SUE BEN:CONVEYOR BELT CHANGING REPORT
Task:
Changing 7 x 6 Feed Conveyor Belt (3ply x 450mm)
Objective :
To change the conveyor belt and replace wearing parts such as rollers before machine
breakdown ,thereby avoiding unwanted breakdown downtime.
Hazards:
Typical hazards include:
Unpredicted belt movements.
Equipment malfunctions.
Manual handling hazards.
Lifting, tracking and securing hazards.
Equipment operation hazards.
Damaged material hazards.
Procedure:
HIRA was done as expected.
LOTO was done and power was isolated.
Unrolled the new conveyor from the stand (we unrolled approximately 3m)
We placed the end of the new conveyor on the timber so that we could use a square
placed 90°to the conveyor belt to obtain straight edges and mark out holes using a
template .
To determine the side which will carry the load , look for the thicker side it should go on
top.
We then proceeded to use a belt punch to make holes on the new conveyor belt.
We again used the template to mark out hole positions on the old conveyor still in
position.
We then attached (matching hole positions) the new conveyor to the old conveyor using
size 2 belt fasteners.
We then stood at different positions along the conveyor belt so that we could monitor it
as power was switched on,we were looking out for any irregularities such as (“is the new
belt still attached to the old conveyor belt,is there any misalignment)
As soon as we noticed as we noticed the two new conveyor ends meet (in close
contact),we switched off power.
We then used clamps to secure both ends of the new conveyor and attached our chain
block at the head pulley side for tensioning purpose,once we were done with tensioning
we removed the slack/cut off slack using a belt knife.
We then used no.2 belt fasteners to join the two new conveyor belt ends.
We then proceeded to cut off the old conveyor belt using a belt knife (we did this so that
we could pull out the conveyor with the help of manpower, as power was switched on we
pulled out the old conveyor).
We used 64 metres of the new conveyor belt.
Observations:
There were sharp edges cutting the old conveyor belt ,we asked for assistance from the
boilermakers to remove the sharp edge.(they helped)
There were 2 worn out return idler rollers.(we replaced them)
The magnet was full of steel wire , showing that it’s not cleaned on a regular basis.
Commissioning the conveyor belt:
Inspected the belt condition for imperfections or irregularities, started the conveyor and
monitored and adjusted tracking, speed and tensions as required, observed belt in
operation and handed it over to the operators.
Recommendations/Improvements:
The belt roll should be covered with a tarp or dark plastic. Exposure to sunlight and rain
can have detrimental effects on the rubber covers.
The belt should not be exposed to extreme temperatures during storage. Ideal temperature
for storing a belt is between 40°F (4°C) and 90°F (32°C). Temperatures outside of this
range for an extended period of time can have detrimental effects on the rubber
compounds.
We should have a storage/room so that our conveyor belts are not exposed to sunlight and
ozone for storing our conveyor belts only , and we should make sure that the floors are
dry at all times and place the rolls on wooden skids so that they don’t accidentally roll.
Return Idler Build up ,we should use rubber disc idlers or we can also use a Spiral
Cantenary Type idler , this idler removes material through the broken surface and
screwing action , it reverse bends the belt to generate a separation of material from the
belt and this can help keep the return strand centered.
The weightometer should always be on a horizontal section.
We should install Belt Cleaners ,in case of dry particles the clinging dry particles are
cleaned by scrapper/wiper, in case of wet and sticky materials:revolving brushes should
be used, scrappers should be mounted at the end pulley and brushes should be mounted
at the lower num
Belt cleaners should be mounted near the discharge pulley.
NB* Following these procedures will increase the life of the belt once it is installed on the
system.
Using data from returned checklist forms , i noticed that fasteners are being constantly
replaced , I recommend we try aligator fasteners as they can achieve their holding power
by penetrating the carcass fibers without damaging them.
