Risk management for belt conveyors is extremely important for the smooth operation of these industrial processes, especially in bulk material handling systems.

According to the international standard, which aims to establish the elements and conduct for risk management, risk can be defined as the result of uncertainty in the expected objectives. Uncertainty, in turn, consists of the absence of concrete data regarding an event, its understanding, the probability of its occurrence and the resulting consequences.

In this regard, existing hazards must be properly documented and controlled due to the presence of risks in work areas and on equipment. In addition, during the operation, the professional conducting the risk assessment must allocate the time and resources necessary to complete this process. Sometimes, certain risks of greater magnitude may require detailed analyses by experts in the relevant field, while others may pose a risk low enough to not require more detailed studies.

The importance of choosing carriers for risk management

Generally speaking, in the day-to-day operations of companies that handle bulk solids, the selection of conveyors to be examined in greater detail may depend on several factors. For example, some of the issues that can significantly influence the selection of these assets include: 

1. 1. State of conservation of civil and metallic structures, as well as mechanical components;

1. 1. Proximity to the sea, particulate emissions or other sources of corrosion;

1. 1. Whether the conveyor is low to the ground or elevated;

1. 1. Criticality of the equipment to the production process. In this respect, it is important to know whether the object under analysis is simple or has redundancy;

1. 1. Access to the object, as well as how to operate and maintain it;

1. 1. Claims history.

Furthermore, from a safety perspective, it is best to conduct these analyses on equipment periodically, starting from the design phase, in order to mitigate the risk of accidents. In this context, even a visual inspection of the structural components is recommended as part of a risk management process in which risks are identified, analyzed, and assessed, and the necessary corrective actions are determined.

How can risk management be carried out efficiently on belt conveyors?

As a result, there is significant potential for the application of risk management tools. Furthermore, in the bulk solids handling market—including mining, ports, and agricultural companies—there are countless belt conveyors that have been in operation for years, from various manufacturers and with different maintenance histories. 

Therefore, the methodology proposed for this risk management must be easy to use for the staff involved in preserving the asset.

First and foremost, when conducting this type of analysis, it is essential to know which phase of the project the carrier is in order to determine the appropriate tool.

There are several stages, some of which are 

1. Project design;
2. Project detailing;
3. Construction planning;
4. Commissioning;
5. Operation;
6. Maintenance.

Ideally, it's best to start analyzing and managing risk right from the project's conception, so that the practices are more effective and require a lower investment cost.

Tools needed for risk management on belt conveyors

Risk management can vary from the use of simpler tools for less complex risks, to processes with a high degree of difficulty, involving mathematical modeling. 

However, choosing the wrong tool can undermine confidence in the risk management process. In short, the two most common mistakes made during the selection process are:

1. 1. Opting for a tool that is not capable of effectively analyzing, evaluating and defining the treatment of risk;

1. 1. Opting for a more complex and/or time-consuming tool than is really necessary given the simplicity of the analysis and the clarity of the treatment.

Risk identification is a phase of paramount importance in this management process. If this phase is not carried out properly, the remaining steps are compromised. To identify existing risks in the field involving conveyors, it is advisable to begin the risk management process by using a checklist, which should be completed during the on-site inspection of the belt conveyor undergoing maintenance or in operation. In addition, vale that the checklist is also suitable for the other stages of the asset’s life cycle.

Checklist for risk management

The development of the checklist should be based on compliance with the relevant standards, as well as the expertise of the team involved. Following that, a brainstorming session or a meeting to finalize the checklist is recommended. 

In this way, undesirable hazards can be grouped so that a probability and impact associated with each risk can be assigned. Therefore, in addition to the checklist, another tool can be used to identify risks associated with the checklist.

Subsequently, for risk management purposes, it is necessary to determine the level and priority of the hazards. At this stage, risks can be classified as tolerable, unacceptable, or mitigable.

During the risk treatment stage, existing controls are evaluated and the need for new supplies to mitigate or eliminate the danger is defined. In this process, there is a great deal of interaction between the assessment and treatment of the threat. At all times, as recommended in the risk standards, attention must be paid to monitoring the stages of the analysis, as well as communicating the study carried out efficiently to all those involved.

Conclusion

Risk management is an extremely important issue in the industrial context as a whole. With it, it is possible to identify, analyze and treat risks from various sources, which could cause the most diverse damage, be it financial, humanitarian, health and/or environmental.

The methodology adopted by Kot Engenharia for risk management in belt conveyors has as one of its main advantages its wide application in countless types of conveyors. In addition, as it does not require complex computational studies, it does not involve a large investment cost.

Kot has the necessary experience to identify, record, analyze, and develop intervention plans related to the risks involved in its companies' activities. Consult our team for more information!

Follow our pages on LinkedIn, Facebook e Instagram to keep up with our content.

Be sure to also read the article Succes story: Evaluating passenger comfort on trains.

FAQ

1. Como o artigo define “risco” e “incerteza” com base nas normas internacionais?

• Risco: É o resultado da incerteza no atingimento dos objetivos esperados.

• Incerteza: É a ausência de dados concretos e consolidados sobre determinado evento, compreendendo o desconhecimento de seu entendimento, de sua probabilidade de ocorrência e das consequências resultantes.

2. Quais fatores determinam quais transportadores de correia devem passar por um estudo de risco mais detalhado?

A escolha dos ativos prioritários para análise detalhada depende de seis fatores principais apontados no texto:

1. Estado de conservação das estruturas civis, metálicas e componentes mecânicos;

2. Ambiente e corrosão, como a proximidade junto ao mar ou áreas com alta emissão de particulados;

3. Posição do equipamento, verificando se o transportador é elevado ou instalado rente ao chão;

4. Criticidade para o processo, avaliando se o equipamento é singelo (linha única) ou possui redundância;

5. Acessibilidade, considerando os caminhos de operação e manutenção;

6. Histórico de sinistros e ocorrências passadas no equipamento.

3. Quais são as fases da vida útil do transportador de correia e qual o momento ideal para iniciar a gestão de riscos?

O ciclo de vida do ativo compreende seis etapas principais:

1. Concepção do projeto;

2. Detalhamento do projeto;

3. Planejamento da construção;

4. Comissionamento;

5. Operação;

6. Manutenção.

O momento ideal para iniciar a gestão de riscos é na concepção do projeto. Iniciar nessa fase torna as práticas de controle mais eficazes e exige um menor custo de investimento financeiro.

4. Quais são os erros mais comuns na escolha de ferramentas de gestão de risco?

Segundo o texto, a seleção incorreta da ferramenta compromete a confiança no processo. Os dois erros mais frequentes são:

• Selecionar uma ferramenta insuficiente, incapaz de analisar, avaliar e direcionar o tratamento do risco de forma efetiva;

• Selecionar uma ferramenta excessivamente complexa ou demorada, desproporcional à simplicidade da análise e à clareza das ações necessárias.

5. Como funciona a etapa de identificação de riscos com o uso de checklists?

A identificação é a fase mais crítica da gestão de riscos; se for mal executada, todas as etapas seguintes ficam comprometidas. O processo inicia-se com um checklist preenchido durante a inspeção em campo (seja na operação ou manutenção), elaborado com base nas normas técnicas do equipamento e na experiência da equipe. Posteriormente, realiza-se um brainstorming ou reunião de consolidação para agrupar os perigos e atribuir-lhes probabilidades e impactos.

6. Como os perigos identificados são classificados e tratados?

Após o mapeamento, os riscos são priorizados e categorizados em três níveis:

• Toleráveis;

• Passíveis de mitigação;

• Inaceitáveis.

Na etapa de tratamento, analisam-se os controles operacionais existentes e define-se a necessidade de novos recursos ou modificações para eliminar ou mitigar a ameaça. Todo o processo exige monitoramento contínuo e comunicação eficiente entre os envolvidos.

7. Quais são as principais vantagens da metodologia de gestão de riscos proposta pela Kot Engenharia?

A metodologia da Kot destaca-se por duas vantagens centrais:

• Ampla aplicabilidade: Pode ser empregada em infinitos tipos e modelos de transportadores de correia;

• Baixo custo de investimento: Não exige a realização de estudos computacionais complexos para a definição das ações de controle e preservação do ativo.

References:

[1] BRAZILIAN ASSOCIATION OF TECHNICAL STANDARDS (ABNT). NBR 13743:1996. Inspection guide for continuous conveyors in operation - Belt conveyors. Rio de Janeiro.

[2] BRAZILIAN ASSOCIATION OF TECHNICAL STANDARDS (ABNT). NBR 13742:2009. Continuous conveyors - Belt conveyors - Safety procedures. Rio de Janeiro.

[3] BRAZILIAN ASSOCIATION OF TECHNICAL STANDARDS (ABNT). NBR 13862:2017. Continuous conveyors - Belt conveyors - Safety requirements for design. Rio de Janeiro.

[4] CEMA (CONVEYOR EQUIPMENT MANUFACTURERS ASSOCIATION). TR 2015 - 01 - Recommended CEMA Risk Assessment Process, 2015.

[5] FERREIRA, AENDER LUCIO BARBOSA - METHODOLOGY FOR RISK ASSESSMENT IN MINING EQUIPMENT APPLIED TO BELT CONVEYORS

[6] ISO. ISO 31000: 2009. Risk management-Principles and guidelines. International Organization for Standardization, 2009.

[7] JOY, Jim; GRIFFITHS, Derek. National Minerals Industry Safety and Health Risk Assessment Guideline, Minerals Industry Safety and Health Centre (MISHC), University of Queensland, Australia, 2005.

[8] JOY, J. Occupational safety risk management in Australian mining. Occupational medicine, v. 54, n. 5, p. 311-315, 2004.

[9] MAQOHSC (MINING AND QUARRYING OCCUPATIONAL HEALTH AND SAFETY COMMITTEE). MAQFRM-001 - Conveyor Safety Inspection Checklist, 2015.

[10] MINISTRY OF LABOR AND EMPLOYMENT. Regulatory Standard No. 12 - Safety at Work in Machinery and Equipment. Ordinance of the Secretariat of Labor Inspection - SIT - No. 233 of 09.06.2011.

[11] MINISTRY OF LABOR AND EMPLOYMENT. Regulatory Standard No. 22 - Occupational Health and Safety in Mining. Ordinance of the Secretariat of Labor Inspection - SIT - No. 202 of 26.01.2011.