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Conveyor belt fires pose a significant risk due to their rapid spread potential. While the belt itself can burn, it's the belt's length and movement that exacerbate the danger, allowing fires to quickly traverse large facility distances. Typically, fires start from friction-induced heat at pulleys or from materials inadvertently loaded onto the belt.
To mitigate these risks, best practices include:
In environments with heightened risks&#;like underground coal mining&#;strict regulations often mandate self-extinguishing belting to replace less stringent flame-retardant options.
It's important to note that all conveyor belts can burn if exposed to sufficient heat and airflow. Governmental regulatory bodies use standardized laboratory tests to categorize the burning characteristics of different conveyor belts. A "self-extinguishing" belt, in general terms, refers to one that does not propagate a fire once the ignition source is removed in a controlled laboratory setting.
Fire-safety standards for conveyor belting are similar among major coal mining countries, including Australia, Canada, China, Germany, India, Indonesia, Poland, Russia, and South Africa. For example, Germany implemented strict requirements over 30 years ago.
Various international regulatory and advisory organizations, such as the British Standards Institution (BSI), Conveyor Manufacturers Equipment Association (CEMA), Deutsches Institut für Normung (DIN), European Standards (EN), and the International Organization for Standardization (ISO), provide guidance on conveyor belt safety.
Tests conducted in these countries typically include:
In the United States, outside of underground coal mines, the regulatory standard for conveyor belts is primarily determined by the Bunsen Burner Test (CFR Part 30 Section 18.65). This test involves exposing a small piece of belt (approximately 150 by 12 millimeters or 6 by 1&#;2 inches) to a Bunsen burner flame for one minute. After removing the flame, airflow is applied for three minutes, and the duration of any flames or afterglow is recorded. To meet the standard, the average of four samples must not burn for more than one minute or exhibit afterglow for more than three minutes.
Historically, Europe and the US differed in belt safety regulations until stricter measures aligned practices globally. For underground coal mines in the US, the Belt Evaluation Laboratory Test (BELT) ensures belts resist flames for extended periods, reflecting updated safety norms.
Other Safety Considerations for Conveyor Belts
Additional standards may apply globally, varying by region or industry. Some countries impose stricter requirements concerning belt toxicity, hygiene, or surface roughness. Detailed specifications can be found in standards established by organizations such as DIN, EN, ISO, BSI, CEMA, and others. It is crucial for conveyor belting to be compatible with the materials it transports, ensuring safety and compliance with applicable standards.
The global leader in conveyor accessories, Martin Engineering, is dedicated to conveyor safety by educating the bulk handling industry on the hazards of conveyor fires. With the Foundations&#; Learning Center, the largest comprehensive free conveyor training archive on the web, Martin experts give detailed insight into the causes and prevention of deadly fires. This article, written in collaboration with the authors of Foundations&#; for Conveyor Safety, gives an overview of how to improve workplace safety.
Conveyor fires can happen anywhere, at any time, even outdoors in the cold. (Pictures: ©Martin Engineering)
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Dust Explosion Pentagon [source: OSHA]
To create a fire there must be three elements: oxygen, heat and fuel (aka, &#;the fire triangle&#;). One factor that makes conveyor fires so hazardous is that the belt itself can be the fuel. According to a study of belt fires conducted by National Institute for Occupational Safety and Health (NIOSH),[1] any of the standard neoprene, PVC, chloroprene and BELT-approved SBR belts can ignite. Although some belts were self-extinguishing, the conclusion is that there is no non-flammable belt, particularly when accompanied by a combustible material. [2]
Table 1: Posible ignition sources Friction Dust/Material/Chemical Mechanical/MaintenenceInadequate belt cleaning in the discharge zone can lead to dust and carryback on the return side of the belt, causing a fouled tail pulley to run under a stalled belt, which creates tremendous heat.
Friction heat between rolling components can be extreme enough to light both the material and belt.
Dust emissions of any kind (combustible or noncombustible) originating from the loading or discharge zones have a tendency to foul rolling components, leading to failure of the seals and then contamination in the bearings and eventually causing the roller to seize. A rolling component can also stall if impact or cargo weight causes the bearings to collapse. Continuous frictional contact with a seized idler or the roller face can cause a loaded belt to exceed safe operational temperatures. It can also potentially result in extreme wear on the belt, degrading the main fire-retardant layer and exposing the heat-sensitive materials found in the belt&#;s inner construction.
Fugitive material control and regular cleaning of spillage are imperative. Without proper belt cleaning, chute sealing and belt tracking, spillage that collects around the loading/discharge areas and along the belt path can damage moving components, restrict access by fire crews and potentially act as fuel.
Dust control is extremely important when handling combustible substances, and it is recommended -- instead of just taking into account the fire triangle -- operators consider the &#;Dust Explosion Pentagon.&#; Examples of highly combustible materials include:
Significant amounts of dust can collect on the walls of the loading zone chute. If a foreign metal object is accidentally introduced into the enclosed area, a spark can potentially create an explosion. Additionally, common maintenance within the chute such as removal of the wear liner using a cutting torch often requires confined space entry by workers. If the inside of the chute is not adequately cleaned, this task could pose a serious hazard.
When examining conveyor equipment, one should approach the task with the same critical mindset as an inspector from OSHA, MSHA or the local fire department. Safety professionals recommend a holistic view of the system and the combustibility of the material. When making a conveyor fire risk assessment, also consider:
Foundations for Conveyor Safety is a 500+ page reference volume dedicated to worker safety.
Often, the potential return on investment (ROI) for prevention equipment isn&#;t recognized until managers are inspecting burnt rubble and negotiating with insurance adjusters. However, safety-minded operators understand that the same equipment they would implement for increased efficiency such as belt cleaners and impact cradles, can also help prevent fires.
Operators should regularly contain airborne dust at transfer points and remove accumulation. Damaged rollers must be replaced promptly. Conveyor belt alignment is also an essential prerequisite to belt safety. Consider using flame-resistant grease and other lubricants. Fire detection and suppression systems must be tested in accordance to regulatory standards. Experience has shown that clean conveyor systems and ongoing maintenance form the best defense against fire.
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