouncing off the belt due to the impact of loading.
Conveyors also have a head / transfer chute that is used to control and direct the material as it
discharges from the conveyor. In most instances, these contain a replaceable striker / wear
plate arrangement that prevents wear to the back wall of the chute.
Chutes are inspected at regular intervals for wear and any build-up of material that can cause
blockages.
3.7.4 Other Conveyor Components and Equipment
3.7.4.1 Introduction
Conveyor systems can also be fitted with a range of other equipment items for specific
operations of operating conditions.
These specialised equipment items include:
 Under-speed sensors
 High burden detectors
 Weightometers
 Metal detectors
 Tramp metal magnets
 Belt rip detectors
 Transfer stations, including blocked chute probes and air cannons
 Pre-start sirens
 Local control stations
 Vibrating feeder / Conveyors
Each of these equipment items are described on the following pages.
3.7.4.2 Under-speed Sensors

The under-speed detector works by comparing the speeds of the drive motor and pulley. It may
be either a centrifugal switch driven by a return idler or a proximity switch, which is an electronic
device that has no physical contact with the tail pulley. If the belt runs slow, power to the motor
is cut off.
Speed sensors are fitted to the tail pulleys to detect:
 Belt slip
 Drive equipment faults
 Broken belt
If any of the above conditions are detected the under-speed sensors activate and stop the
conveyor drive motor.
Pulley under-speed can be caused by:
 Overloading
 Belt insufficiently tensioned
 An object jamming a belt or pulley, e.g. a rock
 Belt broken in half
 Damaged or faulty under-speed unit, e.g. coated in dirt or grease
 Mechanical / electrical problems with the drive assembly
 Wet weather
Speed sensors are also used in conjunction with Weightometers to provide an indication of the
tonnes per hour that are being transported on the conveyor.
This photograph shows an under-speed sensor installed near a Pulley
3.7.4.3 Weightometers
A Weightometer or belt weigher is a special set of idlers (called a load cell) mounted on a frame
in place of a normal roller frame. The idlers drive a tacho-generator providing electronic input.
This diagram illustrates to main components of a Weighometer.
The purpose of the Weightometer is to provide an accurate measure of the weight of material
being transported on the conveyor. The information is calculated by the controlling Process
Logic Control (PLC) system.
The Weightometer provides useful figures for production purposes, e.g. determining how many
tonnes of material per hour are being fed on a conveyor or determining how many tonnes of ore
have been transported in a given period, such as a shift or a day.
These figures are then recorded and combined to create other figures, e.g. monthly and annual
production figures.
To provide an accurate reading, the speed of the conveyor is measured across the weigh cell.
This photograph shows the Weightometer weigh cell
Any conveyor that is fitted with a Weightometer is also fitted with a speed sensor.
The PLC system makes the necessary calculations to provide the Tones Per Hour (TPH)
indication that is required. Weightometers are calibrated regularly using a known weight to
ensure that accuracy is maintained.
Weightometers need to be housed in protective enclosures, so that their accuracy is not
affected by heat or wind. The Weightometer must be kept clear of build-up or the accuracy of
the weight reading is affect.
This photograph shows the Weightometer Local Control and Calibration Station
3.7.4.4 High Burden Detector

The purpose of the high burden detector is to prevent high loads on the belt from reaching either
the metal detector or the tramp metal magnet. Therefore, it is located upstream of these
devices.
The high burden device consists of a steel plate hanging vertically on hinges above the belt at a
set height. When material on the belt strikes the plate it moves away from the vertical, switches
off the conveyor and activates an alarm. It also acts by physically knocking down any high
loads.
Alternatively, the high-burden switch may consist of a cord across the belt. The switch is
activated if the cord is broken. However, in this situation, the cord cannot be tied back together
after a break. It must be replaced.
The main causes of high burdens are surges from the stockpile feeders or rocks lying
awkwardly on the belt.
This photograph shows a conveyor loaded with rocks fitted with a High Burden Detector
3.7.4.5 Metal Detectors

Metal detectors are fitted to a frame that straddles the conveyor belt. When sizeable metallic
objects are detected, the sensors react to shut down the conveyor. As a conveyor cannot be
stopped immediately, the section in which the metal was detected is significantly downstream in
relation to the detector.
This photograph shows a metal detector straddling a conveyor belt
To compensate for this, some metal detectors incorporate a mechanism that drops a brightly
coloured flag onto the conveyor where the metal is detected. Although the flag will not be
positioned exactly at the point where the tramp metal was detected, this system assists the
Operator to rectify the problem and get the conveyor operational again as quickly as possible.
Alternatively, the Operator may know how far along the belt to look for the tramp metal based on
experience.
Metal detectors may also be located after the tramp metal magnet (described on the next page)
to stop the conveyor automatically if any metal not picked up by the magnet is detected.
A metal detector’s used on iron-ore conveyors must be designed to prevent the iron ore
activating the device. This means incorporating methods to detect the higher electrical
conductivity of metals, e.g. stainless steel is detected while iron ore is ignored.
Metal detectors can be programmed to ignore the:
 Steel core material in belts by automatically compensating for a constant amount of
metal beneath
 Increased amount of metal at a belt splice
This is achieved by placing a splice detector ahead of the metal detector. The splice
detector responds to a tag incorporated in the belt by sending a signal to the metal
detectors to reduce its sensitivity as the splice in the belt approaches the detectors.
3.7.4.6 Tramp Metal Magnet

The purpose of the tramp metal magnet is to remove ferrous metal items from the material on
the belt to prevent them from damaging downstream equipment and processes.
Tramp metal magnets (electromagnets) are installed over conveyors in locations where tramp
metals (i.e. ferrous) may occur. The magnet must be mounted high enough above the ore flow
so that it does not pick up iron ore.
This photograph shows a Tramp Metal Magnet suspended above a conveyor system
The tramp metal trash can include excavator bucket teeth, steel wire, chain, lost hand tools and
any other items that find their way into the ore flow. Sometimes, there may be metal deeply
buried in a lump of ore. If left uncontrolled, these items would cause damage to conveyors,
crushers and other equipment items used in the processing of the ore.
Under normal conditions the magnet operates on partial power. If an upstream metal detector
senses tramp metal, power to the magnet is increased to 100% to ensure the removal of the
metal contaminants.
Warning : An operating tramp metal magnet is surrounded a very strong magnetic field.
If you are doing to be working near a magnet always remove any loose metal items from
your person because it you don’t the magnet will.
To be effective, the magnet must be positioned over the belt while the conveyor is running. The
PLC will shut down the conveyor if the magnet is moved clear of the belt while it is running.
Some magnet types must be cleared at regular intervals. This is achieved by moving the
magnet over the trash chute and cutting the power to the magnet allowing the tramp metal to be
released into the trash chute and into the trash bin for later disposal.
In some locations the magnet is controlled manually from a local control station.
Other magnet types are self-cleaning and do not need to be shut down for cleaning if the
mechanism is operating correctly. In a self-cleaning system, the magnet picks up the metal, lifts
up and moves across to the tramp metal chute where the power is reduced to the magnet to
release the tramp metal into the bin for removal. The magnet then automatically travels back to
its parked position over the belt.
3.7.4.7 Belt Rip Detectors

The purpose of the belt rip detector is to identify a rip in the belt before it becomes serious
requiring an entire belt replacement.
Belt rip detectors are used in locations where there is a chance that the carry surface of the belt
can become sufficiently damaged requiring the conveyor to be shut down for repairs.
There are three types of belt rip detectors.
1. A belt rip detector that uses a thin, tensioned line stretched across the width of the pulley to
hold a switch in the Run position.
If the belt becomes torn, fibres and rubber strands protrude from the belt’s surface as it
travels past the rip detector tension line. When the line is broken, the switch springs to the
Off position, the conveyor is shut down and an alarm is raised through the control system.
This type of detector is usually installed between the tail pulley and the tramp metal
magnet.
This photograph shows a Single Type Belt Rip Detector
2. A belt rip detector that uses a light beam and magic eye for monitoring a position across
belt’s surface on its return.
At this point, the belt is flat (not troughed) and is carrying no load. A broken beam indicates
that something is hanging from the belt.
3. A belt rip detector that uses a pan fitted underneath the belt usually located immediately
after a drop box.
If the pan tilts because material has fallen through a rip in the belt, it activates a proximity
switch tripping and stopping the belt. The use of this device depends on regular inspection
and cleaning of the pan.
This photograph shows a Pan Type Belt Rip Detector
3.7.4.8 Transfer Stations

A transfer station is a point where ore falls through a chute or drop-box onto the head of a
conveyor belt.
The inside of a chute normally contains a series of ledges designed to break the fall of the ore
and therefore prevent damage to the belt or other equipment that is receiving the ore. The
ledges are protected by wear plates of special, hardened steel to resist the abrasive action of
moving ore.
The wear plates are bolted into place and may sometimes become dislodged or wear out. If
they are not replaced, the ore causes wear in the shell of the transfer chute, resulting in holes
and spillage.
Side inspection doors may be provided to allow access for inspection and to remove oversize
ore, pieces of wood or other foreign materials that can cause blockages or partial blockages of
the chutes.
Transfer stations have two methods of detecting and clearing blocked chutes.
1. Blocked Chute Probes
2. Air Cannons
Blocked Chute Probes

Transfer chutes often include a blocked chute probe to indicate rising ore due to chute
blockages and to trip a switch that shuts down the conveyor.
The alarm can only be cleared and the conveyor re-started when the probe is hanging vertically.
There may be one or more doors in the side of the chute to allow access to probes.
Three types of probes can be used in chutes to detect blockages.
1. Mercury Probes
A mercury probe activates the alarm when it is tilted more than 150mm from the vertical,
regardless of direction of tilt.
This photograph shows a Standard Mercury Probe
2. Microwave Probes
Microwave Probes send a signal to a receptor unit and if the signal is interrupted by rising
ore, the feed stops.
3. Radiation Probes
Radiation Probes use a bead of radioactive Cobalt-60 to send a beam to a receptor unit
and if the beam is interrupted by rising ore, the feed stops.
The radiation probe is housed in a yellow-painted, lead-lined container.
Warning : Do not disturb or interfere in any way with a radiation source. Radiation Probes can only
be handled by trained and authorised personnel.
This photograph shows a Radiation Probe
Air Cannons
The purpose of the air cannons installed in some transfer stations is to keep the chute clear of
excess ore build-up by periodically blasting the chute with air. The interval between firings is
under PLC control.
A warning alarm or siren is sounded before each firing.
This photograph shows an Air Cannon Receiver Tank
3.7.4.9 Local Control Stations

Local control stations are provided at various points on the conveyor system. These allow an
Operator to start and stop a conveyor under local control.
When a conveyor local control has been locked into the off position, the conveyor cannot be
started manually or automatically from the control room.
Where the control station allows reversing, the Operator manually holds a spring return reverse
switch in the reverse position while pressing the start button.
This photograph shows a Conveyor Local Control Station
3.7.4.10 Vibrating Feeders / Conveyors

Vibrating feeders are mainly used to move material short distances only. They normally have
variable speed drives that are used to measure the flow of material to the equipment being feed.
Although these items of equipment are called feeders, they are a form of conveying because
they move material from one part of the process to another.
This photograph shows an operating Vibration Feeder
Section 4 Perform Operator Maintenance
4 Perform Operator Maintenance
4.1 Overview
4.1.1 Maintenance
The dictionary meaning of Maintenance is simply, the act of maintaining and the state of being
maintained.
Maintenance to industry is any activity carried out on plant and equipment to:
 Ensure that the equipment continues to perform its intended functions
 Repair or replace any equipment that has failed
 Keep the equipment running
 Restore to its favourable operating condition
4.1.2 Preventive Maintenance (PM)

Definition
The definition of Preventative Maintenance is, maintenance tasks conducted at regular
scheduled intervals based on average statistical and anticipated lifetime to avoid failure.
PM tasks can include inspection, service and / or replacement as required.
Task intervals can be scheduled by date or hours of operation.
Background
For many centuries there was no strategy associated with the repairs to equipment and
structures. People were driven to maintain something by the importance of the items for their
needs. For example, a leaking roof. Up to less than 200 years ago there was very little or no
concept of inspecting a roof to check for weaknesses that may require repairs. The thought
never occurred to people until water was coming through the ceiling.
It wasn’t until 1950 that some Japanese engineers started a new concept in maintenance that
consisted of following the manufacturers’ recommendations regarding care, operation and
maintenance of the equipment, machines and other devices. This new trend was called
Preventive Maintenance.
Conveyor Systems Preventative Maintenance

Preventive maintenance actions through effective shift inspections ensure that conveyor system
equipment is operating to maximum efficiency at all times and unnecessary down time is
prevented. Equipment downtime increases operating costs and reduces the supply of material
for production at the plant.
The key objectives of preventative maintenance are to reduce breakdown maintenance to a
minimum, schedule required maintenance to ensure effective use of maintenance, labour and
resources. All necessary maintenance and repair tasks are scheduled and carried out during
scheduled shutdown periods.
It is only during these shutdown periods that maintenance and repairs can be carried out without
the additional costs that result from unscheduled downtime.
The necessary preparations required to ensure that all items of equipment have the required
corrective or preventative maintenance completed with maximum use of the downtime achieved
include:
 Keeping records of equipment that require maintenance
 Noting predictable wear-out points
 Ensuring that appropriate specialist tools are available
 Planning the tasks to ensure that they can be completed within the shutdown period
 Conducting condition monitoring of the equipment
 Gaining experience with the equipment
 Learning from co-workers
Preventative maintenance tasks on the conveyor system include:

 Inspections
 Lubricating
 Adjusting
 Cleaning
 Testing
Results of a Successful Preventative Maintenance Programme

Your understanding and positive contribution to maintaining a successful preventative
maintenance programme for the conveyor system can be measured by:
 Fewer failures
 Safer work area
 Fewer emergency breakdowns
 All work being planned
 Reduction in labour costs
 Effective use of labour
 Extended equipment life
 Improved equipment operation and efficiency
 Less down time
 Maximum production output
4.2 Maintaining Conveyor Components
4.2.1 Introduction
Over the life of a conveyor system most, if not all, components and related equipment will
require some form of maintenance. The maintenance can involve anything from the total
replacement of a component to a minor adjustment.
There are many critical components and items of equipment in a conveyor system that required
specific maintenance tasks to be performed regularly and to a schedule.
These components and items of equipment include:
 Conveyor Deck
 Conveyor Belt
 Drive Motor and Gearbox
 Conveyor Brakes
 Pulleys
 Idlers
 Skirts
 Scrapers
 Tracking Frame
 Belt Drift Switches
 Emergency Stop Devices
 Under-speed Sensors
 Weightometers
 High Burden Detectors
 Metal Detectors
 Tramp metal Magnets
 Belt Rip Detectors
 Transfer Stations
 Local Control Stations
The maintenance requirements for each of these components and items of equipment are
described on the following pages.
4.2.2 Conveyor Deck

The integrity of the deck is essential for the correct and safe functioning of the whole conveyor
system.
Maintenance inspections include checks for:
 All sections of the metal substructure
 Ore build-up and signs of damage
 Damage to steelwork or footings
 Corrosion to steelwork or footings
 Damaged or loose grid mesh
Any damage to the deck must be reported immediately.

All build-up must be cleaned away so that it does not interfere with the operation of rollers or
idlers.
4.2.3 Conveyor Belt

Conveyor belt maintenance inspections include checks for:
 Top cover wear or de-lamination
 Longitudinal grooving
 Abrasion loss at belt edges
 Excessive wear to bottom cover
 Longitudinal grooving of bottom cover
 Gouging or stripping of bottom cover
 Damage to or abrasion of edge rubber
 Wavy abrasion loss of top cover
These types of conveyor belt wear and damage are described below.
The following photo shows an example of a belt rip switch
4.2.3.1 Top Cover Wear or De-Lamination

This condition is identified by the black marks on the top cover of the belt or de-lamination (i.e.
layers coming apart) over the whole length. It can occur over the full belt width or be confined to
a narrow strip.
Possible causes of this condition, as illustrated in the photo below include:
 A seized idler that has been worn away and is slicing off the top rubber cover (a potato
peeler)
 An under-tensioned U-type scraper that is vibrating
 Abrasion caused by loss of rubber lagging from a bend pulley
 Skirt boards not properly adjusted
This photograph shows top cover wear or delamination
4.2.3.2 Longitudinal Grooving of Top Cover

 Materials built-up on the return side rub against the belt surface
 Material build-up at head pulley
 Worn casing of return idler
 Seized return idler
This photograph shows longitudinal grooving to the top cover
4.2.3.3 Abrasion Loss of Belt Edge Top Cover

 Worn casing of return idler
 Material build up
 Skirt boards not properly adjusted
This photograph shows abrasion loss to the top cover
4.2.3.4 Excessive Wear to Bottom Cover

Possible causes of this condition usually occurs over the full length of the belt, as illustrated in
the photo below include:
 Seized trough idlers (potato peeler)
 The belt scraper rubber plate has worn out, i.e. scraper frame is contacting belt
This photograph shows wear to the bottom cover
4.2.3.5 Longitudinal Grooving of Bottom Cover

 Embedded steel rings in the impact idlers have appeared and are contacting the belt
 Carrying materials have been trapped between the belt and the belt scraper
This photograph shows longitudinal grooving
4.2.3.6 Gouging or Stripping of Bottom Cover

Possible causes of this condition, as illustrated in the photo below include the tracking frame
servo idlers being worn away and cut off by the belt with the belt having tracked over the idlers.
This photograph shows gouging marks on the belt
4.2.3.7 Damage to or Abrasion of Edge Rubber

 Abrasion from seized servo rollers
 Belt contacting conveyor framework through poor tracking
 Worn casing of return idle
This photograph shows edge damage
4.2.3.8 Wavy Abrasion Loss of Top Cover

 Improper instillation of U-type cleaner causing belt vibration
 Material build-up on the return idler just behind the U-type cleaner causing the belt to
vibrate during operation
This photograph shows wavy abrasion
4.2.3.9 Drive Motor and Gearbox

While the size and number of the electric motors used to drive a conveyor may vary, the checks
carried out by the Operator are essentially the same.
 Unusual noise from the motor
 Excess heat and vibrations
 General condition of motor and area
A number of different oils are used throughout the conveyor gearboxes in the plant and care
should be taken to select the correct oil used in that specific gearbox. Refer to the relevant oil
type list for the particular equipment.
Typical Operator checks on the reduction gearbox include:
 Unusual noise
 Excess heat and vibration
 Fluid leaks from gearbox
 Oil level – check with dipstick and top up if required
 General condition of gearbox and surrounding area
Always report any problems related to the drive motor or gearbox to the Shift Supervisor as
soon as practicable.
4.2.3.10 Conveyor Brakes

 Unusual noise
 Excess heat or vibration
 General condition of area
eme
4.2.3.11 Pulleys
The maintenance inspections for pulleys include the Drive, Tail, Snub, Bend and Take-Up
pulleys.
The pulley shells have a bonded rubber lagging with the tail being plain and the head or drive
pulley having a diamond tread pattern. This helps to enhance belt traction and prevent
aquaplaning.
Warning : Belt tracking can change if water is placed between pulley lagging and the conveyor belt.

 Clean surfaces and in good repair
 Irregular wear on the pulley lagging – uneven lagging wear can cause additional
stress on the conveyor belt resulting in poor tracking
 Lagging damage, e.g. cuts, tears or missing sections
 Free rotating
 Material build-up between belt and pulley
 Abnormal bearing noise
 Excessive bearing or housing temperature
 Excess vibration of shaft
 Any grease leakage or wear of oil seals
 Looseness of cap or mounting bolts
This photograph shows excessive material build-up around the head
Maintenance inspections for the take up assembly include checks for:

 Corrosion or damage to wire ropes, trolley, sheaves and counterweight
 Condition of take-up winch
 Build-up or spillage
4.2.3.12 Idlers
The maintenance inspections for idlers include carry / troughing, return and impact idlers.
Conveyor idlers are supplied fully lubricated, tested and ready for operation. Do not attempt to
add any additional lubrication to any idler.
 Free rotation of all rollers
 Noisy idler bearings
 Collapsed idler bearings
 Seized idler bearings
 Seized idler from material build up or jammed rocks
 Collapsed rubber discs in impact area
Warning : Never attempt to free a seized idler unless the conveyor has been shut down and isolated.
Use the following procedure to report a faulty idler.

1. Complete an Out of Service tag.
2. Tie the detachable section to the structure adjacent to the faulty idler.
3. Upon completed of your inspections, return the tags to the collection point.
4. Report the faulty idler/s to your Supervisor.
A seized idler can quickly lead to major belt damage if not detected early. As the belt continues
to run across a seized idler a flat spot is worn in the belt causing excessive belt wear. If not
repaired in a timely manner, the worn idler eventually wears through leaving a knife-like edge
that will peel away the belt layers. This situation is commonly referred to as a potato peeler.
Troughing idlers are normally numbered on the wide side of the conveyor catwalk. The
numbering is in sets of five from the tail pulley.
Return idlers are identified by noting their position in relation to a numbered troughing idler. This
system makes it easier to identify damaged or malfunctioning idlers.
The following photos show some of the more common problems found with worn and faulty
idlers.
Vee Return Idler – split casing Corroded and Damaged Return Idler
Holed Return Idler Seized Return Idler
Seized Return Idler Potato Peeler
4.2.3.13 Skirts
Maintenance inspections include checking all skirts at transfer points to ensure that the boards
are properly adjusted to provide the required gap.
If the gap is too wide, the skirt is not effective.
If the gap is too tight, the skirt causes wear along the length of the belt.
The skirt is correctly adjusted when it is barely touching the belt.
A groove close to the edge of the belt is often a sign of an incorrectly adjusted skirt.
Spillage indicates that a gap is too wide.
If skirts are becoming worn, they must be replaced as soon as possible.
4.2.3.14 Belt Scrapers

 Ensuring that the scraper is in contact with the belt
 The general condition of the scraper blade — particularly for unacceptable wear
 All scraper blocks are in place on an H-type scraper
A chattering noise associated with a scraper blade may indicate too much tension or that it has
been inclined to the belt at an incorrect angle.
Note : The scraper steel support must not be in contact with the belt.
4.2.3.15 Belt Ploughs

 Scraper in full in contact with the belt
 The general condition of the scraper blade and plough body
 Linkage points and Bolts for wear
 Safety Chains are in place and secure
This photograph shows belt plough in operation
4.2.3.16 Tracking Frame

Tying back a tracking frame to keep the conveyor running is an acceptable short-term
adjustment. However, the reasons why the belt is tracking off must be investigated as soon as
possible and rectified.
This illustration shows the Handlebar method of adjusting the tracking frame
When a tracking frame has shifted, the easiest way to remember which way to turn a tracking
frame to move a belt across is the handlebar method, as shown in the illustration above.
Stand facing the direction that the belt is travelling and turn the tracking frame as you would a
set of handlebars, i.e. turn the frame in the direction that you want the belt to move.
Warning : Always test the tracking frame by pulling it towards you to avoid the possibility of falling
onto the conveyor.
4.2.3.17 Belt Drift Switches

Causes of Belt Drift
The causes of belt drift include:
 A partially blocked transfer chute causing feed to drop onto one side of the belt
 A tracking idler frame jammed to one side
 Build-up of damp fines on the tail pulley
 Rocks or material build up jammed between belt and framework
 Water on the belt from hosing or rain
If any of these conditions occur, the relevant drift switch may activate and will have to be reset.
Inspecting the Switch

A proximity switch must be reset after the belt has tracked clear of the switch face.
Note : Before resetting the fault, always find the cause of the belt drift and rectify the problem.
If a proximity switch is considered to be faulty, the procedure for checking is to pass a piece of
metal in front of the switch face to simulate activation. The Control room advises if the alarm has
been raised. If so, the switch is operational.
If a mercury tilt switch has been activated, rectify the fault (if possible) and return the switch to
the vertical position. This clears the alarm.
A roller arm drift switch moves out of its set position when activated.
It is important to check all belt drift devices to ensure that the probes or arms have not become
bent, broken or seized.
Correcting the Belt Drift

Use the following procedure to reset belt drift.
1. Contact plant control and have the conveyor put into manual.
2. Find the cause of the drift and rectify.
3. Go to the local start station and start the belt.
4. Track the belt to its normal running position.
5. Check with plant control that the alarm has cleared.
6. When tracking is satisfactory return the belt operation back to the control room.
4.2.3.18 Emergency Stop Devices

 All switches and general condition of the switch box
 Ensuring the lanyard does not have excessive slack – it should be taut
 Ensuring the lanyard is in good condition, i.e. not frayed or cut
Warning : The emergency pull-wire does not make the conveyor safe for maintenance and it is not
an acceptable method of isolation.
The cause of the fault must be identified before resetting the pull wire switch.
If the switch has not been activated by a person pulling the wire, the cause may be:
 Rocks hitting the lanyard
 A cold morning, causing contraction of the lanyard cable (if it is too taut)
 Edge damage to the conveyor belt
Safety Lanyard
When a safety lanyard or emergency stop switch is activated, all equipment up to that point in
the production chain is stopped. All affected equipment, including the safety lanyard switch,
must be reset manually (i.e. under local control) before the conveyor can be restarted.
Dongrif Switch
If the switch is of the Dongrif type, the smaller button is raised when the switch has been
activated. Reset the switch by pulling up the large button. This causes the small button to retract
to its normal position indicating that the switch has been reset.
AVH Switch
If the switch is of the AVH type, the actuator is in the 11 o’clock position when the switch has
been activated. Reset the switch by turning the actuator clockwise. Reset is indicated by the
arrows on both sides of the switch block.
Control Room
Contact the control room to confirm that the switch/es have been reset and the conveyor is
ready for restart.
4.2.3.19 Under-speed Sensors

To reset the conveyor following an under-speed alarm:
1. Find the cause of the alarm, if possible and rectify.
2. Contact the control room and hand control of the belt back to the control room Operator.
4.2.3.20 Weightometers
 Build-up
 Spillages
 Hose – clean if required
4.2.3.21 High Burden Detectors

To reset a high burden alarm:
1. Contact the control room to switch the conveyor to manual control.
2. Make sure the magnet is clear of the belt.
This is an automatic function on some belts and the magnet will move back into position
after a short delay once the conveyor is restarted.
3. Start the conveyor from its local station.
4. Ensure the high burden switch is in its normal operating position.
5. Place the magnet back over the belt.
6. Return conveyor operation to the control room Operator.
If the high-burden switch is a cord type, the cord breaks to activate the high-burden alarm. The
conveyor must be isolated before the cord can be replaced.
4.2.3.22 Metal Detectors

Regularly inspect metal detectors for build-up of ore at the base of the detector. Hose the area
clean if required.
To reset a metal detector alarm:
1. Check the belt for up to 15 metres past the metal detector for tramp metal – locate and
remove any tramp metal.
2. Push the reset button on the metal detector.
3. Contact the control room Operator to check that the alarm has cleared.
Power must be restored to the magnet before the belt can be re-started.
4.2.3.23 Tramp Metal Magnets

Inspect magnets regularly for build-up of tramp metal and clean them at every opportunity
unless they are of the self-cleaning type.
Note : The conveyor must be isolated before any tramp metal can be removed.
Use the following procedure to remove tramp metal.

1. Obtain permission from the control room to isolate the conveyor.
2. Ensure the conveyor is isolated by an authorised person.
You cannot isolate the conveyor unless you are authorised.
3. Activate the conveyor emergency stop.
4. Isolate the conveyor by switching the conveyor isolators and brakes.
5. Ensure that indicator lights have extinguished and that there is a physical break in the
contactors.
6. Attach personal locks and tags to the appropriate locations on the conveyor.
7. Request the control room Operator to attempt a start on the conveyor.
The conveyor should not start.
8. Remove metal from the conveyor by standing on the platform upstream from the metal
detector.
9. After the metal has been removed and using the safe working procedures:
 Reset the metal detector
 Remove lock and tags
 Re-energise the isolators
 Re-set the emergency stop
 Notify the control room that it is safe to re-start the conveyor
4.2.3.24 Belt Rip Detectors

Belt-rip detectors are generally a string or pan type detector.
 Condition of the strings – not broken
 No build-up of material on the pans
To reset a belt rip string:

1. Find the cause of the fault and rectify.
2. Reset the switch so that the toggle arm is in the middle of the metal ring
3. The string may be broken or have only fallen off.
4. Contact the control room Operator and check that the alarm is clear
To reset a belt rip pan:

1. Check the entire belt for rips.
2. Hose all material from the pan and return to its normal operating position.
3. Check with control room Operator that the alarm is clear.
4.2.3.25 Transfer Stations

The maintenance inspections for transfer stations include blocked chute probes and air
cannons.
At all chutes, drop boxes and dust chutes’ (where fitted) maintenance inspections include
checks for:
 Material spillage caused by missing bolts or holes in outer shell (indicating a missing
wear plate)
 Build-up and blockages in the chute
 All chute doors have been closed – for safety and dust suppression
 All access walkways are clear of hazards, e.g. rocks, product spillage and hoses
 Damage to transfer chute main structure, e.g. stairs, grid mesh and handrails
Note : Always seek advice on the best method of clearing a blocked chute before attempting the
task.
The clearance method depends on the type of blockage, e.g. oversize ore and lump of
wood.
To reset a blocked chute probe after an alarm has stopped the belt.
1. Clear the blockage.
2. Restore the probe to a vertical position.
Note : If an air cannon is fitted, the chute access doors cannot be opened until the air cannon
has been isolated and the air receiver has been drained.
4.2.3.26 Local Control Stations

 The stop–start buttons at any local control station are not locked in either of these
positions
 Build-up and damage at local control stations and report any damage or interference
to your supervisor immediately
4.2.4 Washing Conveyor Systems

Refer to the appropriate maintenance procedures at your site for the methods and equipment to
be used to wash down the conveyor systems.
Typically, only a section or selected sections of the conveyor system will require washing at any
one time, e.g. a build-up of foreign matter or cleaning for repairs.
The conveyor components and items of equipment that will periodically require washing include:
 Cutes
 Conveyors
 Transfer conveyors
 Bunding areas
 Ball mills
 Thickeners
 Cyclones
 Pumps
 Walkways
 Work areas around crushers
Remove all slurry, spills and dust build up according to your site’s environmental practices.
Care must be taken to avoid:
 Electricity junction boxes or electronic equipment that may not be properly sealed
 Any personnel walking into or working within the work area when washing equipment
4.3 Troubleshooting
4.3.1 Introduction
Effective troubleshooting is an important aspect of the conveyor maintenance procedures and
the subsequently required high reliability of the conveyor system.
The information in this section discusses:
 Some of the common fault conditions that are likely to occur to the main components
of a conveyor system
 The possible causes of the faults
 The recommended action/s to repair the faults
Obviously, it is not possible to provide examples of every fault that may occur to a conveyor
system or all the faults that may occur to any one component of a conveyor system.
Hopefully the examples given will assist you with some troubleshooting knowledge of the
conveyor system and how to approach similar troubleshooting assessments.
To assist you with identifying the fault and applying the correct repair consult, as required one or
more of the following sources.
These sources are:
 Your Supervisor
 Experienced co-workers
 Site procedures
 OEM documentation
4.3.2 Fault-finding Examples

The following table provides some of the common fault conditions that can occur to conveyor
systems. Due to the complexity of conveyor systems, it is impossible to specify all the faults that
can occur.
Fault Possible Causes
Will not start / operate Switched to manual

Motor isolated
Drift switch tripped
Pullwire / lanyard switch operated
Motor overload triggered
Motor jammed / seized
Gearbox jammed / seized
Belt runs to one side – tracking Material build up on idlers
out or belt drift Load placed unevenly on belt
Sticking idlers
Idlers not square to belt
Idlers not centred on belt
Tracking frames damaged or interfering with belt
Faulty pulleys
Spillage from the chute
Jammed counterweight
Excessive wear on underside of Slippage on drive pulley
belt Build-up of material on underside of belt or return idlers
Sticking idlers
Excessive belt stretch Tension / load too high
Grooving, gouging or stripping of Skirt board seats too stiff and pressed against belt
top cover Excessive space between belt and skirt seats – material
gets jammed under seat
Material hanging under back panel of feed chute
Material jamming in feed chute
Impact rollers worn
Pullwire not operating Faulty reset switch
Broken wire
Wire over-tensioned
Spillage tripped wire
Personnel emergency
Conveyor under-speed Blocked chute
Blocked shirts
Incorrect belt tension
Water on or around the conveyor
Faulty under-speed switch
Belt drift
Lagging head pulley
Fault Possible Causes
Belt edge damage Belt drift

Seized or worn servos
Seized, worn or collapsed idlers
Objects protruding from belt
Skirt out of adjustment
Belt splice damage
Belt edge moulding damaged or broken off
Splice damage Wires broken or damaged
Jammed idlers
Belt rips Chutes, scrapers and skirts out of alignment, broken or
damaged
Section 5 Activities
5 Activities
5.1 Section 3 Operate Conveyor Activities
Activity 1
Complete your site’s conveyor operations pre-start Inspection checklist.
Explain what you are checking and why to the Assessor as you go.
Attach a copy of the completed form to a copy of this Activities page.
Activity 2
There are many safety requirements of which you must be aware and abide by when working in
conveyor operations. List six of what you consider to be the most important safety requirements
for personal safety.
Activity 3
Identify 3 situations when you would have to perform an Emergency Shutdown of a conveyor.
Activity 4
Identify three of the nip points on a conveyor system and state what safety devices are in place
for protection against each of these nip points.
Activity 5
Most conveyor systems have four types of pulleys. What are they and what is their purpose?
Activity 6
A. What are the emergency stop devices installed on most conveyor systems?
B. If the conveyor stops suddenly, but not by the actions of any person, what are the possible
causes for the emergency stop being activated?
5.2 Section 4 Perform Operator Maintenance Activities
Activity 1
What are the reasons for applying preventative maintenance to conveyor systems?
Activity 2
If you are inspecting a conveyor belt, list the potential faults that could be found on a worn and
damaged belt.
Activity 3
What are the operational checks (i.e. while the conveyor is running) that you are required to
complete on the conveyor’s drive motors and gearboxes?
Activity 4
What is a high burden detector and how is it activated?
Activity 5
Why is it necessary to detect and remove ferrous metal from the material being transported on
the conveyor and how is any metal on a conveyor belt identified?
Activity 6
Before bringing a conveyor back into service, list the lanyard and safety switch checks that need
to be performed to ensure that they will operate correctly when required.

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Conveyor

3.7.3.2 Conveyor Nip Points.................................................................................................. 30

4 Perform Operator Maintenance.........................................................................................61

1.1 Purpose of this Resource Manual

1.2 Safety Requirements

1.3 Training Requirements

1.4 Assessment Requirements

1.6 Getting Help

2.2 Understanding Conveyors and Conveyor Applications

Filter A device used for dewatering by extracting water through a porous

pH The unit of measurement of acidity and alkalinity

3.1 Operator Responsibilities

3.2 Identifying Safe Operating Practices

3.2.1 Operational Safety Requirements

 Being constantly aware of conveyor energy sources

3.2.2 Additional PPE Requirements

3.3 Crusher Operations Environmental Concerns

3.4 Pre-Start Inspections

3.4.2 Potential Pre-Start Hazards

3.4.3 Conveyor System Pre-Start Inspection Requirements

3.4.3.2 General Conveyor System Inspections

3.4.3.3 Specific Checks for the Ball Mill Feed Conveyor

 That the belt is tracking correctly

3.4.3.4 Specific Checks for the Weightometer

3.4.3.5 Post Inspection Tasks

3.4.3.6 Pre-Start Sirens

3.4.4 Common Safety Inspections

Access ways for:

Safety railings for:

Lighting and fittings for:

Electrical Wiring for:

3.5 Conveyor Start Up Procedures

Typical Start Up Sequence

Start after Clearing a Blocked Chute

Start after a Belt has Tracked Off

Start after an Ore Surge

Start when there is Slurry on the Belt

Smell: for burning and overheating, electrical equipment, rubber

Operating Conveyor Inspections

3.6 Conveyor Shutdown Procedures

5. Identify and report defects during a post shutdown check.

3.7 Conveyor Types, Components and Specifications

3.7.1 General Description

3.7.2 Conveyor Types

3.7.3 Standard Belt Conveyor System

The main components of a standard belt conveyor generally include:

Conveyor deck Return idlers

Each of these components is described on the following pages.

3.7.3.2 Conveyor Nip Points

Note : Always ensure all conveyor nip points are guarded.

3.7.3.3 Conveyor Deck

3.7.3.4 Conveyor Belt

3.7.3.5 Drive Motor and Gearbox

Conveyor Drive Assembly Gearbox Assembly

3.7.3.6 Conveyor Braking

3.7.3.7 Drive Pulley

3.7.3.8.1 Tail Pulley

3.7.3.8.2 Snub Pulley