CMA SAFETY SYMPOSIUM

1. CMASAFETY SYMPOSIUM Hosted at AAC 2012 – 10 - 24

2. CMA SAFETY SYMPOSIUM – Trapped energy OVERVIEW • Background • Scientific approach • Potential energy • Holdback requirements • Safety issue pertaining to holdbacks • Trapped energy • Managing trapped energy • Conclusion • Recommendations Promoting the excellence of belt conveying in South Africa

3. CMA SAFETY SYMPOSIUM – Trapped energy Background • Attended SACEA meeting earlier this year • Subject discussed safety around conveyors • Specific case noted was referred to as stored energy problem Promoting the excellence of belt conveying in South Africa

4. CMA SAFETY SYMPOSIUM – Trapped energy Scientific approach • Kinetic energy • Applied energy • Potential energy • Energy to be applied Promoting the excellence of belt conveying in South Africa

5. CMA SAFETY SYMPOSIUM – Trapped energy Potential energy • Belt mass slope energy • Material mass slope energy • Position of the counterweight energy • Stretch energy in the belting • The industry refers to this as stored energy Promoting the excellence of belt conveying in South Africa

6. CMA SAFETY SYMPOSIUM – Trapped energy Ground Level BELT MASS SLOPE ENERGY Promoting the excellence of belt conveying in South Africa

7. CMA SAFETY SYMPOSIUM – Trapped energy Material Ground Level MATERIAL MASS SLOPE ENERGY Promoting the excellence of belt conveying in South Africa

8. CMA SAFETY SYMPOSIUM – Trapped energy Counterweight mass H = height Ground Level VERTICAL GRAVITY ARRANGEMENT Promoting the excellence of belt conveying in South Africa

9. CMA SAFETY SYMPOSIUM – Trapped energy Sheaves TAKE-UP CARRIAGE Counterweight mass H = height Ground Level HORIZONTAL GRAVITY ARRANGEMENT without winch positioning Promoting the excellence of belt conveying in South Africa

10. CMA SAFETY SYMPOSIUM – Trapped energy Sheaves WINCH TAKE-UP CARRIAGE Counterweight mass H = height Ground Level HORIZONTAL GRAVITY ARRANGEMENT with winch positioning Promoting the excellence of belt conveying in South Africa

11. CMA SAFETY SYMPOSIUM – Trapped energy Sheaves WINCH TAKE-UP CARRIAGE Ground Level Counterweight mass HORIZONTAL GRAVITY ARRANGEMENT with winch positioning Promoting the excellence of belt conveying in South Africa

12. CMA SAFETY SYMPOSIUM – Trapped energy AUTOMATIC WINCH TAKE-UP CARRIAGE Ground Level HORIZONTAL WINCH TENSIONING ARRANGEMENT Promoting the excellence of belt conveying in South Africa

13. CMA SAFETY SYMPOSIUM – Trapped energy Holdback requirements • When a conveyor is switched off it will come to rest • This is also required on incline conveyors • When material is loaded on an inclined belt, a condition is reached where it will run back • The running back of a conveyor will cause serious spillage • Conveyors are purposely designed with holdbacks to prevent runback Promoting the excellence of belt conveying in South Africa

14. CMA SAFETY SYMPOSIUM – Trapped energy Safety issue pertaining to holdbacks • The inherent function of holdbacks results in unwanted energy being generated under aborted start conditions: • When the tail pulley becomes jammed due to spillage • When the tail pulley becomes jammed due to seized bearings • This presentation refers to this unwanted energy as being trapped energy and labels it accordingly Promoting the excellence of belt conveying in South Africa

15. CMA SAFETY SYMPOSIUM – Trapped energy Trapped energy • This energy cant be observed • All the safety precautions may have been taken in good faith but the dangers could still exist • Example of incident earlier this year Promoting the excellence of belt conveying in South Africa

16. CMA SAFETY SYMPOSIUM – Trapped energy Tensions the same top and bottom Ground Level CONVEYOR IN THE STATIONARY POSITION Holdbacks fitted Promoting the excellence of belt conveying in South Africa

17. CMA SAFETY SYMPOSIUM – Trapped energy Tensions higher in the top than the bottom Ground Level CONVEYOR IN THE ABORTED START CONDITION Holdbacks fitted Promoting the excellence of belt conveying in South Africa

18. CMA SAFETY SYMPOSIUM – Trapped energy Tail pulley jammed Tensions higher in the top than the bottom Ground Level CONVEYOR IN THE ABORTED START CONDITION Holdbacks fitted Promoting the excellence of belt conveying in South Africa

19. CMA SAFETY SYMPOSIUM – Trapped energy Managing trapped energy • Holdbacks are fitted • Holdbacks prime cause of trapped energy • Holdbacks considered unsafe under these conditions • Brakes offered as an alternative to holdbacks but • Brakes can be tampered with • Brakes are subject to wear • Brake application philosophy generate dynamics Promoting the excellence of belt conveying in South Africa

20. CMA SAFETY SYMPOSIUM – Trapped energy Managing trapped energy • The best way of handling trapped energy is to release it. • Trapped energy can only be released on a holdback by turning the holdback backwards • The releasing mechanism needs to be safe to operate Promoting the excellence of belt conveying in South Africa

21. CMA SAFETY SYMPOSIUM – Trapped energy Tail pulley jammed Tensions higher in the top than the bottom Ground Level CONVEYOR IN THE ABORTED START CONDITION Releasable Holdback fitted Promoting the excellence of belt conveying in South Africa

22. CMA SAFETY SYMPOSIUM – Trapped energy Managing trapped energy - cont • Units are currently available in the market place offering the release facility • The permanently applied brake is manually released by unscrewing the pressuring mechanism and releasing the “permanent” brake Promoting the excellence of belt conveying in South Africa

23. CMA SAFETY SYMPOSIUM – Trapped energy CONCLUSIONS • Fitting manual type brakes in conjunction with normal holdbacks overcomes the problem of releasing trapped energy Promoting the excellence of belt conveying in South Africa

24. CMA SAFETY SYMPOSIUM – Trapped energy RECOMMENDATIONS • Users to specify releasable holdbacks on all future projects • Pursue the possibility of retro fitting these units on existing installations with specific reference to high energy applications which are typically relatively long incline applications like shaft conveyors • This presentation was compiled without consideration of the effect of mono directional idlers on this application. Promoting the excellence of belt conveying in South Africa

25. CMA SAFETY SYMPOSIUM – Tail pulleys TAIL PULLEYS • Latest statistics indicate tail pulleys as being the most dangerous area on a conveyor application with specific reference to fatalities • A review is required to highlight the operational issues which lead to these unsafe conditions Promoting the excellence of belt conveying in South Africa

26. CMA SAFETY SYMPOSIUM – Tail pulleys TAIL PULLEYS • Tail pulleys are recirculating type pulleys and are thus not self cleaning • Being local to feed points spillage is always an issue • Any spillage along the length of the conveyor landing on the return strand eventually ends up at the tail pulley Promoting the excellence of belt conveying in South Africa

27. CMA SAFETY SYMPOSIUM – Tail pulleys Pedestals Spillage Ground Level ELEVATION ON TAIL PULLEY ARRGT Promoting the excellence of belt conveying in South Africa

28. CMA SAFETY SYMPOSIUM – Tail pulleys TAIL PULLEYS • Spillage are manually fed onto the belt at the tail • Spillage can be loaded onto the belt by means of skid loaders resulting in “surge loading” Promoting the excellence of belt conveying in South Africa

29. CMA SAFETY SYMPOSIUM – Tail pulleys SUGGESTIONS – vibrating plate feeders • Vibrating plate feeders are ideal for load spillage onto conveyors while the belt is running • Vibrating plate feeders will not cause material surges on the conveyor Promoting the excellence of belt conveying in South Africa

30. CMA SAFETY SYMPOSIUM – Tail pulleys SUGGESTIONS – design and construction • Design the tail pulley framework such that there is ready access for maintenance • Position the tail pulley as far back as possible from the loading section to allow free access • Fully guard the tail pulley • Adequate access to return belt ploughs • Use the support structure as a barrier beam • Endeavour to fit spillage deflectors over the tail Promoting the excellence of belt conveying in South Africa

31. CMA SAFETY SYMPOSIUM – Tail pulleys Barrier beams Pedestals Ground Level ELEVATION ON TAIL PULLEY ARRGT Promoting the excellence of belt conveying in South Africa

32. CMA SAFETY SYMPOSIUM – Tail pulleys THANK YOU QUESTIONS Promoting the excellence of belt conveying in South Africa