CV-300 Overland Conveyor — Belt Splice Isolation
Vulcanised splice on a 2.1 km inclined overland conveyor. Covers gravity take-up restraint, belt runback holdbacks and the stored energy in a tensioned belt across multiple drive stations.
How Setyr addresses Mining & Aggregates →
It refers to equipment that does not exist and illustrates the elements 29 CFR 1910.147(c)(4)(ii) requires a procedure to contain. It is not a document to adopt. Under (c)(4)(i) the employer must develop and document energy control procedures specific to their own machines, and under (c)(6) must inspect them at least annually.
11 points, in sequence
Head-end drive station 11kV isolator, two 750 kW drives.
Method: Open, lock, and prove dead at the switchgear with an approved voltage tester.
Caution: Proving dead at the head does not address the tail drive. This conveyor has drives at both ends.
Tail-end drive station isolator, single 400 kW drive.
Method: Open, lock, prove dead. Confirm with the head-end isolation before any belt work.
Caution: A second drive 2.1 km away is out of sight of the crew at the splice. It is the one that gets missed.
Portable earths applied at both drive stations after proving dead.
Method: Apply earths at head and tail after proving dead. Must remain APPLIED for the duration.
Caution: Earths are applied protection, not isolation. They go on after proving dead and come off before re-energisation.
Drive pulley brake hydraulic supply, spring-applied hydraulic-release brakes.
Method: Close and lock the supply, then bleed the brake accumulator so the brakes stay spring-applied.
Caution: These brakes RELEASE on hydraulic pressure. Leaving the accumulator charged means a residual release path.
Gravity take-up tower, 18 tonne counterweight suspended 22 m.
Method: Land the counterweight on its mechanical stops and confirm the take-up carriage is resting on the stops, not on the rope. Blocks must be ENGAGED.
Caution: This is the largest stored energy on the conveyor. Cutting a tensioned belt with the counterweight airborne releases 18 tonnes through the take-up carriage.
Backstop holdback assemblies on both drive pulleys.
Method: Confirm both holdbacks are engaged before the belt is cut. Must be ENGAGED.
Caution: A loaded incline belt runs back under gravity the moment tension is released. The holdbacks are the only thing preventing it.
Belt clamps applied either side of the splice location.
Method: Apply clamps both sides of the cut and confirm they are torqued and biting before the belt is parted.
Caution: Clamps carry the residual tension across the cut. A clamp that slips releases the belt across the crew.
Drive gearbox lubrication pump disconnect.
Method: Open and lock.
Dust suppression water supply along the splice section.
Method: Close and lock the section valve.
Caution: Suppression spray onto a hot vulcanising press is a burn and steam hazard.
Emergency pull-cord and belt-drift monitoring circuit along the conveyor run.
Method: Do NOT isolate. Confirm the pull-cord circuit is healthy for the length of the run.
Caution: A 2.1 km conveyor is out of shouting distance end to end. The pull cord is how a person at the splice stops something happening at the tail.
Vulcanising press supply, fed from the splice-site distribution board.
Method: Do NOT isolate. This is the supply for the splice press and must remain available.
Caution: Isolating the whole distribution board to lock the conveyor takes the vulcanising press with it.
What your site must supply
This example is structurally complete and factually generic. The things below are the things only you can know — and they are exactly what makes a procedure yours.
- Your own asset and isolation-point tag numbers. The tags shown are illustrative and refer to equipment that does not exist.
- The actual location of every disconnect, valve and vent on your equipment.
- Measured stored-energy magnitudes and the dwell time required to dissipate them.
- Your verification method for each point, and who is authorised to perform it.
- Any additional energy sources present on your equipment and absent here.
Author this properly, once
Setyr holds procedures like this as living documents — bound to real isolation points, with lock registries, group lockout, person-in-charge custody and periodic review built in.