Safety Training Courses
Complete Belt Conveyor System Basic Components and Its Safety
Belt Conveyor is a mechanical device that is used to transport bulk materials from one place to another. It is an endless belt operating system which is driven by a drive special arrangement, pulleys, and support rollers and with the help of this we can move bulk material from one location to another specific location. Basically, two types of belt conveyors are use in power plant/ Cement plants.
- Troughing Conveyor
- Pipe Conveyor
Troughing Conveyor: –
Troughing conveyor is carrying bulk material in a trough conveyor belt with the support of 35 or 45 Degree troughing idlers for use of high capacity and speed conveying of bulk material in the compression of flat conveyor. After transition distance conveyor belt form in a required trough angle in a caring zone.
Transition distance is a distance where belt forms in a regular angle from the Tail pulley and Head pulley.
Troughing angle basically design upon the size, surcharge angle of the material to be handle and the speed and the capacity of the conveyor systems.
Pipe Conveyor: –
Pipe conveyor is a kind of troughing conveyor itself. In this, the troughing conveyor folds and takes the shape of the pipe with the help of finger rollers and travels through the six-roller panel.
Pipe conveyor use and main advantages:
The pipe conveyor is safe to use, enviro-friendly and suitable for difficult layout. It is capable of handling almost all types of bulk materials. The pipe conveyor is also very reliable for long distance bulk material handling.
Main advantages of the Pipe conveyor:
- The pipe conveyor can be easily laid in horizontal and vertical curves.
- Pipe conveyors are also used for spillage free bulk material handling transportation.
- Pipe conveyors are also used for material handling at higher elevations.
- Due to its six-roller panel design, the pipe conveyor has less damage to the edge of the belt.
- The enclosed formation design of the belt in pipe conveyor ensures safe bulk material handling even in heavy rain and wind conditions.
- Pipe conveyor for long distance bulk material handling has a lower cost of installation than normal belt conveyor as the cost of transfer house is saved in easy left right movement.
Disadvantages of the Pipe conveyor:
- Due to the pipe shape formation in the pipe conveyors, a larger width of the belt is required than the troughing conveyors to handle the same material.
- Pipe conveyors have a lot of difficulty in the situation of oversize material and in overloading condition also.
- The pipe conveyor has difficulty in maintenance of belts and idlers.
- Pipe conveyors require more power than the same capacity of the troughing conveyors.
Main Component/ Parts of The Belt Conveyors: –
- Pulleys: A conveyor pulley is a mechanical device that gives direction and support to a conveyor belt.
- Idlers and idler frame: Idlers are a cylindrical roller that is fixed to a frame with the help of its shaft and provides drive support to the running belt with the required spacing.
- Drive arrangements: The drive arrangement is a part of the conveyor system that powers the conveyor to handle the material at the required speed and capacity. The drive unit mainly consists of a motor and a gearbox unit which is connected to the drive pulley of the conveyor with the help of couplings.
- Support Structures: Support structure is an important part of a conveyor system that provides rigid support to the conveyor. Such as stranger, post, conveyor gallery support, drive, and pulley support structures etc.
- Safety Protections devices/switches of the conveyors: Whenever a danger situation arises in the belt conveyor system, this safety equipment protects the equipment and the person from any danger to the conveyor system. There are some 07 safety devices which must be installed in the conveyor system.
- Pull cord Switches: In a conveyor belt system, pull cord switches are installed across the length on both sides of the belt and are connected by a wire rope. This allows to stop the conveyor belt by pull the rope from anywhere in the event of any abnormalities.
- Belt sway switches: In belt conveyor systems, belt sway switches are fitted to a required spacing across the length of both sides of the belt. If due to any reason the belt deviates from its path while moving, the sway switch on that side gets operated and the belt is stopped.
- Zero speed switch: In a belt conveyor system, the zero-speed switch is always mounted on a non-driving pulley. If due to any reason the belt slips while running, then there is a difference in the speed of non-drive and drive pulley and this switch is operated and the belt is closed.
- Hold back: A hold back or backstop in a belt conveyor system is a device that is attached to its drive arrangement that does not allow the belt to rotate in reverse direction. It is installed in all inclined conveyors so that whenever the belt conveyor is closed in load condition or no-load condition, the belt tries to rotate in reverse due to gravity, but holdback is never allow to rotate conveyor in reverse direction.
- Belt tear/ rip protection switches: In conveyor belt system, the tear detection switch is placed near the conveyor belt, which detects the tear or rip of the belt and stops the conveyor.
- Chute blockage switches: In conveyor belt system, chute blockage detection switch is installed on one side of the discharge chute which detects the chute blockage and stops the conveyor. By which the carrying material gets saved due to spillage.
- Plant warning siren: A warning siren is a device that must be installed in a conveyor system. Which gives us a warning before the system starts.
6. Dust Controlling System: Dust control system is a method and combination of device. Which controls the dust during the material movement in the belt. To control the dust in the belt conveyor system, it is necessary to install dust superaction and dust extraction system with proper sealing. By which dust is controlled at the time of transportation of bulk material.
- Conveyor Belt: In the conveyor system, the belt is the only part on which the bulk material is safely conveyed. The selection of conveyor belt is mainly done with the help of its strength, width, ply number, top cover, bottom cover, thickness, length and types of fabric and rubber grade.
- Belt cleaners/ Scrappers: A belt cleaner or scraper in a conveyor system is a device mounted on or immediately after the discharge pulley to clean the bulk material being conveyed after it is discharged.
- Counterweight Arrangement: The conveyor system is equipped with a counterweight arrangement to always maintain the required tension. In this, the weight is attached to the counterweight pulley with the help of counterweight structure. It is of both horizontal, vertical, and combined type according to the requirement of the system.
- Belt Foreign Material separator/ Detector: The conveyor system consists of a device for detecting and separating foreign materials for belt and equipment safety. It has an in-line magnetic separator which removes the ferrous material from the belt in running condition and there is another metal detector which detects both ferrous and nonferrous metal going into the conveyor belt and stop the belt immediately.
- Chutes and skirting: The conveyor system consists of a device for detecting and separating foreign materials for belt and equipment safety. It has an in-line magnetic separator which removes the ferrous material from the belt in running condition and there is another metal detector which detects both ferrous and nonferrous metal going into the conveyor belt and stop the belt. While receiving the material through chute skirting is protect the material to avoid spillage and dust emission around the system.
- Sample collection unit: This device is fitted in the conveyor system to collect the sample from the belt at the time of bulk material handling. From where the sample is prepared according to the required standard and sent to the lab for the result.
- Guards and Protections: Conveyor belt systems must have rotating equipment guards for protection. And according to the requirement, nip protection, net and handrail are installed.
- Gallery and hoods: Conveyor belt system has gallery on both sides for maintenance and observation and there is a hood for environment protection.
- Belt Weigher: Belt weigher is a device in a conveyor system by which we take the feed rate and weight of the material going on the belt at the time of bulk material handling.
- Conveyor interlockings: Interlocking is a type of logic to control in the conveyor system by which the belt operation is secured through PLC. And it does not allow to run the system to start in unhealthy conditions.
For the conveyor system to run safely and according to its requirement, no part or equipment should have been removed without valid permission, always insuring the availability of all safety equipment and interlockings from time to time.
Basic knowledge of Scaffolding and Its Hazards
What Is a Scaffold?
Scaffolding is an elevated structure which is created on temporary basis to facilitate for the erecting, construction, repair & maintenance when the work is to be carried out at the height.
Types of Scaffolding
Generally scaffolding are categorized into three parts:
- Suspended Scaffoldings : Suspended scaffolding are the platforms which are hanging with an overhead/top structure.
- Supported Scaffoldings: It is a most common types of scaffolding which are supported with the posts from the ground base.
- Aerial lift type Scaffoldings: It is a vehicle mounted device which are use for lift the persons for the job as a man lifter.
Scaffold duties / Rated capacity
As per the OHSA standards scaffolds are created with the consider with three types of its duties.
(a) Light duty: Approx 125 kg/m2
(b) Medium duty: Approx 250 kg/m2
(C) Heavy duty: Approx 375 kg/m2
Scaffolding Components/ Parts
Sole plates / Boards
Boards are made by the Steel, Aluminum, or wood that can be used for the preparing platform for the base of the work area.
The sole plate is a big plate of size 300 x 300 x 6 mm . Where there is a soft surface, a sole plate must be used under the base plate of the scaffold.
Base plates
Plates provide solid base to the post of the scaffolding. The base plate is a metal plate of size 150 x 150 x 6 mm on which the post/standards are mounted. Base plates are mainly of two types.
(a) Fixed base plate : Fixed type its has center circular shank. Shank/ Spigot diameter is 80% of the standards diameter, 20% margin available for the movement of standards on it.
(b) Adjustable base Jack plate : Its used for the levelling of the scaffold at initial. Its load taking capacity is 3000 Kg. Lift of jack nut is not allowed more than two third (2/3) of its total height.
Standards or Posts
It’s a metal tubes that transfer the load of the weight to the base of the bottom plates to increase the length or height of the scaffolding by using pins and the socket joints for the connection of the standards.
As per the fitting types of the scaffolding many types of standards are comes as follows:
(a) Plane (Coupler) tubes type standards
(b) Cup lock type standards
(c) Ring lock rosette type standards
(d) Quick lock type standards
Ledger/ Runner
It’s a horizontal tube that joints the two standards in the bay of length is known as ledger. Ledgers are used as decide the height of the working platform for connecting the standards.
Transom/ Bearer
Transoms are used for the supporting of the posts of standards in the bay of width is known as transom/ bearer and transom are always fixed at the right angles to the ledgers.
Transvers bracing
Its used for the strengthening of the scaffold structure to carry more loads.
Scaffolding Clamps/ Couplers
Couplers are the jointing tools to fix the tubes together. Their are some main types of coupler with SWL as follows; Right-Angle Coupler, Swivel Couplers, Sleeve and Putlog Couplers.
(a) Right angle coupler (fixed or double coupler) SWL 630 kg : Used to connect horizontal and vertical tubes.
(b) Swivel coupler SWL 530 kg :- Used to two connect any angle tubes.
(C) Sleeve coupler (box clamp) SWL 300 kg :-Used to joint two straight tubes.
(d) Putlog coupler SWL 53 kg :- Used to fix plank with the transom.
Scaffolding Guard (Top, Mid) Rails
Handrail & Mid rail used for the safety of the workmen.
Scaffolding Toe boards/guards
Toe boards (width 150 mm) are used for the safety of the workmen and also to protect the objects to fall down.
Scaffolding plank
Plank provide the fixed platform fixed with transoms. Size comes in 2100 x 280 x 38/50/63 mm and its should be defect free. Transoms tube should be install maximum 1.5 meter below platform. If two plank overlap it should be minimum 12 fit.
Scaffolding Ladder
Ladder is equipment which is used for the safely climbing up and down at the required place. Ladder should be fix and follow all safety rules during installation and its use.
Scaffolding training and its requirements
OSHA requires the employers that have to provide a proper training by competent authority and develop scaffold skill of their workers who will be erected or dismantle a safe scaffolding.
As per the OSHA guidelines scaffolding training shall include for each employee who will be participated in the scaffolding work with the following topics:
- Types of Scaffolding hazards
- The right & systematic procedures for all types of the scaffold jobs like erecting, disassembling & inspecting of the scaffolding.
- Scaffolding load capacity & duty type.
Pre Planning for the Safe Scaffolding
A qualified or a trained person have to do proper pre planning for the safe scaffold. These planning must include :
- Insure scaffold materials are inspected and fit to use.
- Maximum load of the scaffold.
- Type of the scaffold require.
- Good & leveled Foundation of the scaffold.
- Electrical hazard availability.
Scaffolding erection
Some sequence/ procedures and note should be follow for the safe erection of the scaffolding.
- Request Permit to work (PTW) for the erection of type type and duty of the scaffolding.
- Check for the ground conditions.
- Sole plate (If required as per the ground conditions)
- Base plate (Fixed type for the plane surface or adjustable jack type for uneven surface)
- Scaffolding tube fitting (Standards) install on the base plate ( Standards joints will not comes at the same height for the safety)
- Base/ Kicker lift placed by ledger (length) and transoms (width) maintain water lever at the height of 150mm from base plate. Projection of ledgers and transoms should be between 50 to 150 mm.
- First lift (2.1 to 2.7 meter from the base lift)
- Second and every next lift should be every 1.8 meter till required height.
- Create service platform at the required height with the planks on the transoms (gap between plank should not more than one inch). Always transoms should be fitted above the ledger for the safety of the platform.
- Top handrail (Height 1050 mm), middle handrail (Height 525 mm) with the toe board (Height 150 mm) should be provide for safety at the service platform.
- Cross bracing should be provide for the rigidness and stability of the scaffolding. Cross bracing should be maintain between 35 to 55 degree width help of swivel clamp not more than 300 from the node.
- Swing gate with locking system should be provide for the safety of entry/ exit point at service platform near ladder.
- Ladder should be provide (more than the 3 fit height, left or right side of the landing platform, ) for the safe access till service platform with the maintaining of 4:1 ratio (75 deg.). A single ladder will be provide up to six meter height sequentially with landing platform. ladder step area 300×300 mm and step capacity minimum 225 to 235 kg.
- Barrication of the all side area of the scaffolding to avoid hit by the vehicle movement and safety for others.
- Provide suitable tags at the visible area during erection, modification and after inspection for ready to use of the scaffolding.
Scaffold Safety Tagging
Every scaffoldings are required to inspect and tagged properly. Tags are define the current status of the scaffolding. Untagged Scaffoldings are never to use. Tagged are locate near access of scaffoldings at eye level. Scaffolds tags are as follows.
- Red Tags :- Scaffolding is unsafe to use or incomplete.
- Yellow Tags :- Scaffolding some modification required to meet work requirement.
- Green Tags :- Scaffolding is a safe to use.
Hard Hat Stickers for Scaffold workers
Hard Hat sticker is required for Trained and qualified scaffold workers for the creating safe environment. sample Hard hat sticker for sample as below.
Scaffolding Hazards and Risks
As per the case studies of OSHA found approx. 65% of the project or construction work required scaffoldings to perform their work on height. Therefore, scaffolding hazard will be increased as its height can be increases. Their are some major scaffolding hazards the can occur :
- Falls from height due to improper guardrail during installation of the scaffolding.
- The Scaffold collapse due to improper erection.
- The falling Material from the scaffolds due improper protection on scaffolding.
- Electrical hazards due to improper planning.
- Slips & falls from the boards.
- The platforms felled due to overloading
- Hazards due to wheel not locked of the rolling scaffolding.
Therefore, you should always require to inspect the scaffolding every day before starting any jobs on the scaffolding. The world Occupational Safety and Health Administration (OSHA) given a clear guidelines to follow the checklists for the confirmation of the healthiness of the scaffoldings. Maximum organizations follow the checklist before use of the scaffolding.
Safety of Scaffolding Do’s and Don’ts
Do’s of the Scaffoldings :
Don’ts of the Scaffoldings :
Scaffolding Codes for IS standards
IS : 3696 ( Part 1 & 2 ) : 1987 (Ladders) Safety code of scaffolds and ladders
IS 4014-1 (1967): Code of practice for steel tubular scaffolding
OHSA 1926.451 – General requirements for scaffolds
Section 32 in The Factories Act, 1948 : Floors, stairs and means of access.—In every factory
Scaffolding Inspection and checklist
Before the use of scaffolding its regular inspection and certification must require for the Strength and stability of the scaffolding. Scaffolding should be inspected by qualified or competent person only at regular basis.
- Checked after installation or before first use of the scaffolding
- Checked minimum every week.
- Checked every time after adverse weather conditions.
Scaffolding Inspection Checklists download :
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Test your Knowledge by Scaffolding Quiz: Quiz! on Scaffolding safety
Also Read : Job Safety Analysis || JSA
New 2022 Job Safety Analysis | JSA | JHA
Here we are going to know about basic concept of the job safety analysis ( JSA ) and provides its step-by-step procedure for creating JSA/JHA made simple.
Definitions :
Hazard :-
” Anything that have a potential to harm with current situation can be able to do any type of worst effect on the health.”
Risk:-
” Chance that will be harmed to person health after exposed to hazard. ”
Hazard meaning in Hindi
हिंदी में हज़ार्ड को जोखिम, खतरा, संकट , विपत्ति आदि कहते है। लेकिन साथ में रिस्क को भी जोखिम, खतरा, संकट , विपत्ति कहते हैं। जबकि हज़ार्ड तथा रिस्क दोनों ही बिलकुल अलग चीजे है। यहाँ हम आपको आसान तरीके से आपको हज़ार्ड को समझायेंगे तथा यह और रिस्क अलग कैसे होता है उसे अच्छी तरह से समझायेंगे जिससे आपको कभी भी इसमें समझने में भविष्य में कोई दुविधा नहीं होगी।
(Hazard in Hindi is called risk, danger, crisis, calamity etc. But at the same time, risk is also called risk, danger, crisis, calamity. Whereas both Hazard and Risk are completely different things. Here we will explain you Hazard in an easy way and explain it and how risk is different so that you will never have any problem in future to understand it.)
खतरा एक ऐसी स्थिति या स्रोत है। जिसमें मानव स्वास्थ्य, पर्यावरण या मौजूद संपत्ति को नुकसान हो सकता है। या एक ही बार में सभी को नुकसान पहुंचाने की क्षमता रखते हैं। यह किसी असुरक्षित कार्य, असुरक्षित स्थिति या ऐसी चीजों के कारण हो सकता है जो या तो अभी मौजूद हैं या किसी असुरक्षित कार्य, असुरक्षित स्थिति या स्थिति में बदलाव से किसी भी समय मौजूद हो सकती हैं।
(Hazard is one such condition or source. In which human health, environment or property present can be harmed. Or have the potential to cause harm to all at once. It can be caused by any unsafe act, unsafe condition or things that are either present now or can be present at any time from an unsafe act, unsafe condition or change in situation.)
बहुत से लोग खतरे (Hazard) और जोखिम (Risk) के बीच के अंतर को नहीं समझते हैं या इसे एक ही मानते हैं। यहां हम आपको एक बात स्पष्ट कर देते हैं कि खतरा (Hazard) और जोखिम (Risk) समान नहीं हैं। Risk हमेशा वहां मौजूद hazard का परिणाम होता है। अगर हम किसी Hazard के संपर्क में आते हैं तो हमें नुकसान या चोट का Risk होता है। हम हमेशा हैजर्ड को खोज करके तथा कंट्रोल करके रिस्क को कम या ख़त्म कर सकते है।
(Many people do not understand the difference between hazard and risk or consider it to be the same. Here we make one thing clear to you that Hazard and Risk are not the same. Risk is always a consequence of the hazard that is there. If we come in the contact with any hazard, we are at risk of damages or injury. We can always reduce or eliminate the risk by finding and controlling the hazard.)
किसी भी कार्य को करने से पहले हमे वहाँ उपस्थित हज़ार्ड की पहचान जरूर करनी चाहिए। तथा उसको उचित कण्ट्रोल करने के बाद ही काम को शुरू करना चाहिए। ताकि किसी भी वजह से उस हैज़ार्डस के संपर्क में कोई भी न आसके सके। था हर तरह के रिस्क से हम सुरक्षित रह सके। इसके लिए ही आजकल हर कंपनी के काम स्टार्ट करने से पहले JSA/JHA/HIRA का निर्माण करते है। जहाँ हम ज्यादातर श्रमिक और टास्क तथा इसके अलावा उपयोग होने वाले टूल्स, इक्विपमेंट तथा मौसम के बीच हो सकने वाले सम्बन्ध पर फोकस करते है।
(Before doing any work, we must identify the Hazard present there. And the work should be started only after proper control. So that no one can come in the contact with those hazards due to any reason. We could be safe from all kinds of risks. For this, nowadays every company manufactures JSA / JHA / HIRA before starting the work. Where we mostly focus on the relationship between the labour and the task, as well as the tools, equipment used and the weather.)
What is a Job Safety analysis/ job hazard analysis ?
JSA/JHA is a tools or technics that concentrated on tasks, location & work environment of the define job for identifying the hazards with its control measure for the all identified hazards by elimination or reduction till acceptable risk level prior to start the job.
JSA Format (Download):
Here you will find the JSA/ JHA standard format in the “.xls format” for your reference and working for making your job safety analysis.
Click Here to Download XLS file :
[su_button url=”https://www.oparya.com/wp-content/uploads/2021/10/JSA-Format.xlsx” target=”blank” style=”3d” background=”#09da35″ color=”#07071f” size=”10″ wide=”yes” center=”yes” icon=”icon: download” text_shadow=”0px 0px 0px #170101″ desc=”Click to Download .Xls file” download=”JSA in XLS Format”]Job Safety Analysis Standard Format[/su_button]
Job Safety Analysis flow chart:
- Select job to be perform
- Divide the job into sequential task
- Identify hazards for the each tasks.
- Recommend control to mitigate hazards
- Define Responsibilities
- Communication of JSA to all in Toll box talk/ TBT.
- Periodically review and improve it.
Job safety analysis step by step:
Job Safety Analysis is as follows :
- Select the job
- Breaking the job in to sequential tasks
- Identifying the all possible hazards
- Preventive measures to control the hazards till acceptable risk
- Given communication to others
How basic tasks are stabilized ?
Tasks are the elements of complete job. Job completion needs to complete the all tasks in a sequentially manner. If any task missed out in a sequence its may be create a hazard & also its increase the timeline & quality of the job. therefore if we are creating a JSA we have to need record the tasks in a proper sequential manner.
Job safety analysis example of the sequential tasks mapping for the car tyre replacement job:
How identify the potential Hazards ?
There are the famous tools for identifying the hazards.
- Based on change analysis.
- Based on unwanted energy and barrier.
Change Analysis :-
Change analysis is a technics which can help us to identify the significant of changes that can adverse effect on health of person or environment causing an unexpected incidents. Change analysis is a powerful technics which is a first introduced by C.H. Kepner and B.B. Tregoe in 1965. As a managerial tool is used for solve the production/ operational problems as well as it was equally use in occupational health and safety issues from the 1970. When its adopted its get easier to point the hazards & its consequences and its also help us to minimize the risk by asking systematic questions of each tasks which begin with “What if….?”
Tips which helps in change analysis : –
Words which will be guide you for “What if” questions.
Example, change analysis can be applied to the “changing a car tyre” job. The first task “park the vehicle” insists on the “location” of the vehicle as a main parameter. The vehicle must be parked out side the road before removing any wheel. Now we are applying “What if questions to this task.
Unwanted energy flow and energy barrier approach :-
Controlled energy is essential to perform the work. Uncontrolled energy has the potential to result an accident. controlled flow of electrical energy will equipment’s & lighting. Uncontrolled electrical result an electric shocks. therefore hazards are define as a uncontrolled energy and the contact with person resultant injury & accident.
In the process of the energy barrier look barrier factors for the each task for energy source, way to contact with energy & define the any chance to contact with energy.
Types of Energy source :-
Way to contact with uncontrolled energy:-
For the identifying hazards each task we have to verify the type of energy and way to contact with energy with the support of above both tables.
Identifying potential hazards for car tyre replacement job.
Hazard control methods :-
To control the each hazard till its acceptable risk we have to follow its systematic control procedures these are :-
- Elimination – Physically remove the Hazards
- Substitution -Hazard replace with non-hazardous or with the other option.
- Engineering Control – Isolate the equipment, energies and person from the hazard.
- Administrative Controls – Change the way of working to control the hazard.
- Personal Protective Equipment (PPE) – Protect yourself with use of required PPEs according to the job.
An example of Job safety analysis sheet with activities, hazards, control measures and responsible person (JSA needs to mention responsible person whose responsible for assurance of the job which will be perform as per the define step with control measures safely )
How should I communicate the prepared JSA/JHA before starting the Job ?
JSA is communicate in the toolbox talk meeting.
Also read :- Toolbox Talk Meeting (TBT) || 3Q Meeting
Why follow-up and review of the Job Safety Analysis ?
It is essential to establish a process to follow-up and review process of the job safety analysis for the following :
- Ensure new hazards are not generated / created.
- Mention all feedbacks after performing the job.
- JSA periodically review is required for its continuous improvement.
What are the economic benefits of JSA/ JHA ?
- Reduce direct & indirect cost of the accidents and the maintain reputation of the company.
- Improve the productivity and quality of the job.
- Improve the knowledge with safety and the moral of people.
The effort and time consume for the preparing of a JSA is an investment to control accidents/ Injury and the productivity of the job.
Test you knowledge in Job Safety Analysis by an interesting Quiz!
Also read: Workplace Safety