Belt Conveyor Troubles and Solutions

Belt Conveyor Safety Operation

Belt conveyors are effective for transporting large amount of raw material or fuel and so widely used in materials industry, energy industry and so on.

Accidents are relatively decreasing nowadays but it may cause various troubles when facilities become old.

So, it is important to understand characteristics of belt conveyors for stable operation of belt conveyors and safety of workers.

This article shows such typical troubles and those countermeasures.

Problems at the site

Serious troubles or accidents may occur in conveyor belt operation, such as:

• Material Spillage: Material falls off the belt due to improper loading or worn edges.
• Fire accidents: These can occur due to heat from friction or electrical failures and are especially dangerous when dealing with flammable materials.
• Conveyor belt rip accidents: Wrong obstacles transported with material may stick into the belt and tear it.
• Belt cut break accidents: Belt breaks due to excessive tension or the inclusion of foreign objects.
• Blocking chute: Chute gets clogged due to improper material input or poor design.
• Human injury: Workers are injured by being caught or pinched in rotating parts

To prevent these problems, regular inspections, installation of appropriate safety devices, and safety training for workers are essential. Other important measures include the introduction of emergency stop systems and the maintenance of fire prevention equipment.

Causes of Troubles, Countermeasures and Recommended Safety Devices

Common causes of this trouble include the following:

1. Dirt, material build-up, or adhesion on pulleys or rollers.
2. Rollers that do not rotate properly or are damaged.
3. Changes in material loading conditions (e.g., off-center loading).
4. Damaged skirt rubber or trapped material inside the skirt area.
5. Damage to the conveyor belt itself.

These issues can lead to conveyor belt misalignment (belt snaking), which may result in materials spillage, production losses, and increased maintenance costs.

Following equipment is effective for preventing this trouble:

Common causes of this trouble include the following:

1. Belt slippage between the conveyor belt and the drive pulley.
2. Heat generated by malfunctioning or rotating components
   such as bearings and rollers.
3. Frictional heat caused by contact between a misaligned belt
   and the conveyor frame.
4. Heat buildup due to accumulated dust around roller stands
   and other conveyor components.
5. Ignition caused by hot work at the site.

These conditions can lead to fire accidents, resulting in production losses, increased maintenance costs, personal injury, health hazards, and air pollution.

Following equipment is effective for preventing this trouble:

A common cause of this trouble is as follows:

Incorrect materials or foreign objects, such as sharp solids or metal pieces mixed into the transported material, can penetrate the conveyor belt and become lodged in the impact roller located directly beneath the transfer chute.

This can lead to a belt rip accident, resulting in production losses and increased maintenance costs.

Following equipment is effective for preventing this trouble:

Common causes of this trouble include the following:

1. Frequent belt slippage between the conveyor belt and the drive pulley.
2. Wear of the belt cover rubber, resulting in exposure of the fabric carcass.
3. Cracks or scratches in the fabric carcass exceeding 10% of the belt width.
4. Severe tear damage or deep cuts.
5. Multiple repaired sections on the belt.

These conditions can lead to a belt cut or breakage accident,
resulting in production losses, increased maintenance costs,
and serious personal injury.

Following equipment is effective for preventing this trouble:

Common causes of this trouble include the following:

1. Belt slippage on the upstream (transfer) conveyor.
2. Conveyed material becoming blocked inside the transfer chute and failing to discharge onto the downstream belt conveyor.

These conditions can lead to a chute blockage accident,
resulting in production losses, increased maintenance costs,
and environmental pollution.

Following equipment is effective for preventing this trouble:

Common causes of this trouble include the following:

1. The conveyor being started by another operator during maintenance or repair work.
2. The conveyor being activated by an automatic control system during maintenance.
3. Removal of accumulated material while the conveyor is still in operation.
4. Accidental contact with an exposed rotating pulley on a conveyor without a safety guard.

These conditions can lead to a caught-in or entanglement accident, resulting in serious personal injury and production loss.

Following equipment is effective for preventing this trouble: