The solution for replacing a 600-metre, 60-ton conveyor belt.
The problem:
The previous method for replacing the 600-metre, 60-ton conveyor belts was to use two large floats, a Mac truck, two operators at hydraulic controls, and a reverse belt winder. Since the controls were not coupled, problems occurred if either winder rotated because the other would remain fixed. Inherently, there would be a risk of one or both belt winders becoming unstable, toppling over and potentially falling off the float. In addition to this, the winders were only held in place by chains, the winder footprint was larger than that of the float, and the floats tended to sway under the motion of the winders.
Solution:
Chris Ryde’s new strategy completely restructures the processes for a safer, more efficient replacement practice. Weeks before shutting down the system, two conveyor belt winders are positioned on the ground (one new belt reel and one empty reel for the old belt to reel on) at 90 degrees to the conveyor system. These are aligned with the turning frames as they are positioned on the conveyor module. During the shutdown, the old conveyor belt is clamped and cut, and belt ends are moved away from the structure by crane. The turning frame mounting stands are then fixed to the system, and the new conveyor belt is attached by a pulling plate to one of the old conveyor belt ends through the turning frame. The second conveyor end of the old belt is then put through the second turning frame and attached to the remaining belt winder, initiating the conveyor belt’s replacement. The new belt is fed off the winder through the turning frame and onto the conveyor system, while the other winder pulls off the old belt.
The work at BHP Billiton is a premiere case of exemplary asset management, and the Asset Management Council is proud to have worked with the organization in the past. For the full Case Study on BHP Billiton’s conveyer belt maintenance, please read the release here, also, feel free to follow BHP Billiton on Twitter.
