Technibelt conducted independent laboratory belt testing of a large number of rolls for an underground coal mine in NSW. The test results were compared against Australian Standard requirements, as well as our Client/Technibelt specifications. The belts were tested before delivery to the mine. Of major concern was approximately one third of belts failed to comply with the drum friction test requirements of AS 4606 (surface temperature of the drum exceeded 325°C with some samples showing visible glowing). The other two thirds of belts, although complied with the drum friction test requirements of AS 4606, had the surface temperature of the drum substantially higher than normally expected. In addition, a large number of belts failed to meet various Australian Standard requirements and/or our Client/Technibelt specifications (full thickness tensile strength in the longitudinal direction, full thickness tensile strength in the transverse direction, abrasion resistance and tear resistance).
Technibelt was commissioned to develop ply and steel cord belt specifications, an independent laboratory belt testing program and belt splicing quality assurance documentation for a new coal handling facility in NSW. Belt purchased and spliced against strict technical specifications and verified by independent testing ensured quality belt installations. Belt and splice life continue to exceed operational, maintenance and life cycle cost expectations of the company.
Technibelt was commissioned to investigate a ply belt splice failure at a hard rock mine in QLD. The splice had been extensively repaired on the top and bottom covers. An existing top cover repair had failed and was exposing the pocket of delamination through several steps of the splice plane. The adjoining parent belt (not within the splice) had alarmingly low ply to ply and cover to ply adhesion levels. The adhesion levels within the splice plane were also low. The alarmingly low parent belt adhesion levels further deteriorated after the hot splice/repair process and contributed to the splice failure. The low adhesion levels through the splice plane due to problems with process control also contributed to the splice failure. Splices cannot be repeatedly repaired as the physical properties of the belt and splice plane deteriorate. The rate of deterioration is dependent on the quality of the belt. Splices that require extensive repair are now scheduled for resplice.
Technibelt was commissioned to work closely with the maintenance and reliability teams at a coal mine in NSW to radically decrease downtime caused by conveyor belt and splice failures. The modern conveyor systems were designed on the lower limits relating to pulley diameters and belt/splice factors of safety. The demand on the conveyor belts and splices is arduous and needs to be technically correct and vigilantly monitored. Belt is purchased against strict technical specifications and verified by independent testing to ensure only quality belt is supplied and installed on the conveyors. Belt change dates are scheduled based on a combination of cover thickness test data and a wealth of knowledge on overall belt condition (site operational information and laboratory test data).
QA supervision of splicing has significantly increased the reliability and life of splices. Belt scraper adjustments and maintenance, based on actual performance (carry-back test data), has decreased carry-back spillage and increased consumable component life. The conveyors continue to exceed operational, maintenance and life cycle cost expectations of the company.
Technibelt was commissioned to investigate ongoing solid woven finger splice failures at an underground coal mine in QLD. The full belt width transverse failures occurred in parent belts within the prepared section of the splices but outside the fingers. Independent laboratory testing of the parent belt found the belt to comply with Australian Standard requirements as well as our Client/Technibelt specifications. Testing the parent belt after simulating the splice process found no adverse effect on the tensile strength of the belt or the ability of the belt to be spliced. Adhesion levels of the top and bottom covers panels within the finger splice were as expected from a quality constructed splice. Testing found workmanship issues in the preparation of the parent belt and fingers resulted in critical loss in the tensile strength of the parent belt or fingers. An extensive Technibelt R&D program determined the safe workmanship limits for a quality finger splice and identified the trigger point that will result in an imminent splice failure.
Technibelt was commissioned to investigate high belt change rates associated with total/imminent splice failures at a hard rock mine in NT. Independent laboratory testing of the splices found significant issues with splice workmanship and process control. However, laboratory testing of the parent belt found the belt specifications were the major cause of the premature splice failures and belt changes. Technibelt developed site and conveyor specific belt specifications and belt splicing quality assurance documentation. Belt purchased and spliced against the correct technical specifications and verified by independent testing ensured quality belt installations. Belt changes are now scheduled due to cover wear and/or cover wear/impact damage.
Technibelt was commissioned to investigate high belt scraper component failure rates at a hard rock mine in NT. Major structural component failures were significant. However, unacceptably high consumable component failure rates (ranging from less than one shift to less than 4 weeks on critical conveyors) were of greatest concern. Through an extensive R&D program, Technibelt designed and implemented a series of cost-effective, innovative, engineered and tested solutions to optimise belt scraper performance. Since the upgrade, there have been no major structural component failures and consumable component life exceeds the shut interval on all conveyors.
Technibelt developed belt cleaning system performance specifications for a number of new coal handling and preparation plants in NSW and QLD. The average preset performance guaranteed carry-back level across all run-of-mine, reject and product conveyors was 10-12 kg/hr. The design and commissioning of Technibelt custom belt cleaning systems resulted in an average carry-back level of <1 kg/h with an average over the first 5 years of <5 kg/hr. Belt scraper adjustments and maintenance are based on actual performance (carry-back test data) not time in service. Belt cleaning system performance and scraper/conveyor component life continue to exceed operational, maintenance and life cycle cost expectations of our client.
Technibelt conducted benchmark performance monitoring (carry-back testing) of the existing belt scrapers at a hard rock mine in SA. After servicing by the existing belt scraper maintenance team (to ensure optimum performance), Technibelt recorded an average carry-back level of 420 kg/h across 13 conveyors (worst conveyor 875 kg/h). The benchmarking data and a review of the operational requirements of each individual conveyor was used to develop a performance specification (average preset performance guaranteed carry-back level of 11 kg/h). The design, supply, installation and commissioning of Technibelt custom belt cleaning systems resulted in an average carry-back level of <1 kg/h (worst conveyor 4 kg/h) with an average over the first year of 4 kg/hr (worst conveyor 8 kg/h). Belt scraper adjustments and maintenance were based on performance not time in service. Low carry-back levels also resulted in reduced spillage clean-up and increased roller and pulley lagging life.
Technibelt was commissioned to investigate major belt mistracking issues at a materials handling facility in NT. The tracking data confirmed at various locations along the conveyor, the belt tracked centrally or to LHS or RHS cutting through structure. Surveying found the conveyor structure to be significantly out-of-tolerance (parallel, straightness, squareness, level and alignment). The worst surveying data coincided with the worst mistracking data. The time frame and cost of structural rectification was prohibitive. Technibelt engineered a belt tracking system to ensure the belt always tracked well within AS 1332 requirements and never rubbed on structure.
Technibelt was commissioned to investigate major belt mistracking issues at an underground coal mine in NSW. The mistracking posed a major risk to safety and business and resulted in a notice being issued to rectify the problem or cease operation of the conveyor. Technibelt belt tracking monitoring technology determined the mistracking exceeded 250 mm and was well outside AS 1332 requirements. The tracking data confirmed the excessive belt mistracking was inherent within all rolls of belt and independent of the alignment of structure, pulleys or splices. All rolls of belt were replaced under warranty.