Project Overview:

Drift or ‘Slope’ conveyors are key infrastructure in that they are responsible for conveying ore and minerals either up or down large vertical distances. Typically designed with slopes of to up to ~16° and in some cases covering many kilometres, maintaining these systems can be challenging and present issues not seen on short-centred and overland conveyor systems.   

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In another bench-mark example of successful collaboration between multiple companies, the methodology, engineering and execution for this critical project for a client located in NSW, Australia was successfully completed over 9 months in 2018… on-schedule, on-budget and most importantly, reportable incident-free.

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This Drift Conveyor hauls metallurgical coal from underground up a lift of ~480mtrs to the surface wash-plant at a rate of up to 1250 tonnes/hour over a horizontal length of 1650mtrs. The ~3.5km of 1067mm wide ST4500 conveyor belt (i.e. 5 x 695m belt lengths each with a combined weight of 40.0t) was prepared and spliced into one continuous length and arranged in a 1.0m high x 120m long pile. Belt movement was safely completed within a scheduled 9 day period including the installation and removal of a sizable amount of temporary equipment to facilitate the work. Highlights included; an equipment electrical interlocking system, real-time load monitoring of belt tension applied to the tail-take-up trolley to prevent structural overloading, and use of a camera network system to provide key visual information to equipment operators in real-time.

 

Scope of duties performed:

• Development of work methodologies for belt replacement

• Calculation of design belt hauling and braking loads in accordance with relevant industry standards & norms

• Calculation of conveyor system belt tensions, including permanent, thermal and elastic belt elongations for the correct set-out of the conveyor belt take-up system

• Calculation of demand power for all equipment

• Selection of equipment required to facilitate the works and provide effective motive and braking force

• Conceptual design of equipment support platforms

• Mechanical & electrical design of a temporary Pony Drive system

• Provide SME advise to 3rd party for detailed design of equipment support platforms

• Design reviews & approval for equipment support platforms

• Author project design risk assessments

• Design & draft SLD & electrical schematics for belt control & equipment interlocking system

• Designed take-up load-monitoring system  

• Authored multiple technical work instructions for such tasks as; correct set-up and operation of machinery & equipment, conveyor belt take-up set-out, belt mechanical joint procedure, belt clamping procedures & other.

• Operated heavy duty clamping system during belt replacement operations

• Provided on-site engineering & technical leadership during belt preparation & replacement works