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J B S K U M A R CONVEYOR BELT HOT SPLICING MANAUL

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TABLE OF CONTENTS

SLNo

CONTENTS

1. Scope

2. Purpose

3. Company Profile

4. ISO Certificate

5. Quality Policy

6. Organization Structure

7. Project Specific Information

8. General Recommendations

9. Tools and Equipment

10. Materials

11. Splicing Procedure

12. General

13. QA /QC

14. Safety

15. Flow Chart

16. Employee profile

17. MSDS

18. Rema Tip Top Manual




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Scope :

Purpose

2.0DISTRIBUTION: 2.1 EXTERNAL

2.2 INTERNAL

This Manual describes the Operational and QualityAssurance Procedures established and practiced atCompany to ensure the Conveyor Belt splicing isconsistent Quality to satisfy customerrequirements and applicable to the Hot splicingprocess of Conveyor belt. The Quality Assurance Procedures detailed in thismanual are in accordance with the Quality System

adopted for the preparation Conveyor Rubber Beltfor Hot splicing, Curing, Inspection and delivery of the Conveyor Belt in our Factory and customer site.Manufacturing, inspection, packing and delivery of the product is based on ISO 9001: 2000 QualitySystem Standards.

The purpose of this instruction is to set the scopeand sequence of the works involved in splicing of the all Conveyor Belt with fabric piles, so that allthe necessary HSE, equipment, tools, manpowerand supervision can be organized to demonstrateto the permit issuing authorities that the work hasbeen adequately planned for safe and efficientexecution.

This document also serves as a guide to siteoperatives who undertake the work.

This Manual is confined to companies, contractors

manufacture or regulatory organizations concernedwith conveyor Belt joining.

Executive Director (ED)Factory Manager (FM)Production Manager (PRM)Quality Assurance Manager (QAM)Sales Manager (SM)




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Client Name :

Project :

Size :

Qty :

Location :

PROJECT SPECIFIC INFORMATION

Conveyor Belt splicing at site

1000mm x 12 mm

6 Nos.




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Working Place

Conveyor Belt

AmbientConditions

Storage of splicingproducts

Equipmentand tools

GENERAL RECOMMENDATIONS

In order to ensure quality and durability of a coldsplice a clean working place and proper usage of the splicing products are essential.

The conveyor belt must be clean and dry.Water-soluble contaminations should be scrapedoff and then washed away with water and dried.

Oil and grease should be removed with cleaningfluid.

1. The ambient temperature and thetemperature of the splicing products shouldbe between + 10 °C and +45°C.

2. Humidity influences such as condensationwater ( below dew point ) must be avoided.

3. precondition products to ambient

temperature if necessary.

4. erect a splicing shelter/tent for protectionagainst sun, dust, wind, rain etc.

1. Splicing products should be stored in a dryand dark place at a temperature between15°C and 25°C.

2. Please observe expiry date on the box.

3. Observe the safety instructions on thecontainers.

Tools and equipment must be in perfect workingorder. Measuring instruments have to becalibrated.




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TOOLS AND EQUIPMENTS

1. Belt Tensioners2. Chain or Cable Winch3. Screw Clamps4. Measuring Tape5. Metal Ruler6. Flat Angle7. Marking Crayon8. Plumb line9. 6” Knife10. Don Carlos Knife11. Off-set Knife12. Ply Knife13. Ply Lifter14. Whetstone15. Scissors16. Pincers17. Grip Tongs

18. Hand Brush19. Cement Brush20. Stitcher21. Double acting Roller22. Hammer23. Cable Drum24. Safety goggles25. Hand gloves26. Buffing Motor ( with flexible Shaft and

wire brushes)27. Rotating wire brushes

28. Grooved wire brushes29. Thickness gauge30. Vulcanizing press including edge bars &

clamps.31. Rubber Cut.32. Cover Cloth33. Polyethylene Film

MATERIALS

1. Rubber Solution.




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2. Cleaning Solvent3. Uncured intermediate Rubber4. Uncured cover Rubber5. Tie Gum Rubber6. Silicone paper7. Pressure compensating cloth.8. Petrol




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Procedure PREPARATION OF THE BELT LAYING AND PLATFORM

• Lay down the conveyor belt on the conveyorsystem.

• Move the pulleys as close as possible to theconveyor system. Any counter weight loadsshould be lifted as close as to the conveyorsystem.

• Choose the area for the working platform in asuitable area on the conveyor system.

• If necessary, remove the carrier rollers to getthe conveyor belt lies straight on theconveyor system.

• Position the belt in such a way that theconveyor belt lays on the conveyor systemeven and straight without tension.

• Keep the lower part of the vulcanizing pressunderneath the belt (on the conveyorsystem).

• Keep one each ply wood or similar material oneither side of the press.

• Pull the belt ends together until the belt istensioned.

•

Clamp the belt near the ends leaving thesplicing area.

• The belt ends have to be aligned in such a waythat they overlap each other on the lower partof the vulcanizing press.

• The length of the overlapping areas has to besplice length plus bias cut length.

BELT SPLICING PROCESS

• Identify splicing location to be used.

• Belt splicing is a continuous activity therefore




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provision for night shifts may be required.

• Prior to splice the conveyor belt, it shall becleaned free from oil, grease substances withcleaning solvents within a dry condition.

• Structure and dimensions of hot splices shallbe carried out in accordance with vendorinstruction.

•preparation of the lower part of the belt.

• Fold back the upper part of the belt.

• Make a bias cut (0.3 x belt width) on the lowerpart of the belt.

• Fold back the lower part of the belt and drawa line parallel to the bias cut on the pulleyside at 25mm.

•

Also mark the belt rubber edges to bepreserved.

• Prepare the steps as per the beltmanufacturer’s instruction.

• Second : preparation of the upper part of thebelt.

• Superpose the belt ends ensuringcorrect alignment.

• Secure both parts against dislocation.(e.g. with clamps)

• Exactly transfer the cut edges of thetop fabric ply of the lower part to the upperpart.

• Transfer the subsequent fabric stepsof the lower part to the upper part

• Cut off the excess length of upper part put on

the lower part.

• Draw a line on the carrying side 25mm from




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General

aligning them exactly and avoiding airentrapment.

• Press the whole splicing area with doubleacting roller properly.

• Apply one strip of the filler rubber on the joint.

• Cover both the joints with the silicone paper.

VULCANIZING PROCEDURE

• Apply edge fitting strips to either belt edges.

• Keep the edge bars, which should be 1 to2mm thinner than the belt thickness.

• Cover the whole splicing area with a pressureequalizing cloth.

• Position the upper part of the vulcanizingpress on the belt in such a way that it shouldcover the whole splicing area.

• Secure the upper and lower cross arms andgenerate the pressure and heat according tothe operating instruction of the press.

• Switch on the heaters.

• Keep the temperature of 150 degree C for aminimum of 30 minutes for 10mm and more

thickness of the belt as per the instructionfrom the manufacturer.

• After the curing cycle, switch off the curingsystem.

• Let the conveyor belt cool down to atemperature below 60 degree C, in the closedvulcanizing press under the pressures.

• Then release the pressure and unlock the

cross arms.

• Remove the upper part of the vulcanizing




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QA/QC

Safety

press

• Pressure and temperature will be recordedduring the vulcanizing process every after 15minutes.

• Once splicing of the belt is completed, check hardness, porosity, elasticity and thickness of splice.

•Remove and clean excess material from theoverflow (with scissors, buffing tool) and cuteven the belt edges.

• Remove the lower part of the vulcanizingpress and the working platform.

• Reinstall the carrying idlers if necessary.

• Remove the belt clamps.

•

Ensure the vulcanized splice cured tospecification before preferential engineering.

• The conveyor belt shall put into operationpossession.

• Apply and obtain appropriate Permits fromRLIC and QGII with the necessarydocumentation requirements.

• Ensure that all personnel involved in the work are safety trained qualified personnel. All

necessary safety and personnel protectiveequipments (PPE) will be utilized.

• Check used by date for the splicing kits.

• Safety orientation for all personnel involvedwith emphasizes on safety , environment,scope of work, and anticipation of workingcircumstances before starting the actualconstruction.

• No chemical or other hazardous substance

(waste rubber, corrosive chemical wasteempty cans) will be dumped into ordinaryskips.




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• GREEN skips will be used for non hazardousmaterial.

• All hazardous substance will be disposed of into the predetermined clearly labeled skipsfor chemical waste (resin, tie-gum and glue).

• RED skips will be used for hazardous material.

• All hazardous material waste generatedduring the construction phase will be handledand disposed off in accordance with localGovernment waste management plan.

In process & Final inspection and Testing data willbe recorded in Conveyor Belt Splicing Record Sheet(TP-CBR )

• All Safety equipment required for Belt splicingwork (vulcanizing) to be in the proximity of the working area.

• All personnel in working area using properPPE includes chemical resistance gloves.

• The area around scaffolding will have warningsigns. Barricadding the work areas to ensureno unauthorized entry.

• Scaffolding has to be inspected and tagged foruse.

• Tool box talks every morning to discuss work

activities and job hazards.

• Personnel working above 1.8 m. to wear fullsafety harness.

• Ensure that adequate fire protection isprovided where hot work is to be carried out.

• Temporary safety signs shall be provided atall work areas.

•Construction works shall be coordinated at alltimes and confirmed with the company.

• Safety standards shall be observed at all




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times.

• Sufficient illumination of work areas, storagearea and access shall be provided whileworking at night. The sub-contractor shallmaintain good housekeeping standards at alltimes.

• All splicing equipments and tools shall beinspected and color coded prior to use.

• All lifting equipment slings, hooks etc., shallhave valid test certificates.

• Work permits will be obtained for installationactivities. Ensure that all hazardous materialsare stored on impermeable pads with fullcontainment.

• All MSDS sheets shall be available on site.

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