[Link].

org © 2022 IJCRT | Volume 10, Issue 6 June 2022 | ISSN: 2320-2882

RISK ASSESSMENT AND BEST SAFETY

PRACTICES ON CONVEYORS
A.V. BALAN, [Link], [Link]
Professor and Head, Associate Professor, Student
Department of Mechanical Engineering,
KSR College of Engineering, Namakkal, India

Abstract: This project deals with various types of hazards identification & finding a risk assessment (HIRA) and identifying
best safety practices on conveyors including conveyor guarding, hazardous energy isolation and visual inspection procedures
for industries that utilize conveyor systems. The safe working operation of conveyors needs to identify the hazards, assess the
associated risks and bring the risks to tolerable level on a continuous basis. Each year, physical contact with machines and
powered equipment accounts for a significant number of life-altering injuries and fatalities. A number of these incidents involve
conveyor systems. The majority of these incidents occur during maintenance activities with conveyors still in operation and
danger zones unprotected. A risk assessment is an important step in protecting the conveyors and humans from such conditions.
It helps us to focus on the risks that really have the potential to cause harm. Risk classification by probability and severity can
be performed by using a risk assessment class. Then risk level is assigned to each hazard for identifying required Preventive
measures to minimize the risk or eliminate the Hazard. Preventive measures should be implemented in order for work on or
near conveyors to be performed safely. Right from the design stage, worker exposure to hazards should be controlled by
reducing the frequency of conveyor clean-ups, conveyor maintenance, removal of jams, etc. This project to best safety practices
suggests possible preventive measures, but it is by no means exhaustive. In many situations, hazards must be analysed before
any preventive measures are implemented.

Index Terms - hazards, risk assessment, safety practices, conveyors, safeguards.

[Link]

1.1 CONVEYORS
A conveyor system is a fast and efficient mechanical handling apparatus for automatically transporting loads and materials
within an area. This system minimizes human error, lowers workplace risks and reduces labour costs among other benefits. They
are useful in helping to move bulky or heavy items from one point to another. A conveyor system may use a belt, wheels, rollers,
or a chain to transport objects.
1.1.1 Conveyor systems work.
Typically, conveyor systems consist of a belt stretched across two or more pulleys. The belt forms a closed loop around
the pulleys so it can continually rotate. One pulley, known as the drive pulley, drives or tows the belt, moving items from one
location to another. The most common conveyor system designs use a rotor to power the drive pulley and belt. The belt remains
attached to the rotor through the friction between the two surfaces. For the belt to move effectively, both the drive pulley and
idler must run in the same direction, either clockwise or counter clockwise. While conventional conveyor systems such as
moving walkways and grocery store conveyors are straight, sometimes, the unit needs to turn to deliver the items to the proper
location. For the turns, there are unique cone-shaped wheels or rotors which allow the belt to follow a bend or twist without
getting tangled.
1.1.2 Benefits of conveyor systems

The main purpose of a conveyor system is to move objects from one location to another. The design allows for
movement of objects that are too heavy or too bulky for humans to carry by hand. Conveyor systems save time when
transporting items from one location to another. As they can be inclined to span multiple levels, they make it simpler to move

IJCRT22A6459 International Journal of Creative Research Thoughts (IJCRT) [Link] d813

 [Link] © 2022 IJCRT | Volume 10, Issue 6 June 2022 | ISSN: 2320-2882
items up and down floors, a task that, when performed manually by humans, causes physical strain. Inclined belts can
automatically unload material, eliminating the need for someone to be on the opposite end to receive pieces.
1.1.3 Types and examples of conveyor systems
You can probably imagine a large warehouse filled with conveyors using belts and rollers to move boxes and other
heavy equipment, but this is just one of several types of conveyor systems. You’ll also find conveyor systems in airports, where
they’re used to transport luggage. Other examples include escalators and ski lifts. These apparatuses still use a belt or chain and
pulleys to move heavy items from one point to another.

There are many types of conveyor systems, including:

 Belt
 Roller
 Slat/apron
 Ball transfer
 Overhead
 Pneumatic
 Bucket
 Chute
 Magnetic
 Vertical
 Wheel
 Walking beam
 Vibrating
 Screw/auger

1.2 COMPONENTSOF A CONVEYORBELT

Fig.1; components of belt conveyor

1.3 PARTS OF BELT CONVEYORS
:

Belts: Various types of textile belts are employed in belt conveyors: Camel hair, cotton(woven or sewed), duck cotton.
Rubberized textile belts are widely used. Conveyors belts
shouldmeet thefollowingrequirements:

 Low hygroscopocity
 High strength
 Chain
 Low own weight (Light in weight)
 Small specific elongation
 High flexibility
 High resistivity to ply (Layer of material)  Long service life

Rubberized textile belts: Rubberized textile belts are made from several layers known as plies of a rough woven cotton
fabric known as belling. The plies are connected by vulcanization with natural or synthetic rubber. Sometimes the plies are
made of extra – strong synthetic fabrics, Capron, perlon, nylon etc.

1.3.1 Idlers
Generally the belt is supported by idler rollers, in rare cases by a solid wood, or sheet steel, runway or a combination support
comprising sections of a runway alternating with idle rollers. Idlers are used mainly in conveyors handling bulk loads, less
frequently unit loads, while runways and combined supports are predomiantly used for piece goods. According to their
IJCRT22A6459 International Journal of Creative Research Thoughts (IJCRT) [Link] d814
 [Link] © 2022 IJCRT | Volume 10, Issue 6 June 2022 | ISSN: 2320-2882
location on the conveyors, idlers are classified as upper (supporting the loaded strand of the belt) and lower (supporting the
idler return strand of the belt).

1.3.2 Centering device

A number of reasons, such as eccentric loading, soiling, sticking of the material to the pulleys and rollers etc., may cause the
belt to run crooked. To prevent the belt from running off the rollers, special “Belt training idlers” of various designs are used.
These idlers automatically maintain belt alignment with respect to a device (idlers) called centering device.

1.3.3 Take ups.

A belt conveyor may have a mechanical (screw type) or counterweight (gravity type) take up. The latter may in turn be
divided into carries – type (sometimes called horizontal and vertical. In the screw take up the tensioning pulley simultaneously
serves as deflecting til or pulley and rotates on a fixed shaft (best design) or in terminal bearings (worst design). In gravity
take ups the tensioning pulley (serving simultaneously as tail and pulley) is placed on a movable carriage which is pulled
backwards by means of a steel rope and deflecting pulleys. The vertical counterweight take up consists of three pulleys, (two
deflecting and one tensioning) and are installed on the return strand of the conveyor. N.B. The carriage type take-up is
superior to the vertical type because it is of much simpler design of considerably less height.
1.3.4 Drive units
In belt conveyors motive power is transmitted to the belt by friction as it wrapsaround the driving pulley rotted by an electric
motor; the drive comprises the following parts: the pulley (Sometimes two pulleys), motor and the transmission gear between
the motor and the pulley. Drives of inclined conveyors include a braking device which prevents slipping back of the loaded
belt under the weight of the material conveyed if the current supplying the motor is interrupted.
1.3.5 Loading & discharging
Loading depends on the nature & characteristics of the load conveyed and the method of loading. Example:
Charging
For piece goods various types of chutes are directly loaded onto the belt. For loose materials feed hopper Discharging:
Generally employed by

- Scrapper ploughs
- A throw – off carriage known as tripper (only used for bulk materials.

1.3.6 Belt Cleaner:

In case of dry particles: The clinging dry particles are cleaned by scrapper/wiper In case of wet and sticky materials: Revolving
brushes are used
Scrappers are mounted on end pulley Brushes are mounted on
lower num.
Belt cleaners are mounted near the discharge pulley.

1.3.7 Automated hold back brakes:

A sudden stoppage of a loaded inclined belt conveyor may cause slipping back of the loaded belt. This will happen if
longitudinal component of load weight which is larger than the forces of frictional resistance to belt motion.
 To prevent this type of spontaneous movement of the belt, a special hold back brake is mounted on the main or auxiliary
shaft which keep inclined in conveyor.
 It is a special protecting device which automatically disconnects the drive when the belt slips on the pulley.

1.4 SCREW CONVEYOR

A screw conveyor or auger conveyor is a mechanism that uses a rotating helical screw blade, called a "flighting", usually within
a tube, to move liquid or granular materials. They are used in many bulk handling industries. Screw conveyors in modern
industry are often used horizontally or at a slight incline as an efficient way to move semi-solid materials, including food waste,
wood chips, aggregates, cereal grains, animal feed, boiler ash, meat, and bone meal, municipal solid waste, and many others.
The first type of screw conveyor was the Archimedes' screw, used since ancient times to pump irrigation water.

IJCRT22A6459 International Journal of Creative Research Thoughts (IJCRT) [Link] d815

[Link] © 2022 IJCRT | Volume 10, Issue 6 June 2022 | ISSN: 2320-2882

Fig.2; screw conveyor

1.5 BUCKET ELEVATOR

A bucket elevator, also called a grain leg, is a mechanism for hauling flowable bulk materials (most often grain or fertilizer)
vertically.

It consists of:

1. Buckets to contain the material;

2. A belt to carry the buckets and transmit the pull;
3. Means to drive the belt;
4. Accessories for loading the buckets or picking up the material, for receiving the discharged material, for maintaining
the belt tension and for enclosing and protecting the elevator.

A bucket elevator can elevate a variety of bulk materials from light to heavy and from fine to large lumps.

A centrifugal discharge elevator may be vertical or inclined. Vertical elevators depend entirely on centrifugal force to get the
material into the discharge chute, and so must be run at a relatively high speed. Inclined elevators with buckets spaced apart or
set close together may have the discharge chute set partly under the head pulley. Since they do not depend entirely on
centrifugal force to put the material into the chute, their speed may be slower.

Fig.3; bucket elevator

1.5.1 Working principle

Charge/ Load: Here, no extra force is needed to collect the bulk material. Only gravitational force is acting on the
material.
IJCRT22A6459 International Journal of Creative Research Thoughts (IJCRT) [Link] d816
[Link] © 2022 IJCRT | Volume 10, Issue 6 June 2022 | ISSN: 2320-2882
1.6 CHAIN CONVEYORS
A chain conveyor is a type of conveyor system for moving material through production lines.

1.6.1 Operation
Chain conveyors use an endless chain both to transmit power and to propel material through a trough, either pushed
directly by the chain or by attachments to the chain. The chain runs over sprockets at either end of the trough. Chain conveyors
are used to move material up to 90 metres (300 ft), and typically under 30 metres (98 ft). Chain conveyors utilize a powered
continuous chain arrangement, carrying a series of single pendants. The chain arrangement is driven by a motor, and the
material suspended on the pendants are conveyed. Chain conveyors are used for moving products down an assembly line and/or
around a manufacturing or warehousing facility. Chain conveyors are primarily used to transport heavy unit loads, e.g. pallets,
grid boxes, and industrial containers. These conveyors can be single or double chain strand in configuration. The load is
positioned on the chains, the friction pulls the load forward. [2] Chain conveyors are generally easy to install and have very
minimum maintenance for users.
1.6.2 Types
Types of chain conveyor include apron, drag, plain chain, scraper, flight, and en-masse conveyors.

IJCRT22A6459 International Journal of Creative Research Thoughts (IJCRT) [Link] d817

[Link] © 2022 IJCRT | Volume 10, Issue 6 June 2022 | ISSN: 2320-2882
1.6.3 Drag conveyor

Drag conveyors, variously called drag chain conveyors, scraper chain conveyors and en-masse conveyors, are used in bulk
material handling to move solid material along a trough. They are used for moving materials such as cement clinker, ash, and
sawdust in the mining and chemical industries, municipal solid waste in cinerators, and the production of pellet fuel.

The difference between drag conveyors, scraper conveyors, and flight conveyors largely depends on whether the chain links
have obvious flights or paddles attached. In a drag conveyor, the chain moves the material directly, while a flight conveyor uses
a series of wood, metal, or plastic flights attached to the chain at regular intervals, which push the material along the trough.

IJCRT22A6459 International Journal of Creative Research Thoughts (IJCRT) [Link] d818

 Fig.4; drag chain
[Link] conveyor © 2022 IJCRT | Volume 10, Issue 6 June 2022 | ISSN: 2320-2882
METHODOLOGY
Hazard identification and risk assessment is a combinations deterministic, probabilistic and quantitative method. The
deterministic methods take into consideration the products, the equipment
cationand
of the quantifi
various targets such as
people, environment and equipment. The probabilistic methods are based on the probability or frequency of hazardous situation
apparitions or on the occurrence of potential accident. The quantitativerious
methods
data numerically.
analyses va

The five steps of hazard identification and risk assessment are:

Step1: System Description
Step2: Hazard Identification
Step3: Risk Assessment
Step4: Risk Rating
Step5: Resolve the Risk
The above steps for hazard identification
and risk assessment (HIRA)
Step1: System Description:

Define the system and there subsystem and operations or activities.

II.

Step2: Hazard Identification

Defining and describing a hazard, including its physical characteristics, magnitude and severity, causative factors, and
locations or areas affected.

Step3: Risk Assessment

Analyse the Probability, frequency or likelihood the potential losses associated with a hazard.

Step4: Risk Rating

Risk Classification Screening Table is formed and value of hazard or calculated risk class gives the require action to
be
taken.

Step5: Resolve the Risk

Corrective action recommended preventing, reducing or transferring the risks, by short and long term planning.

III. MAJOR HAZARDS DESCRIPTION IN CONVEYORS

The given table as follows to the major hazards in the conveyors. Table.1
[Link] SPECIFICATION HAZARDS
1. Power transmission
Drive shaft; shaft end; sprocket; pulley; chain; drive belt; gear coupling
moving parts

IJCRT22A6459 International Journal of Creative Research Thoughts (IJCRT) [Link] d819

[Link] © 2022 IJCRT | Volume 10, Issue 6 June 2022 | ISSN: 2320-2882
2. Belts Belt in good condition.
Deteriorated belt or belt splice
3. Conveyor belts in a In-running nips between the rollers/load beds under the hopper
straight run Load side under the skirt board or skirt.
In-running nips between load side and support rollers in a straight run
In-running nips between lower strand and return rollers in a straight run

Return strand scrapers.

Return rollers

4. Curved zone In-running nip between the belt and rollers in the curved zone

5. Transition zone In-running nips between the load side and the load carrying rollers in the
transition zone
6. Drums In-running nips between belt and drums

Take-up system
Junction between two conveyors.
In-running nips between belt and drums.
7. Moving loads Load and load carrying rollers exceeding belt width.

Loads falling from the belt

8. Moving sub assembly

Pushers; bumpers; ejectors; sorters

9. Moveable conveyors Vertical and/or horizontal movement

10. Screw conveyors Screw conveyors are troughs with a revolving shaft with a spiral or twisted
plate. In‐going nip points for the entire length of the screw conveyor exist
between the revolving shaft and trough. Because the trough may not be
covered and the conveyor may be located at or near floor level, screw
conveyors can be particularly dangerous.

11. Chain conveyors Nip points occur when a chain contacts a sprocket. Nip points also occurat
drives, terminals, take‐ups (automatic take‐ups may also have shear points),
and idlers. Clothing, jewelry, and long hair may also get entangled and
caught in the moving chain conveyor.

12. Roller conveyors Roller conveyors are used to move material on a series of parallel rollers that
IJCRT22A6459 International Journal of Creative Research Thoughts (IJCRT) [Link] d820
 [Link] © 2022 IJCRT | Volume 10, Issue 6 June 2022 | ISSN: 2320-2882
are either powered or gravityfed.
Powered roller conveyors can snag and pull hands, hair, and clothing into
the area between the rollers and the stationary components of the conveyor.
In‐going nip points may exist between the drive chain and sprockets;
between belt and carrier rollers; and at terminals, drives, take ‐ups, idlers,
and snub rollers.

IV. HAZARD IDENTIFICATION AND RISK ASSESSMENT

Hazard Identification and Risk Assessment (HIRA) is a process that consists of a number of sequential steps
such as hazard identification, consequence & frequency assessment, risk estimation based on the existing controls and
recommendations to reduce those risks which are not under acceptable limits. Hazard Identification and risk assessment
vary greatly across industries, ranging from simple assessment to complex quantitative analyses with extensive
documentation.

Risk assessment is a process or application of a methodology for evaluating risk as defined by probability and
frequency of occurrence of a hazard event, exposure of people and property to the hazard, and consequences of that
exposure. Different methodologies exist for assessing the risk of natural hazard events, ranging from qualitative to
quantitative. A tool for helping to identify, evaluate and control the risk. The tool facilitates to assess each manufacturing
step with respect to critical operations and identify the hazardous process.

4.1 STEPS INVOLVED IN HIRA:

Step 1 -Identification of Hazard

Step 2 -Risk Assessment

Step 3 -Monitor and Review

Step 4 - Control

4.1.1 Step 1-Identification of Hazard:

Accurately identifying potential hazards in the workplace is the first step in developing a HIRAC. Conduct a
work site inspection and observe how work tasks are performed, assess equipment workers are using, and analyze the
design and layout of the work area. Consider non routine operations, such as maintenance, cleaning operations, or changes
in work cycles. All the processes and situations that could possibly harm workers, students, or visitors that may be on
campus must be considered. Hazards can be identified by reviewing manufacturers’ manuals, safety reports, and work site
inspections, as well as conducting worker interviews and reviewing incidents in the workplace or similar work areas.
Other common hazards include, motorized equipment, energized equipment, extreme temperatures, noise, vibration,
violence work design (poor ergonomics), working alone, material handling, fuel storages, raw material moving work and
theft.

4.1.2 Step 2 Risk Assessments:

Once hazards are identified, the next step is to decide what to do about them risk assessment. Risk
assessment uses a rating system to quantify risk and prioritize mitigation. Risk is assessed by considering the probability
of an event occurring in combination with the severity of harm the event would cause to the University community, the
public and the environment if it occurred. Each identified risk is given a rating using the Risk Rating Matrix which is
recorded on the HIRAC plan.

PROBABILITY FACTORS are scored based on the likelihood of risk occurrence:

IJCRT22A6459 International Journal of Creative Research Thoughts (IJCRT) [Link] d821

[Link] © 2022 IJCRT | Volume 10, Issue 6 June 2022 | ISSN: 2320-2882
Rare - Possible but unlikely – Likely – Often – Frequent

SEVERITY FACTORS are scored based on the impact of the risk:

Insignificant – Minor – Significant – Major – Catastrophic

[Link] Probability matrix

Rating Category Indicative Frequency (expected to occur)

5 Frequent Daily or twice in a week
Occurs several times per year ie., Once in a month or up
4 Often
to three months
3 Likely Once in a year
2 Possible but unlikely Once in every ten years.
1 Rare Once every 30 years.

Table.2; Probability matrix

IJCRT22A6459 International Journal of Creative Research Thoughts (IJCRT) [Link] d822

[Link] © 2022 IJCRT | Volume 10, Issue 6 June 2022 | ISSN: 2320-2882
[Link] Severity table:

Rating Category Consequence

Multiple fatalities, or significant irreversible effects to more
5 Catastrophic
than one persons.
Single fatality and/or severe irreversible disability (>30%) to
4 Major
one or more persons
Serious injuries requiring off-site treatment by medical
3 Moderate practitioner or immediate hospitalization. Potential long-term
or permanently disabling effects.
Injuries requiring on-site treatment by medical practitioner.
2 Minor
Personnel unable to continue to perform duties.
Minor injuries, which may require first aid. Injured personnel
1 Insignificant
can continue to perform normal duties.

Table.3; Severity table

4.1.3 Step 3 Monitor And Review:

Assess effectiveness of selected controls the worker and the worker’s supervisor are responsible for the
evaluation of the effectiveness of the hazard control selected and to make improvements where deficiencies are
identified. This can be done through regular inspections, testing and monitoring, evaluations of complaints or concerns
received and investigations into near misses or other incidents. Other situations that may prompt evaluation include:
Repeated noncompliance, which could be of lack of training, supervision, or other problems in the control that cause
persons to be reluctant to implement them. For example, implementing control that creates another hazard. Failure to
reduce risk. For example, testing may demonstrate that there has been no change in the measured risk after the control
has been implemented.
IJCRT22A6459 International Journal of Creative Research Thoughts (IJCRT) [Link] d823
[Link] © 2022 IJCRT | Volume 10, Issue 6 June 2022 | ISSN: 2320-2882
In other cases students/staff or others may have a continued complaint.

Controlling hazards requires ongoing effort. Monitor the effectiveness of the hazard controls in place and improve
those that don’t measure up.

Best practice includes

 Regular inspections.
 Testing (e.g. air quality, if applicable)  Reviewing Injury/illness statistics.
 Identifying new hazards.
 Addressing safety concerns as soon as possible.

4.1.4 Step 4 Control:

All hazards must be controlled either by removing the hazard or reducing its risk of harm to an acceptable
level, both proactively (to prevent its occurrence) and reactively (to minimize harmful effects in the event it does occur).
Often, more than one hazard control method must be implemented. For example, certain chemicals require a
combination of proper storage, labeling, safe work practices, the use of Personal Protection Equipment (PPE) and
emergency response equipment, procedures, and training in order to effectively control the hazards. When considering
how to reduce the risk, best practice is to follow the hierarchy of hazard controls.

[Link] Elimination or substitution

Eliminating the hazard completely is always the first choice (e.g. redesign the work process).
Substitution involves replacing the material or process with a less hazardous one. Consider these questions: o Can I find
safer ways to perform the task? For example, if falling is a hazard, eliminate the risk by storing stock at lower heights so
workers don't have to reach the goods. o Can I use something less harmful? For example, if stock is stored high, consider
substituting a step stool for a rolling staircase with a railing. Make sure the substitution doesn't create new hazards such
as tripping.

[Link] Engineering controls

If it’s not practical to eliminate the hazards or substitute safer alternatives, engineering controls are the next best
options. Engineering controls are physical changes to the workplace that prevent workers from being exposed to a
hazard and may include machine guards, noise enclosures, ventilation to dilute the concentration of a hazardous
substance). For example, while working at heights cannot be avoided in construction, guardrails can be installed to
prevent falls from happening.

[Link] Administrative controls

Administrative controls involve identifying and implementing safe work procedures. A risk assessment will usually
form the basis of these safe work procedures. Examples of administrative controls include implementing working alone
procedures, training, and supervision.

[Link] Personal protective equipment and clothing (PPE)

Personal protective equipment is a common control, and is a last resort to protect workers from hazards that are
difficult to eliminate or engineer out. For example, the use of protective eyewear will help to reduce the exposure risk to
foreign bodies for work involving cutting and grinding.

The worker and the worker’s supervisor are responsible for the evaluation of the effectiveness of the hazard control
selected and to make improvements where deficiencies are identified. This can be done through regular inspections,

IJCRT22A6459 International Journal of Creative Research Thoughts (IJCRT) [Link] d824

[Link] © 2022 IJCRT | Volume 10, Issue 6 June 2022 | ISSN: 2320-2882

testing and monitoring, evaluations of complaints or concerns received and investigations into near misses or other
incidents.

V. BEST SAFETY PRATICES ON CONVEYORS

5.1 SAFEGUARDS AGAINST HAZARDS
5.1.1 Hazard assessment and reduction

The process for hazard assessment and reduction. The following guidelines will be helpful in hazard assessment,
elimination and control:


Hazard assessment must be done to identify existing and potential hazards.

Identified hazards must be eliminated or reduced.

The hazard assessment process must be documented and, should any changes in process occur, repeated.

Workers must be informed of all hazards, and all affected workers must be involved in assessment, elimination and
control of hazards identified.
 For each hazard that cannot be eliminated or reduced by engineering or administrative controls, safeguards or
protective devices must be installed.
5.2 SAFEGUARDS AGAINST MECHANICAL HAZARDS

5.2.1 GENERAL PRINCIPLES

Many danger zones exist in and around conveyor belts. Hazards are located in these danger zones. Section 310 of the
Code describes provisions relating to the installation of guards and protective devices on machines.

A conveyor must be constructed in such a way as to not allow access to danger zones or, by default, must be equipped
with guards and protective devices. Deterrent devices may also be used.

Various types of conveyor belt protectors and deterrent devices, as well as safety requirements for conveyor sub-
assemblies, are described below.

Preventive measures for hazards related to conveyor operation must be implemented when a hazard is 2700 mm or less
from the floor or working platform.

5.2.2 GUARDS
A guard is a machine element that makes the danger zone inaccessible by isolating it. Guards on conveyor belts are
required to be designed with operating conditions in mind. They should be capable of resisting the loads to which they will
be subjected. These devices must not create additional hazards or tempt workers to bypass their use. The dimensions and
weight of movable guard components should to be designed to allow for easy handling. To this end, it is preferable to have
articulated or hinged guards. Guard removal and reinstallation should be quick and easy. Ideally, guards should be self-
locking when closed. For more information on user-related characteristics (color, ease of manipulation, etc.) and guard
construction, see Appendix A of this guide.

There are three types of guards:

1. fixed guards

 surrounding fixed guards

 barrier guards (fixed distance)

 in-running nip fixed guards

2. interlocking guards

3. interlocked guards with guard locking

5.2.3 Fixed guards

A fixed guard is a permanent part of the machine. It is not dependent upon moving parts to perform its
intended function. It may be constructed of sheet metal, screen, wire cloth, bars, plastic, or any other material

IJCRT22A6459 International Journal of Creative Research Thoughts (IJCRT) [Link] d825

[Link] © 2022 IJCRT | Volume 10, Issue 6 June 2022 | ISSN: 2320-2882
substantial enough to withstand whatever impact it may receive, and to endure prolonged use. A fixed guard is
usually preferable to all other types because of its permanence and relative simplicity.

Guards may be easily opened with tools or keys, for instance when equipped with quarter-turn latches. When keyed
latches are used, responsibility for controlling and distributing socket keys or tools must be assigned.

5.2.4 Surrounding fixed guards

This is a fixed guard that either completely or partially surrounds the danger zone. (Because of openings required
for belt and load passage, surrounding fixed guards may only partially surround the danger zone.)

In conveyor belts, fixed guards that only partially surround the danger zone take on two principle shapes:

 partial cages, as illustrated and used mainly for head and return drums side screens, as illustrated
Guards must extend beyond the in-running nips between the belts and rollers so as to make them inaccessible from above,
below and from the ends.

5.2.5 Barrier guards

Barrier guards do not completely surround danger zones but rather restrict or prevent access by their size and separation from
the danger zone.
5.2.6 In-running nip fixed guards
A fixed guard can be placed at a height of an in-running nip that will not allow access to this zone. In-running nip fixed guards
may be form-fitting or made from angled deflectors with side plates. They are well suited to an individual load conveyance, as
well as to rollers and drums with a smooth, unbroken surface. They may be used in troughed conveyor belts as long as they
have followed the belt profile. However, these guards are ill-suited to cleated type, ribbed or raised-edge belts.
5.2.7 Interlocking guards
A guard equipped with an interlocking device should have the following characteristics. It should:
 cause the machine or the operation of its hazardous components to stop as it is slightly opened!
 make it impossible to start the machine or to operate its hazardous components for as long as it is not in place
 not cause the machine or its hazardous components to restart once it is fully restored to its place
5.2.8 Interlocked guard with guard locking
An interlocked guard equipped with a locking device should have the following characteristics. It should:
 remain locked in place for as long as the machine or its hazardous components are moving
 make it impossible to start the machine or to operate its hazardous components for as long as it is not in place and
reactivated
 not cause the machine or its hazardous components to be restarted once it is restored to its place and reactivated.

5.3 SAFEGUARDS AGAINST OTHER HAZARDS

5.3.1 HAZARDS GENERATED BY POOR ERGONOMIC DESIGN

Equipment must be designed so that operators and other users need not assume constraining work postures, overexert
themselves or carry out repetitive movements.

Control devices must be grouped near workstations to allow easy access for operators and other users. Such devices
must be located outside danger zones so that activating them does not create hazards and so that workers do not have to
enter the danger zones to access them. They must be positioned to prevent unexpected start-ups, and protected.

5.3.2 Heat-related hazards

Where conveyed products or any part of the equipment may cause burns, take the following precautions:

 Prevent contact with conveyed loads and hot (or cold) surfaces by using screens or fixed surrounding or barrier
guards.

 Reduce the temperature of hot surfaces

5.3.3 ELECTRICAL HAZARDS
Conveyor electrical equipment must conform to the Canadian Electrical Code. Such equipment includes materials, accessories,
devices, appliances, fasteners and other equipment used in the electrical power supply of a conveyor or in connection with a
conveyor, including power disconnect devices.
5.3.4 FIRE AND EXPLOSION HAZARDS
IJCRT22A6459 International Journal of Creative Research Thoughts (IJCRT) [Link] d826
[Link] © 2022 IJCRT | Volume 10, Issue 6 June 2022 | ISSN: 2320-2882
The use of a conveyor can present a fire and explosion hazard. This hazard can be caused by the use of the conveyor
itself or by the load (for example, combustible particles) the conveyor is carrying. Such hazards may be amplified by
tunnels or by the stack effect. Preventive measures that may be implemented.

5.3.5 INAPPROPRIATE PERSONAL PROTECTIVE EQUIPMENT AND UNSAFE ACTS

Based on the hazard assessment of the work site, adequate personal protective equipment, including clothing, footwear and
respirators, must be selected and worn by workers.

Unsafe acts such as climbing over or under a conveyor, or stepping over, walking on or riding on a conveyor, must not be
tolerated.

5.4 SAFEGUARDS AGAINST CONTROL SYSTEM FAILURES OR MALFUNCTIONS

5.4.1 Start-Up
Start-up of equipment must require a voluntary action. Equipment start-up must be prevented in the following situations:

 during the closing of a guard

 during the actuation of an operation mode selector

 during the resetting of an emergency stop device

 during the resetting of a thermal protection device

In conveyors designed to supply loads to other conveyors, start-up of the supply conveyors must be linked with the receiving
conveyors, using appropriate interlock devices. These devices must control and ensure sequential start-up, and must prevent
conveyor overloading (whether the conveyor is fully loaded, or not in use)

To prevent unexpected start-up, replace two-stable position (toggle) switches (start-stop) with self-powered or
singlestable position control devices. These switches will bring the controls to an off-circuit mode (open contacts)
should there be a power outage or conveyor failure.

5.4.2 REGULAR STOP

There must be a device or method accessible to the worker(s) where equipment operations can be interrupted safely,
while also ensuring that equipment cannot be unexpectedly restarted.

An all-stop switch is not designed to put an end to a recurring dangerous situation; this is the role of an emergency
stop device. A stop command has priority over a start comman

5.4.3 EMERGENCY STOP DEVICE

The emergency stop device of a conveyor to which workers have access comprises several control devices
located at the loading and unloading areas, as well as along the length of the conveyor. These devices must be
easily visible and clearly identified and must activate on a single action.

Emergency stop devices must be installed at a height of between 0.6 and 1.7 meters from the floor. In addition, the device
must have the following features:

 one or more push button switches

 one or more emergency stop pull-cords if required,

 a conveyor power-disconnect device, if the distance to the disconnect device is less than 10 metres from any conveyor
access point

An emergency stop device must allow equipment to shut down in the safest possible way. This can be achieved by slowing
down moving parts at an optimal rate, as follows:

 by an immediate interruption of power to the motors

IJCRT22A6459 International Journal of Creative Research Thoughts (IJCRT) [Link] d827

[Link] © 2022 IJCRT | Volume 10, Issue 6 June 2022 | ISSN: 2320-2882
 by a controlled stop (motors remain energized to bring the equipment down to a progressive stop and power is
interrupted once the equipment has come to halt)

The resetting of an emergency stop device must not by itself cause the start-up of the machine unless the conveyor is a
slowmoving type which workers can access safely. Start-up must be confirmed by a manual action (manual resetting).

The emergency stop command has priority over all other commands. Emergency stop devices must stop any upstream
or downstream conveyors which may pose a safety risk to workers. The emergency stop device must not be used to bring
the conveyor to an all-stop state. The emergency stop must not be used as a regular stop.

Remember that an emergency stop device does not replace appropriate protection devices. As well, emergency stop devices
must not replace equipment lockout procedures during maintenance requiring access to danger zones.

5.4.4 Emergency stop pull-cords.

If workers can access a conveyor in operation, it must be equipped with an emergency shutdown device along the full
length of conveyor.

A sheathed metal strand cable shut-down device (pull-cord) must function as an emergency stop switch,
whatever direction the cable is pulled in, or when the emergency stop switch is broken. A spring failure must also
trigger an emergency stop.

A horizontal force of less than 125 N, when applied midway between two support rings and perpendicularly to the
cable, must be sufficient to activate an emergency cable. Lateral movement of the cable (between the position while at
rest and the activation point) must not exceed 300 mm. The cable must be able to resist a tension force 10 times greater
than the tension required to activate the emergency shut-down switch, when such force is applied perpendicularly to the
cable.

The cable must move freely within its supports, particularly at bends. Cables must not be twisted nor suffer the risk
of being twisted during use. If a belt width is 800 mm or less, a single central cable may be used above the belt.

Maximum cable length and other characteristics must conform to manufacturers’ recommendations (for support rings
and pulley protection, freeze-up prevention, variation in length due to temperature changes, etc.)

Other appropriate cable devices, as determined by the hazard assessment, may be used where activation of the
switch is done by pressure, compression, torsion, or tension applied to the cable. This method is best suited to
complex cable runs and to dusty or heavy-vibration environments.

5.5 SAFEGUARDS WHILE PERFORMING MAINTENANCE

5.5.1 GENERAL PRINCIPLES

Equipment must be designed in such a way that maintenance adjustments, greasing, lubricating, temperature
and/or vibration monitoring, cleaning, un-jamming, unclogging, etc.) can be done away from danger zones and
without having to remove guards or other protective devices.
An employer must provide safeguards if a worker may accidentally, or through the work process, come into contact
with

a) moving parts of machinery or equipment,

b) points of machinery or equipment at which material is cut, shaped or bored,
c) surfaces with temperatures that may cause skin to freeze, burn or blister,
d) energized electrical cables,
e) debris, material or objects thrown from machinery or equipment,
f) material being fed into or removed from process machinery or equipment,
g) machinery or equipment that may be hazardous due to its operation, or h) any other hazard.
5.5.2 Lockout (controlling hazardous energy) procedures
Lockout/isolation procedures or controls should be an integral part of overall maintenance and operating procedures.
Through the hazard/risk assessment process, the requirement for lockout(s)/isolation should be identified, evaluated and
controlled.

Procedures for controlling hazardous energy should include (but are not limited to) the following:

 the equipment must be brought to a complete stop

 all sources of energy (electric, pneumatic, hydraulic, mechanical, thermal, chemical, radiation and gravity) must be
disconnected

IJCRT22A6459 International Journal of Creative Research Thoughts (IJCRT) [Link] d828

[Link] © 2022 IJCRT | Volume 10, Issue 6 June 2022 | ISSN: 2320-2882
 all accumulated energy must be removed (by purging reservoirs, removing counter weights, unloading springs, etc.)

 personal lock(s) must be applied to each energy-isolating device

 the equipment must be tested to verify that it will not operate or move

5.5.3 Safeguards for maintenance within operating danger zones

At the core of injury and loss prevention is an understanding of workplace hazards and the associated risks. Hazard
assessment is a systematic process of reviewing job methods and workplaces to identify, evaluate and prioritize hazards.
Assessing hazards and understanding their nature and potential are critical to developing acceptable controls for avoiding
incidents, injury and losses. Good solutions or controls are a result of adequate hazard assessments.

if emergency action is required to control or eliminate a hazard that is dangerous to the safety or health of workers:

 only those workers competent in correcting the condition, and the minimum number necessary to correct the
condition, may be exposed to the hazard, and
 every reasonable effort must be made to control the hazard while the condition is being corrected.

5.6 WORKER TRAINING

All workers who work on or in the vicinity of conveyors must be informed of the hazards they may encounter
and must receive training in established preventive measures and work procedures. All safety-related procedures
and instructions must be documented.

5.6.1 WORKER TRAINING

Only competent and authorized workers must be allowed to start up, operate and interrupt the normal operation of a
conveyor. Workers must be trained in:

 conveyor start-up

 normal shutdown and the use of emergency stop devices

 required checks for restarting a conveyor after an emergency shutdown or accidental stoppage  proper loading

procedures to prevent overload

5.6.2 Maintenance crew training

Assign only competent workers who have the technical skills to maintain conveyors. Assigned workers must
be informed of the conditions under which various maintenance tasks are to be completed. Workers must be
trained in lockout procedures.

When the removal of a guard or deterrent device is scheduled, workers must receive detailed instructions
relative to their tasks, including procedures for installing and repositioning guards or deterrent devices.
Supervisors and workers must check that guards and deterrent devices are back in place after maintenance
activities are completed.

VI. RESULT AND DISCUSSION

Hazards in various operational area of the conveyors is as follows, Table.6
6.1 RISK CLASSIFICATION SCREENING TABLE
[Link] HAZARDS POTENTIAL RISK RISK PROTECTIVE MEASURES
CONSEQUENCES (P) (S) SCORE
1 POWER TRANSMISSION MOVING PARTS
Drawing-in and 3 9 Guard all rotating devices
Drive shaft; crushing. including the rotating shaft. (If
hazard is less than 2700 mm
shaft end; From floor or
Entanglement of
sprocket; loose clothing in working platform)
pulley; chain; protruding or
drive belt; moving parts
gear coupling
IJCRT22A6459 International Journal of Creative Research Thoughts (IJCRT) [Link] d829
[Link] © 2022 IJCRT | Volume 10, Issue 6 June 2022 | ISSN: 2320-2882
2 BELTS

2 3 6 Load Strand:
Belt in good Friction burns or Workstation:
condition abrasion. Install guard, as per

Impact with belt, hazard assessment.

drawing-in
(Depending upon Return Strand:
belt characteristics Workstation Install guard, as
per hazard assessment.
and speed)
Damage on
Throughway parallel to
moving belts. conveyor

Install guardrail, as per hazard

assessment.

Throughway
passing under conveyor
Install protection plate as per
hazard assessment.

Service way passing under

conveyor.
Install protection plate, as per
hazard assessment.

Deteriorate Drawing- 1 2 2 Change the belt splice design or

d belt or in, burns, manufacture.
belt splice pokes, cuts

IJCRT22A6459 International Journal of Creative Research Thoughts (IJCRT) [Link] d830

[Link] © 2022 IJCRT | Volume 10, Issue 6 June 2022 | ISSN: 2320-2882

Maintain belt and/or splice.

3 CONVEYOR BELTS IN A STRAIGHT RUN

In-running Drawing-in, Shearing 3 4 12 Install surrounding or barrier guard.
nips
between Belt burns
the
rollers/load
beds
under the
hopper

Load side
under the
skirt board
or
skirt
In-running Drawing-in 2 2 4 Workstation:
nips Install surrounding fixed guard (plates
between between rollers).
load side Throughway and service way: As
and support determined by
rollers in a hazard assessment.
straight run

In-running Dragging 3 9 Workstation (beside or under conveyor)

nips Install surrounding or in-running nip guards
between Impact with rollers (may lead to severe injury or and
lower fatality) additional protection plates, if the control
strand and station is located below return rollers.
return Throughway parallel to
rollers in a conveyor
straight Install deterrent devices (guardrail side
run plate).
Install surrounding in-running nip guard or
barrier guard, or other deterrent devices.
Throughway under a conveyor Install
surrounding in-running nip or barrier guards
or deterrent devices (guardrail) and add
protection plates.

IJCRT22A6459 International Journal of Creative Research Thoughts (IJCRT) [Link]

d831
[Link] © 2022 IJCRT | Volume 10, Issue 6 June 2022 | ISSN: 2320-2882
Return Impact with rollers 2 3 6 Install retaining device for return rollers, as
rollers per
Crushing by falling hazard assessment.
rollers
It is possible to reduce risk with a
preventive maintenance
program,

which should be taken into account when

doing the

hazard assessment.

Return Trapping and 2 3 6 In accordance with hazard

strand crushing assessment results, the
scrapers scraper protection device
Belt may be combined with a
abrasions drum protection device.

Severe injury
fatality
4 CURVED ZONE
In-running nip Drawing-in 3 4 between 12 Install surrounding in-
the belt and rollers in the curved zone running nip or separation
barrier guard.

5 TRANSITION ZONE
In- Drawing-in 3 4 12 Install surrounding or in-
running running nip guard.
nips
between
the load
side and
the load
carrying
rollers in
the
transition
zone
6 DRUMS
In- Drawing-in 3 4 12 Install surrounding in-
running Severe running nip or barrier guards.
nips
between injury/fatality
belt and
drums.
In- Crushed by 3 3 9 Install surrounding or barrier
running falling guards.
nips weights
between Install deterrent device
belt and Drawn-in at (guardrail) to prevent access
drums under the weight.
pinch points
Take-up
Severe
system
injury/fatality

IJCRT22A6459 International Journal of Creative Research Thoughts (IJCRT) [Link]

d832
[Link] © 2022 IJCRT | Volume 10, Issue 6 June 2022 | ISSN: 2320-2882
Junction Drawing-in 2 4 Install fixed guard (plate) or
between and trapping freewheeling pop-up roller.
two
conveyors

7 MOVING LOADS
Skirtboards Trapping 2 2 4 Workstation
between Limit gap between skirt
Individual belt and board and belt to a
moving skirtboard maximum of 5 mm.
loads or between
load and Remove skirt board.
skirtboard
Design a
surrounding fixed guard, if
need determined by
hazard assessment. Other
Areas Hazard assessment.

Individual Crushing 2 2 4 Fixed guard or deterrent

loads and between device in accordance with
fixed loads hazard assessment results, in
obstacles and fixed respecting the safe
not part of objects distances between loads and
the obstacles.
conveyor,
Shearing
e.g., post, The following are the
wall, minimum distances for
tunnel Impact with
entrance, loads or
enclave, other objects
associated
fixed
equipment
(such as
detectors),
etc.
Large or
bulky loads
(such as
IJCRT22A6459 International Journal of Creative Research Thoughts (IJCRT) [Link]
d833
[Link] © 2022 IJCRT | Volume 10, Issue 6 June 2022 | ISSN: 2320-2882
boulders)

different situations:
If entire body can be drawn in:
500 mm
If arms can be drawn in: 120
mm If legs can be drawn in:
180 mm

Load and Trapping 2 2 4 Workstation

load Crushing Install fixed barrier guard
carrying (separation type or plates
rollers between rollers).
exceeding Other areas
belt width Install fixed barrier guard
(separation type or plates
between rollers) or deterrent
device.

Loads falling Impact with 2 3 6 Install protection plate, mesh

from the belt moving netting or guiding rail to
loads maintain individual loads
on the conveyor and prevent
Crushed by them from falling off, in
falling loads accordance with hazard
assessment results.

8 MOVING SUB ASSEMBLY

Pushers; Crushing and 2 2 Install surrounding fixed or
bumpers; shearing barrier guards.
ejectors;
sorters

9 MOVEABLE CONVEYORS

IJCRT22A6459 International Journal of Creative Research Thoughts (IJCRT) [Link]

d834
[Link] © 2022 IJCRT | Volume 10, Issue 6 June 2022 | ISSN: 2320-2882
Vertical Crushing; 1 2 2 In accordance with hazard
and/or entanglement assessment results: barrier
horizontal ; trapping guard, deterrent device or
movement ground markings or signs to
indicate the conveyor’s
operating area. It is also
possible to use electronic safety
devices (surface
detectors, etc.).

1 Screw Conveyors
0
Screw Drawing-in 3 3 9 A screw conveyor housing must
conveyors are Severe completely enclose moving
troughs with elements (screw mechanism,
a revolving injury/ power transmission
shaft fatality apparatus), except for loading
with a spiral and discharge points.
or twisted Permanently affixed grids or
plate. polycarbonate can be installed
In‐going for visibility purposes to allow
nip the
points for the
entire length
of the screw
conveyor
exist
between
the
revolving
shaft
and trough.
Because the
trough may
not be
covered and
the

IJCRT22A6459 International Journal of Creative Research Thoughts (IJCRT) [Link]

d835
[Link] © 2022 IJCRT | Volume 10, Issue 6 June 2022 | ISSN: 2320-2882

conveyor operator to see the operation.

may be
located at or Alternatively, trough side walls
near floor should be high enough to prevent
level, screw workers from reaching into or falling
conveyors into the trough.
can be
particularly If open troughs are used, workers
must be protected by secondary
dangerous.
safeguarding methods, such as a
railing or fence. Feed loading and
discharge points can be guarded by
enclosures, screening, grating, or
some other interruption across the
openings
which allow the
passage of materials but do not allow
entry of a part of the body.

11 Chain Conveyors
Nip points Drawing-in 3 9 Enclose moving chains if possible.
occur when a Severe
chain If moving chains cannot be enclosed
Contacts a injury/fatality without impairing the functioning of
sprocket. Nip the conveyor, barrier guards can be
points also installed around moving parts, or nip
occur and shear points can be eliminated by
At a guard at the nip point or shear
point.
drives,
terminals, Other secondary safe guarding
options include safeguarding by
takeups distance (location) and the use of
(automatic awareness devices.
take‐ups may
also have
shear points),
and
idlers.
Clothing,
jewelry, and
long
hair
may also get
entangled
and
caught in the
moving
chain
conveyor.
12 Roller Conveyors

IJCRT22A6459 International Journal of Creative Research Thoughts (IJCRT) [Link] d836

 [Link] © 2022 IJCRT | Volume 10, Issue 6 June 2022 | ISSN: 2320-2882
Powered roller from nip and shear points. For
conveyors can example, the unused
snag section of rollers closest to the
and pull hands, worker should be guarded
hair, and clothing when transporting small items
into the area on a roller conveyor that do not
between the require the use of the entire
rollers and the roller width.
stationary
components of the Eliminate or
conveyor. minimize projections from the
In‐going nip roller through the use of pop‐up
points may exist rollers.
between the drive
chain and Other secondary safeguarding
sprockets; options include safeguarding
between belt and by distance (location) and the
carrier rollers; and use of
awareness devices.
at terminals,
drives, take‐ups,
idlers, and snub
rollers.

Roller Drawing-in 3 3 9 Enclose roller conveyors if possible.

conveyors Severe
are used to Install permanent barrier guards to
move injury/fatality protect workers
material on
a series of
parallel
rollers that
are either
powered or
gravity fed.
VII. CONCLUSION
In this project we observe and involve that risk assessment and best safety practices on conveyors, it’s very helpful.
for finding hazards identification and conditions of conveyors. Risk Assessment can be used to establish priorities so that
the most dangerous situations are addressed first and those least likely to occur and least likely to cause major problems
can be considered later. Risk Assessment is performed using the Risk Matrix as described in the literature study, the results
obtained from this risk assessment are the 12 potential hazards present in the conveyors, according to the existing
categories of extreme risk, high risk, medium risk and low risk then the findings are grouped into each risk category. The
risk rating of the present and possible hazard is evaluated which divide them into basic, acceptable and significance risk
level. Which risks are in significance level their possible protective control measures also recommended to improve safety
measure and analysis. The results of this analysis will be of valuable to find out the consequence on emergency that may
occur. And involved on this project to best safety practices and safeguard against from the hazards with this knowledge, the
level of preparedness can be assessed and measures taken to enhance capabilities through training and preparation of a
more effective response to such occurrences.

IJCRT22A6459 International Journal of Creative Research Thoughts (IJCRT) [Link] d837

 [Link] © 2022 IJCRT | Volume 10, Issue 6 June 2022 | ISSN: 2320-2882
VIII. REFERENCES
[1] Best Practices on Conveyor Safety, Research. Laurent Giraud, June 2015,DOI: 10.13140/RG.2.1.1901.8404,
[Link]
.
[2] An evaluation of the use of the conveyor safety guide: review and perspectives Conference Paper June 2010, Laurent
Giraud, publication at: [Link]
.
[3] Conveyor Safety, Author- Patric McCon, Industry Practice Leader –, Manufacturing, Zurich Services, Corp.– Risk
Engineering, Schaumburg,Ill., USA. Apr 2021, Iron & Steel Technology. [Link].

IJCRT22A6459 International Journal of Creative Research Thoughts (IJCRT) [Link] d838