Project Overview:

Described as one of the largest, most complex, and innovative belt changeout operations in Australia’s iron ore mining history. In an industry bench-mark example of successful collaboration between multiple companies. The methodology, engineering scoping and execution for this unique project in Western Australia’s Pilbara commenced back in 2020 and was successfully completed in August 2023… ahead of schedule, under budget and most importantly, reportable incident-free.

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This Overland Conveyor is the client’s longest existing single flight conveyor system, delivering up to 5000 tonnes/hour of High-Grade iron ore over 11.7km from its mining operations to the processing plant. The ~23.8km of 1500mm wide ST4000 conveyor belt (i.e. 40 x 600m belt lengths each with a combined weight of 50.5t) was prepared and spliced into one continuous length and arranged in 2 x 300m long piles at 1.4m each in height. Belt movement was completed in 85 hours versus a scheduled 142 hours with an average cycle time (per 600m roll length) of 1 hr 40 minutes - significantly faster than acceptable industry standards.

 

Scope of duties performed:

• Development of work methodologies for belt replacement

• Calculation of design belt pulling/hauling 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 force

• Calculate & furnish reaction loads for custom belt handling equipment

• Conceptual design of equipment support platforms

• 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

• Calculation of load sharing arrangement for the dual pony drive system

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

• Provided on-site engineering & technical leadership as requested by client during belt replacement works