INTEGRATED RISK MANAGEMENT SYSTEM

PROCEDURE

Document Name: STANDARD MAINTENANCE PROCEDURE FOR BELT CONVEYORS

Division: MAAMBA COLLIERIES LIMITED
Document Number: SMP-TPP-MECH-CHP-010 Date issued: 18.09.2020 Rev: 2
Additional References: Approved By: Y. Phiri

1.0 Purpose

This Standard Maintenance Procedure (SMP) provides maintenance instructions including safety and health
instructions during maintenance of belt conveyors to protect the personnel and equipment.
2.0 Scope of application

This procedure applies to all activities associated with the Routine Maintenance, Preventive Maintenance
and Overhaul Maintenance of belt conveyors.
3.0 Responsible person(s) & Authorities

a) Head of Department - Mechanical maintenance

b) SHEQ Manager
c) Area in Charge/ Engineer
d) Technician
e) Craftsperson
f) Helper

4.0 Safety precaution required

 Ensure safe work permit is issued before carrying out any maintenance activities.
 Keep the fire extinguishers ready within reachable limit for any exigency.
 Ensure use of periodically tested proper lifting tools & tackles.
 Use appropriate PPE
 Ensure good housekeeping of maintenance bay.
 Put barricade tapes around the equipment under maintenance
 Obtain safe working permit before working
 Conduct risk assessment for the work to be done
 Conduct tool box talk
 Ensure safety clearance is given before working at height, hot works, confined space
 Adhere to risk safety measures

4.1 Required Personal Protective Equipment (PPE)

Belt conveyors maintenance carried out both in online & offline condition depending upon nature of job.
Safety during the maintenance of belt conveyors includes general safety, protection against the coal dust,
cutting, welding and greasing works while doing the maintenance. The following are the PPEs to be used
during maintenance.
a) Safety helmet
b) Hand Gloves
c) Goggles
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d) Nose mask
e) Safety belt

4.2 safety hazards

a) coal dust inhalation
b) hot work (cutting, grinding, welding, grinding, buffing etc.)
c) working at height(ladder)
d) material lifting with chain block/hoist
e) rotary equipment’s (pulleys, motors, belt etc.)
f) sharp edges

5.0 Belt Conveyors Technical Parameters

5.1 Introduction

A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt conveyor). A belt
conveyor system is one of many types of conveyor systems. A belt conveyor system consists of two or
more pulleys (sometimes referred to as drums); with an endless loop of carrying medium the conveyor belt
that rotates about them. One or both of the pulleys are powered, moving the belt and the material on the belt
forward. The powered pulley is called the drive pulley while the unpowered pulley is called the idler pulley.
Material flowing over the belt may be weighed in transit using a belt weigher.

This document is the property of Maamba Collieries Limited and may not be copied or redistributed to any third party without the
permission of the SHEQ Manager. All documents on the server is regarded as the latest version. The SHEQ Manager is the custodian of
the signed master copy and all other documents should be regarded as for information only.
If this document is printed it is only valid for 24 hours from 12/17/2024 10:14:28 AM
 INTEGRATED RISK MANAGEMENT SYSTEM
PROCEDURE

Document Name: STANDARD MAINTENANCE PROCEDURE FOR BELT CONVEYORS

Division: MAAMBA COLLIERIES LIMITED
Document Number: SMP-TPP-MECH-CHP-010 Date issued: 18.09.2020 Rev: 2
Additional References: Approved By: Y. Phiri

5.2 Specifications

VERTICAL
LIFTING
HORIZONTAL
RATING BELT HEIGHT
CONVEYOR BELT WIDTH CONVEYOR SLOPE
CAPACITY SPEED (FROM HEAD TAKE-UP TYPE DRIVE TYPE
NO. (M) LENGTH ()
(T/H) (M/S) PULLEY TO
(M)
TAIL PULLEY)
(M)
C-1AB 1200 750 2.0 173.7 20.4 12 Vertical take-up Single drive
C-2AB 1000 750 2.8 46.408 10.0 14 Vertical take-up Single drive
Hydraulic Double drives at head
C-3A 1000 750 3.15 457 12 0
pressure and tail reversible
C-3B 1000 750 2.5 154.15 21.6 12 Vertical take-up Single drive
C-3C 1000 750 2.5 11.75 0 0 Screw Single drive
C-3D 1000 750 2.5 11.75 0 0 Screw Single drive
C-4AB 1000 750 3.15 199 20.5 12 Vertical take-up Single drive
C-5AB 1000 750 3.15 189.327 5.286 1.6 Vertical take-up Single drive
C-5CD 1000 750 3.15 126 17.3 14 Vertical take-up Single drive
C-6AB 1000 750 3.15 126 18.6 14 Vertical take-up Single drive
C-7AB 1000 750 3.15 250.677 51.432 14 Vertical take-up Double drives
C-8AB 1200 750 2.0 10.5 0 0 Screw Single drive reversible
C-9AB 1200 750 2.5 112.527 5.3 14 Vertical take-up Single drive with
movable tripper
C-10 650 200 1.8 107 20.966 14 Vertical take-up Single drive
C-11 650 200 1.8 121.316 25.8 14 Vertical take-up Single drive
 INTEGRATED RISK MANAGEMENT SYSTEM
PROCEDURE

Document Name: STANDARD MAINTENANCE PROCEDURE FOR BELT CONVEYORS

Division: MAAMBA COLLIERIES LIMITED
Document Number: SMP-TPP-MECH-CHP-010 Date issued: 18.09.2020 Rev: 2
Additional References: Approved By: Y. Phiri

6.0 Maintenance Procedure

A. Routine maintenance

 Check the oil level .and cleaned the Equipment.

 Checking the oil level in gear box
 Checking for any oil leakage in hydraulic line system
 Leakage from Travels motor to be checked
 Checking the Impact Idler Rubber and Bearing Condition.
 Checking the skirt rubber and Discharge chute Deflector Plate in welding condition
 Checking the abnormal sound from Plummer block.

B. Preventive maintenance

 Belt & its joint condition

 Gear Box Oil leakage & it's seal condition
 Gear Box oil level & contamination
 Tightness of Gear Box foundation bolts
 Condition of Breather plug & cleaning
 Condition of Geared Coupling Grease
 Condition of Geared Coupling
 Tightness of Geared Coupling bolts
 Cleaning of DSS nozzle checking
 Fluid coupling oil level checking
 Fluid coupling nut bolt tighten
 Check the all-Pulley lagging & drum condition
 Check the all Bearing condition

C. Overhauling / Major Maintenance Checks

 Take permit after checking following points

 Belt conveyor/ feeder is isolated electrically and mechanically
 No materials on the belt
 Check for any leakage from gear box/ fluid coupling and its oil level. If required, oil top up to be
done.
 All coupling bolts are to be checked.
 Check the idler conditions- jammed/damage/missing, repair the same.
 Check the skirt rubber, adjust/replace if required,
 Check the “V” Scrapper. Adjust / replace If required.
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 Check deflector plate condition.

 Check Conveyor joint and its edge, Repair /replace if required.
 Check Hold back condition.
 Check/top up oil in gearbox and clean the breather plug.
 Check /adjust belt tension.
 Check Gear box, Fluid couplings, Hold backs, pin bush Coupling.
 Greasing of all the bearings by pump.
 Deflectors to be checked.
 coupling bolts/bushes to be checked and if required replaced.
 Check the Joint/edge condition of conveyor belt.
 Take up guide clamp/plate to checked and fixed for alignment.
 All Plummer block bolts to be tightened.
 All bearings clearance to be measured, labyrinth seal & lock nut to be tightened & greased by PP
(one 3 months Plummer blocks to greased after opening the top half).
 Check bolt tightness of drive unit.
 Check pulley lagging for distortion.
 Check deflector pulley bearings condition and grease it. Also check for any shift in shaft of deflector
pulley. Replace deflector pulley bearing if required Adjust labyrinth seal of pulley P/block frequency
of clearance measurement must be mentioned as working of installation.
 Check belt scrapper condition and adjustment/replacement if required.
 Check skirt rubber condition and adjust/replace as per requirement.
 Check condition of counter weight rope
 All Pulley bearing. Clearance is to be measured & greased. Damaged bearing to be replaced if
required.
 Grease flap gate bearings & operation to be ensured.
 Check/repair/replace deflector in the chutes.
 Check takes up pulley wire rope and lubricate.
 Check guide clamp & replace.
 Check ZSS, Pull Cord, Sway switch, calibrate/replace if required

D. Trouble shooting

Problem Cause Solution

Conveyor not starting or  Motor is overloaded  Check conveyor load. Remove
motor stalling excessive load

Loud popping or grinding  Faulty bearing  Tighten set screw and check key
noise  Loose drive sprocket set  Replace bearing
screw
 Loose drive chain
Motor and gear reducer  Faulty bearing  Replace unit
makes excessive noise  Damaged gears  Replace bearing
This document is the property of Maamba Collieries Limited and may not be copied or redistributed to any third party without the
permission of the SHEQ Manager. All documents on the server is regarded as the latest version. The SHEQ Manager is the custodian of
the signed master copy and all other documents should be regarded as for information only.
If this document is printed it is only valid for 24 hours from 12/17/2024 10:14:28 AM
 Doc. SMP-
STANDARD MAINTENANCE PROCEDURE
TPP-MECH- Revision: 00 Page 6 of 7
FOR BELT CONVEYORS
CHP-010

Motor or reducer  Conveyor overloaded  Check conveyor load.

overheating  Low voltage to motor  Remove excessive load
 Reducer lubricant level  Correct voltage level
low  Fill reducer reservoir

Drive pulley turns but belt  Conveyor overloaded  Check conveyor load.
does not move or moves  Loose conveyor belt  Remove excessive load
with a jerky motion  Loose conveyor belt  Tighten conveyor belt
 Belt installed upside down  Install belt right side up
 Belt slips and squeals  Tighten conveyor belt
Excessive belt stretch  Belt over tensioned  Reduce belt tension.
 Check drive pulley for proper lagging
Belt creeps to one side of  Head pulley or idlers  Realign by advancing (adjust in the
head pulley preceding are out of direction of belt travel) the end of the
alignment end of the pulley or idler to which the
belt has shifted

Belt creeps to one side at  Improper loading of belt  Realign by advancing (adjust in the
one spot along the length  Frozen idlers direction of belt travel) the end of the
of conveyor  Conveyor frame out of idler to which the belt has shifted
square or not level  Center load on belt
 Debris build up on pulleys  Replace idlers
or idlers  Square and level conveyor frame
 Remove debris from pulleys or idlers

7.0 References

a) Belt conveyors General assembly drawings

b) Spares list of Belt conveyors
c) Belt conveyors OEM manual
d) Safety Work Permit (SWP) Practices
e) Risk Assessment Document (RAD)

8.0 Records

Sl. No. Record No. Records

9.0 Revision history

DATE REV CHANGES NAME

New Procedure Bhagavath Ram
18/9/2020 Document No. changed from SMP-TPP-MECH-031 to Richmond Chilwalo
SMP-TPP-MECH-CHP-001.
Addional points on: Scope of Application, Responsible
00 Person(s), Required Safety Precautions & safety
hazards.

This document is the property of Maamba Collieries Limited and may not be copied or redistributed to any third party without the
permission of the SHEQ Manager. All documents on the server is regarded as the latest version. The SHEQ Manager is the custodian of
the signed master copy and all other documents should be regarded as for information only.
If this document is printed it is only valid for 24 hours from 12/17/2024 10:14:28 AM
 Doc. SMP-
STANDARD MAINTENANCE PROCEDURE
TPP-MECH- Revision: 00 Page 7 of 7
FOR BELT CONVEYORS
CHP-010

APPROVAL SIGNATURES

PREPARED BY MR. RAKESH KUMAR TITLE HOD-MMD SIGN

AUTHORISED BY MR. LAXMI PRASAD TITLE HEAD- O & M SIGN

APPROVED BY MR. YOTHAM PHIRI TITLE SHEQ MANAGER SIGN

This document is the property of Maamba Collieries Limited and may not be copied or redistributed to any third party without the
permission of the SHEQ Manager. All documents on the server is regarded as the latest version. The SHEQ Manager is the custodian of
the signed master copy and all other documents should be regarded as for information only.
If this document is printed it is only valid for 24 hours from 12/17/2024 10:14:28 AM