Setyr worked example — CV-300 Overland Conveyor — Belt Splice Isolation Not approved for use. Version 1 · 2026-09-25
Worked example only — your site must author, review and approve its own
procedure under 29 CFR 1910.147(c)(4). setyr.com/procedures
CV-300 Overland Conveyor — Belt Splice Isolation
Bulk materials handling
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.
This is a worked example, not a procedure you can adopt. It describes equipment that does not exist, with illustrative tag numbers.
29 CFR 1910.147(c)(4) requires the employer to develop, document and
utilise energy control procedures specific to their own machines, and (c)(6)
requires the employer to inspect those procedures periodically. Neither duty
can be delegated to a vendor or discharged by this document.
Isolation points
| # | Tag (illustrative) | Type | Disposition | What it does and why | Dwell |
|---|---|---|---|---|---|
| 10 | CV-300-HD-ISO | Disconnect | Isolate & lock | Head-end drive station 11kV isolator, two 750 kW drives. Caution: Proving dead at the head does not address the tail drive. This conveyor has drives at both ends. Open, lock, and prove dead at the switchgear with an approved voltage tester. | — |
| 20 | CV-300-TL-ISO | Disconnect | Isolate & lock | Tail-end drive station isolator, single 400 kW drive. 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. Open, lock, prove dead. Confirm with the head-end isolation before any belt work. | — |
| 30 | CV-300-EARTH | Chain | Apply & verify | Portable earths applied at both drive stations after proving dead. Caution: Earths are applied protection, not isolation. They go on after proving dead and come off before re-energisation. Apply earths at head and tail after proving dead. Must remain APPLIED for the duration. | — |
| 40 | CV-300-BRK-HYD | Valve | Isolate & lock | Drive pulley brake hydraulic supply, spring-applied hydraulic-release brakes. Caution: These brakes RELEASE on hydraulic pressure. Leaving the accumulator charged means a residual release path. Close and lock the supply, then bleed the brake accumulator so the brakes stay spring-applied. | 90s |
| 50 | CV-300-TAKEUP | Block | Apply & verify | Gravity take-up tower, 18 tonne counterweight suspended 22 m. 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. 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. | — |
| 60 | CV-300-HOLDBACK | Block | Apply & verify | Backstop holdback assemblies on both drive pulleys. Caution: A loaded incline belt runs back under gravity the moment tension is released. The holdbacks are the only thing preventing it. Confirm both holdbacks are engaged before the belt is cut. Must be ENGAGED. | — |
| 70 | CV-300-BELT-CLAMP | Block | Apply & verify | Belt clamps applied either side of the splice location. Caution: Clamps carry the residual tension across the cut. A clamp that slips releases the belt across the crew. Apply clamps both sides of the cut and confirm they are torqued and biting before the belt is parted. | — |
| 80 | CV-300-LUBE | Disconnect | Isolate & lock | Drive gearbox lubrication pump disconnect. Open and lock. | — |
| 90 | CV-300-DUST | Valve | Isolate & lock | Dust suppression water supply along the splice section. Caution: Suppression spray onto a hot vulcanising press is a burn and steam hazard. Close and lock the section valve. | — |
| 100 | CV-300-PULLCORD | Switch | KEEP ENERGISED | Emergency pull-cord and belt-drift monitoring circuit along the conveyor 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. Do NOT isolate. Confirm the pull-cord circuit is healthy for the length of the run. | — |
| 110 | CV-300-VULC-PWR | Disconnect | KEEP ENERGISED | Vulcanising press supply, fed from the splice-site distribution board. Caution: Isolating the whole distribution board to lock the conveyor takes the vulcanising press with it. Do NOT isolate. This is the supply for the splice press and must remain available. | — |
What your site must supply
- 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.
Authorship and validation
This example was authored by Setyr for domain validation. It is not derived from any customer's controlled documents. It illustrates the elements 29 CFR 1910.147(c)(4)(ii) requires a procedure to contain — it does not certify compliance, which is a property of an employer's programme rather than of any document.