Project Overview:

The process of ‘belt flaking’ is used frequently for larger conveyor systems to reduce the time to install and replace belt during mine and plant shutdowns. The flaking process typically involves a number of lengths of conveyor belt being spliced together to form one continuous length, with the belt laid out along a predetermined length in a convenient area nearby the conveyor in preparation to be hauled onto the system.  

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Traditional belt flaking systems required the flaking roll be removed at the end of every flaking cycle and transported back to the start of the flake pile and inserted under the belt to begin a new flaking cycle. This was a time-consuming process and one that exposed operators to hazards including; interaction with mobile plant, manual-handling, stored energy, poor ergonomics and pinch-points.

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The new design allows the flaking roll to travel back and forth (bi-directional) along the flake-pile and eliminated the need for the removal and insertion of the flaking roller and the associated hazards. The new design also improved control of belt guiding and alignment, and reduced flake cycle times.

 

Scope of duties performed:

• Application research and conceptual design lead

• AS 4024 Design Risk Assessment lead (SiD RA’s throughout project)

• Development of safety performance level requirements

• Development of design loads in accordance with AS1170, AS1418, AS3990 and other relevant industry standards

• Calculation of hauling loads involved & selection of appropriate primary & retrieval cable winches

• Coordinated and led the affiliated design team to complete structural checks of the equipment including; structural frames, rollers, spread-bars, other key load-bearing components

• Drafted equipment specifications for supply tenders (ie steel structures & mechanical packages, idler & rollers package, primary & retrieval cable winches)

• Design reviews & approvals

• Authored equipment IOMM (Installation, Operation and Maintenance Manual)

• Performed AS3007 Audit (for cable winches)

• Oversaw live field testing of the system

• Worked with patents lawyer to apply for and have patent awarded