Tag Archives: Conveyors

Autonomous conveyor belt condition monitoring in times of a crisis

Bulk handling, Equipment maintenance, IoT, Mining consumables, Mining equipment, Mining maintenance, Mining safety, Mining services, Mining software, , , , , ,

As the digitalisation of processes in mines progresses, machines linked into the Industrial Internet of Things (IIoT) gain in importance, according to Bernd Küsel of CBG Conveyor Belt Gateway.

An important part of predictive maintenance and accident prevention is the continuous examination and diagnosis of steel cord conveyor belts, which are mainly used in the long-distance conveying of ores, coal and other raw materials. These conveyor belts are essential to many mining and loading facilities.

Many operators still rely on inspection personnel from service companies equipped with portable devices to inspect conveyors, but their appointment can be problematic. And, with today’s travel restrictions, this is close to impossible.

The problem comes as such inspections provide an insufficient picture of the condition of a conveyor belt that is reliant on interpretation by trained persons, with portable devices that only cover parts of a conveyor belt, according to Küsel. Moreover, inspections only offer a snapshot in time without the possibility to intervene in the case of threatening belt defects that could lead to a total failure of the conveyor system.

In times of crisis, such as the current COVID-19 pandemic, it is even more important to use a self-sufficient, automatic diagnostic system, according to Küsel.

“The virtually maintenance-free CBGuard scanner provides complete knowledge of the condition of the conveyor belt in real time,” he says. “It is operated from the user’s control centre or via the Internet.”

Damage can be repaired at the best possible time for the customer, reducing unnecessary downtime and the associated costs and loss of production that come with this.

The CBGuard scanner can be an indispensable part of a predictive maintenance program, Küsel says.

“With it, conveyor belts can be integrated into the IIoT, ie into seamless communication with other electronically monitored systems. CBGuard provides a complete, detailed knowledge of the condition of the conveyor belt – non-stop and online,” Küsel said. “Virtually every cubic millimetre of the conveyor belt is checked during operation. The CBGuard scanner compares the detected values with the target values in real time. Every critical change triggers a reaction. The operating personnel are immediately informed of serious errors via SMS. In addition, the exact thickness of the entire conveyor belt can be measured and outputted as a contour map.”

The CBGuard Life Extender, meanwhile, detects internal damage such as steel cord breakage, corrosion, misplacements and other defects of the tension member. The exact condition of each steel cord can be viewed on a monitor in real time. The same applies to certain belt breakers and conductor loops.

Damage such as holes, foreign bodies, protruding ropes, edge breakage, bubbles, rubber cover abrasion and even insufficient belt cleaning are detected. Each defect automatically generates a predetermined, individual reaction. Information about the findings is additionally available at any time as a photo, video or inspection report, which tells personnel exactly what kind of damage it is, how severe it is and the location of said damage.

The CBGuard scanner also prevents fatal consequences caused by splice defects, Küsel said. As the weakest links in a conveyor belt, splices pose a greater risk to the operation – with potentially devastating consequences.

The CBGuard Life Extender scans all splices. Every single splice is individually assigned in the database and compared with its target state. Any critical deviation generates an alarm or a stop of the system in case of threatening defects.

“No other method available on the market can provide such exact and comprehensive results,” Küsel said.

The way CBGuard works is similar to that of X-ray machines in the healthcare sector or in airports.
The device consists of an X-ray generator with a tube, a receiver module and a control unit. The generator produces artificial X-rays from electricity, with the ionising rays penetrating the moving conveyor belt and then hitting the receiver module – an amorphous silicon imaging field.

It is a process like that of photo diodes in a digital camera. Countless, seamless images are continuously generated and defined by CBGuard’s smart software – based on advanced face and palmprint recognition algorithms – checking the condition of the belt, while accounting for the individual structure, size, colour and position of deviations and reporting them as a specific event (eg damage).

“Using a CBGuard is safe,” Küsel said. “The device complies with all international regulations on radiation emission. It does not contain radioactive material!”

The compact design and low weight of the CBGuard makes for a quick and easy installation on almost any belt conveyor. The scanner is also almost wear-free, according to Küsel, as it has no moving parts or contact with the conveyor belt.

All functions of the CBGuard Life Extender can be remotely controlled via TCP/IP, with maintenance or programming work possible from anywhere in the world. The analysis software runs under Windows 7 and 10, and the program is intuitive and easy to use, he said.

CBGuard has proven its performance in over 300 applications, according to Küsel, noting that large copper mines in Peru and Chile rely on CBGuard. There are many other applications in Australia and Asia in the limestone and coal sectors, he added.

The CBGuard scanner ensures fully automatic, complete monitoring of steel cord conveyor belts making inspections by personnel or devices that only cover a part of the conveyor belt spectrum unnecessary, Küsel says.

The gain in safety, the independence from personnel availability and the reduction of capital expenditure and operating expenditure are convincing arguments for the use of a CBGuard, he explained.

On the operation expenditure side, for example, there is no longer a need to employ internal maintenance personnel or outsource external services to inspect the belt. Such inspections, typically carried out weekly, are conducted in belt ‘creep mode’ and involve a full shut down, according to Küsel.

“With the CBGuard, you do not have any production downtime because it is carrying out the inspections all the time at the normally operating conveyor, at its normal speed,” he said.

Belt repairs also only occur when necessary, with details of failures coming from the CBGuard. “You will see serious damage immediately, so you can repair them before they get worse and cost much more money to fix,” he said.

This also provides capital expenditure benefits, with the CBGuard telling operators when and which part of the belt is worn out. In many cases, only part lengths will have to be changed, not the entire belt length.

This comes with inventory benefits too, with companies no longer having to carry extensive stock belting as the CBGuard is able to predict in good time when the belt will need to be replaced.

BEUMER Group makes the economic case for ore transport by conveyor

Bulk handling, Environmental, Mineral processing, Mining equipment, Mining services, Sustainable mining, , , , , ,

BEUMER Group thinks more miners should include the use of conveyor belts for ore transport in their mine development calculations, as, on many occasions, the investment can pay off in the short- to medium-term.

Raw materials must be transported from the mine to a factory or port, often over uneven ground and across populated areas. To do this, companies often choose trucks for transportation.

As an alternative, system suppliers including BEUMER Group offer open troughed belt conveyors or closed pipe conveyors. These solutions are more environmentally friendly and can be considerably more economical, according to BEUMER.

“Deciding if the investment is worthwhile depends on several factors,” the company said, adding that a feasibility study and cost comparison can help with the decision.

Richard Munson, who manages the development and sales of conveying systems for the energy, cement and mining industries and port terminals, says a positive investment outcome depends on the application at hand, adding: “Companies should carry out a profitability evaluation beforehand.”

Whether it is calculating the net present value, or carrying out a cashflow analysis, the comparison needs to factor in the topography, length and power consumption associated with running the conveyor systems.

BEUMER Group says costs for conventional conveying systems average between €1,000 ($1,084) and €3,000 per metre. “More costs are added for the construction, supply and the mechanical and electrical installation,” it said.

Complex construction work is also often necessary, which makes the initial investment in a conveying system fairly high, the company says.

Munson says the operating costs are, however, considerably lower than the use of trucks.

The costs for the vehicles also include the labour input, vehicle depreciation, maintenance, repair, fuel and street maintenance, for example. And, oftentimes there are additional, more difficult to identify charges.”

To operate a conventional conveying system, the typical costs for transporting one tonne of material amounts to €0.20, with trucks the costs are roughly €3, according to BEUMER Group.

“The biggest variable for the vehicles is the number of trips per hour,” Munson said. “In the case of short and direct routes, this ranks better than for long routes, where detours are necessary to get to the destination.”

Troughed belt conveyors and closed pipe conveyors lead directly to the destination, on the other hand. They can also be adapted to the specific surroundings, with an essential feature of the technology being the ability to handle horizontal and vertical curves. Angles of inclination of up to 15° are possible, depending on the characteristics of the material to be transported and the topography, with lengths greater than 12 km.

“Due to their ability to navigate curves, considerably fewer and − in some cases no − transfer towers are required,” BEUMER Group said. “This results in substantial cost savings for the customer and the system continuously transports the material even over challenging ascending and descending sections, rivers or street crossings.”

Using BEUMER calculation programs, the experts precisely calculate the static and dynamic tractive forces of the belt during the system development phase. This is the prerequisite for the safe dimensioning of the curves, according to the company.

For trucks, more cost factors must be accounted for that are not as easy to estimate; control measures against dust and rain drainage, for example. These variables are eliminated completely in the case of closed pipe conveyors.

Munson said: “If circa-1 Mt of bulk material are moved per year, then the gross differential value between trucks and a conveyor, using the above mentioned costs of the material that needs to be conveyed, is at €2.8 million.”

According to Munson, such a conveying system pays for itself after only a few years.

The electric drives and low-energy belts also have a positive effect on the operating costs of the belt conveying systems. They are also better for the environment compared with truck transport.

“Therefore, especially in these times of climate change and increasing greenhouse gas emissions, they are considered a more sustainable option,” BEUMER Group said. “The motors used for these systems are usually adjustable, which permits the loads to be optimally distributed on the drive units under various operating conditions. If the belt conveying system conveys downhill, the system works in regenerative operation. The generated electric energy is fed to the mains by a regenerative feedback unit. This way the owners can further reduce the operational costs of the entire system.”

Depending on the project, belt conveying systems require up to 90% less primary energy compared with truck transport, Munson says, referencing a project implemented for China cement manufacturer Sichuan Yadong Cement. Here, trucks operated with diesel fuel required a specific primary energy of 11.4 kWh for each tonne of transported material at the site. The belt conveying system built later on required only 1.44 kWh.

“If, as in this case, 7.5 Mt of raw material are transported annually, the user can save a total of 74 million kWh/y with the belt conveyor,” BEUMER Group said. “This corresponds to an energy consumption of more than 20,000 single-family houses. Solely by saving diesel fuel, the operational costs of the company are reduced by more than €5.5 million/y.”

Munson concluded: “In the end, the operator needs to consider the total costs per tonne over time when evaluating both transport options.”

The operational costs for a belt conveyor are considerably lower than for a truck, but the decisive factor is how much material is transported during the project term and the environmental concerns at play with the project.

BEUMER Group helps coal miners with environmental impact, optimal stockpiling

Bulk handling, Coal technology, Environmental, IoT, Mine operation news, Mine surveying, Mining equipment, Mining services, Sustainable mining, , , , , , , , , ,

The combination of BEUMER Group’s sophisticated modelling techniques and use of drones has enabled Knight Hawk Coal’s Prairie Eagle mine, in the Illinois Basin of USA, to reduce its long-term environmental impact.

Drone technology is being used more frequently during project planning, implementation and documentation to optimise the design phase, according to BEUMER. The recorded aerial photos are reconciled with regards to their perspective and evaluated photogrammetrically.

The software calculates a point cloud in order to generate 3D models from the 2D views, ie digital terrain models, allowing stockpile designs to be generated for both greenfield and brownfield developments.

Opened in 2005 as a surface mine, Prairie Eagle was expanded over time to include two underground mines, Knight Hawk’s main coal preparation plant and multiple truck load-out facilities. Now one of the most efficient underground mining plants in the US, according to BEUMER, it produces around 5 Mt/y of coal, of which more than 80% is processed and delivered to the Prairie Eagle preparation plant.

Management was looking for a more sustainable operating solution that reduced its reliance on truck transportation, according to Andrea Prevedello, System Technology Global Sales Director, BEUMER Group, Germany.

“We provided an overland conveyor that transports the coal from the mine to the main processing plant,” he said. “Our conveyor helps the company to considerably reduce its ecological footprint. With this technology, Knight Hawk can significantly reduce its long-term environmental impact compared to using truck transportation.”

BEUMER’s solution at the mine features a single-flight curved conveying system that eliminates the cost of tower steel, and greatly reduces the quantity of components and necessary spare parts, according to the company. It reduces the dust, noise, maintenance and operating costs associated with the transfer points, BEUMER said.

BEUMER not only supplied the conveying solution to Knight Hawk. As a system supplier, the company also supported the mining group in building a stockpile for hard coal.

“The requirements for storing coal are obviously very different from other materials,” Prevedello said. Some of the requirements change if the stockpile is covered and if explosion-proof equipment is needed. Hard coal is very susceptible to spontaneous combustion, which is why the height of the stockpile must, in certain cases, be limited.

Depending on the customer, stockpile dimensions and design can vary. Two layouts are generally available: circular and longitudinal.

“Their dimensioning and design depend on the purpose of the stockpile,” Prevedello said. Space availability and possible future expansions are also critical factors.

The application must also be considered: does, like Knight Hawk, the customer want to store the bulk material temporarily, then continuously feed it for further processing? “Then longitudinal stockpiles are your best choice,” Prevedello said. These structures can also be extended, if necessary, according to BEUMER. The irregular flow of bulk material arrives at the stockpile and can then be continuously introduced to the process.

Circular stockpiles are frequently used for other bulk materials, eg limestone and clay.

Once the layout of the stockpile has been decided on, the next task is to stack the bulk material efficiently. BEUMER also provided these components, such as the stacker, to Prairie Creek.

“Depending on its mobility, the systems can be categorised into three groups,” Prevedello said. The stacker can be stationary, travel on rails, or be circular with endless movement.

If the machine is circular with endless movement, it is positioned on a column in the centre of the stockpile. Over a conveyor bridge installed above the stockpile, the material is transported directly into the axis of rotation of the stacker, and from there distributed centrally. Depending on the stacking method, the boom conveyor can be fixed, or it can be lifted and tilted.

The stacking method of choice depends on whether the bulk material is only temporarily stored, or if it also needs to be blended.

“For simple stockpiling without blending, we provided the simple ‘cone shell method’,” Prevedello said. The stacker only moves up and down, ie does not slew, and the stacker design can be simplified. This method works for longitudinal as well as circular stockpiles, according to BEUMER.

For blending the bulk material, the ‘Chevron method’ can be used. The boom of the stacker starts in its lowest position; the first row is deposited in the centre of the stockpile and the next rows are layered on it. In longitudinal stockpiles, the stacker usually moves in a tilting and slewing motion; in circular stockpiles, the stacker moves in a circulating and luffing motion.

Prevedello said: “The perfect system solution is always an optimal relation between stacker and reclaimer.” Reclaimers such as side reclaimers or bucketwheel reclaimers remove the material as necessary. The best option for the customer depends, again, on the stockpiling task at the end.

Side reclaimers work for both types of stockpiles – longitudinal or circular – with the bulk material reclaimed from the front or the side. When reclaiming from the side, scraper chains move the material on a belt conveyor. Front reclaiming usually uses a rake that, in small side-to-side movements, pushes the material on a scraper chain to be transported further to the conveyor, BEUMER explained. The advantage is the bulk material is reclaimed from the entire cross-sectional area. Bucketwheel reclaimers are generally used when the bulk material, especially large quantities, needs to be blended.

Each operator has their own specific requirements when it comes to the stockpile and stockyard machines.

This is shown in a project BEUMER engineers are currently implementing for a customer in the energy industry. The order includes the delivery of several conveyors, including pipe conveyors, and a ship loader. The challenge: “On the ground where we will install our solution, there can be violent gusts of wind,” Prevedello said. “That’s why we pay special attention to the dimensioning of the steel structure.”

The system provider will be able to hand over a tailor-made system to the customer, with investment expenditure tailored precisely to them, according to BEUMER, which said the expected commissioning is scheduled for the September quarter of 2020.

REMA TIP TOP to splice things up at Rio Tinto’s West Angelas

Bulk handling, Equipment maintenance, Mine operation news, Mineral processing, Mining equipment, Mining services, Steel and iron ore, , ,

REMA TIP TOP Australia has been selected by Monadelphous to provide splicing capabilities across more than 10 km of new overland conveyor and modifications to three existing plant conveyors at Rio Tinto’s West Angelas Deposits C & D project, in the Pilbara of Western Australia.

Benedikt Schneider, CEO of REMA TIP TOP Asia Pacific, said he was “thrilled to be able to bolster our partnership with Monadelphous and leverage our proven relationship in delivering unmatched capabilities for Australia’s largest mining houses”.

He added: “We pride ourselves on our ability to provide best-in-class services.”

Schneider concluded: “As Australia’s only Registered Training Organisation with the ability to train both our own people and also to develop skilled workers from across the materials processing industry, we take our role of being an expert in conveyor installation, repair and servicing very seriously.”

With a total of 39 splices across five conveyors, with run of mine and overland conveyors connecting the site with Rio Tinto’s existing West Angelas process plant and stockyard, the A$1.2 million ($770,000) scope of works is set to commence this quarter.

Flexco and Uptake devise new predictive analytics tool for conveyor belts

Bulk handling, Equipment maintenance, IoT, Mining equipment, Mining software, , , ,

Flexco says it has introduced a new innovative, real-time monitoring system that harnesses the power of predictive analytics so mining, aggregate, and cement operations can remotely gather critical insights to optimise belt conveyor productivity and heighten operational efficiencies.

Flexco Elevate™ Belt Conveyor Intelligence™ is a wireless platform that transfers data insights to an intuitive cloud-based dashboard via edge technology, allowing remote monitoring of belt cleaners, according to the company. With intelligence that grows over time, this easy-to-use platform is designed to simplify and accelerate belt maintenance using its powerful, data-driven engine, Flexco says.

Chip Winiarski, Vice President of Marketing at Flexco, said: “Flexco has a 110-year history of innovation, working alongside our customers to deliver solutions that are in alignment with their operational goals. We are proud to introduce Flexco Elevate. It’s the first technology solution of its kind and will quickly bring increased efficiencies and improved productivity to our customers’ operations.”

Created in partnership with Uptake, an industrial AI and IoT data science leader, Flexco Elevate reduces the need for on-site inspections and allows operations to access real-time insights remotely from an intuitive dashboard, so users are able to quickly address belt conveyor performance issues and minimise unexpected downtime.

“The insights pipeline begins by installing a state-of-the-art Flexco Elevate i3 Device to the end of each Flexco belt cleaner where cutting-edge analytics are immediately aggregated and processed,” Flexco says. “The information is then wirelessly transferred to the Flexco Elevate Dashboard where operations have immediate, remote access to action-oriented insights and service information for all of the Flexco cleaners throughout the operation.”

Flexco Elevate alters the way operations are run and the solution’s multi-faceted benefits streamline internal processes, according to the company. They include:

  • Increased Productivity: the Elevate solution makes it easy to manage belt cleaner service;
  • ROI from day one: data insights are immediately transferred to the dashboard so operations realise operational efficiency from day one;
  • Improved safety: the Flexco Elevate solution reduces the need for dangerous physical inspections along beltlines;
  • Asset management: digital mapping of installed Flexco cleaners provides visibility of assets for more efficient resource planning;
  • No guesswork: the operations team knows exactly what, when, and where service is needed;
  • Leverages existing assets: the Elevate platform works with existing Flexco belt cleaners – no additional investment in cleaners is required; and
  • Remarkably easy: installation and activation in as little as five minutes for a user-friendly experience.

Severstal to circumvent haulage cost hike at Tsentralniy open-pit with new conveyors

Bulk handling, Mine operation news, Mineral processing, Mining equipment, Mining services, Steel and iron ore, , , , ,

Severstal is readying an investment in a new conveyor system at the Karelsky Okatysh iron ore complex in northwest Russia as part of a major project to reduce haulage costs at the Tsentralniy open-pit mine.

In the company’s capital investment 2020 announcement at the end of January, it said one of the major investment projects being run by its Severstal Resources division was the “construction of a conveyor belt for run-of-mine transportation at the Tsentralniy pit”.

This conveyor system will help the complex continue to process 20 Mt/y of iron ore and 45 Mt/y of overburden.

Since this announcement, IM has received more detail about this planned installation from a Severstal spokesperson.

The conveyor complex will consist of three production lines, according to the spokesperson:

  • The ore production line includes a semi-mobile gyratory crusher, with capacity of up to 3,500 t/h, a conveyor that lifts the crushed ore to the pit surface and transports it to a warehouse for storage, a warehouse conveyor and a stacker;
  • The second production line is for overburden. It has a more powerful semi-mobile gyratory crusher with capacity of up to 7,300 t/h, lifting and transmitting overburden conveyors and a dump conveyor that feeds the overburden to the spreader that forms the tailings heap; and
  • The third production line is intended for “contaminated ore”. It consists of an eccentric crusher, a dry magnetic separation unit and a conveyor system. After separation, refined ore will be fed to the first ore line and the waste rock will be fed to the second overburden line.

The total length of all the conveyors is 6.5 km, with the largest single conveyor being 1.85 km. The spokesperson said the height of the overburden lift by the conveyor system is 320 meters.

Severstal Resources says the goal of the project, which should launch in 2023, is to reduce haulage costs associated with transporting rock using dump trucks.

“Today the Tsentralniy pit is 350 m deep, 4 km long and 2.5 km wide,” the spokesperson said. “Dump trucks are carrying ore and overburden for about 5 km; by 2023 this will increase to 7 km – hence the decision to build the conveyor complex.”

The project has the added benefit of reducing emissions as there will be less exhaust from the equipment in the pit, the spokesperson added.

REMA TIP TOP Australia builds up infrastructure capabilities

Bulk handling, Equipment maintenance, Mining mergers and acquisitions, Mining services, , , , ,

REMA TIP TOP Australia says it is extending its existing range of material processing, wear protection and surface protection capabilities with the addition of civil, structural steel, mechanical and piping entity Drew Project Services.

The new agreement bolsters REMA TIP TOP’s experience in the installation and maintenance of conveyor systems for Australia’s leading industrial companies, adding a new and unmatched capability to provide broader infrastructure services, it said.

Steve Hipwell, REMA TIP TOP’s National Projects and Tenders Manager, said: “We’ve long been recognised as a leading provider of products and services that help keep Australian industry on the move. From conveyor belt design, componentry and specialist repair services, we’ve been able to hone our skills over decades to become expert in the installation, maintenance and the replacement of conveyor belts globally.”

This new agreement with Drew Project Services extends the company’s capability to provide turnkey solutions for customers in civil and mechanical disciplines across both maintenance and project requirements, Hipwell explained. “These services include detailed design and fabrication, detailed earthworks, form work and steel fixing, concreting, project management and supervision, heavy construction, site installation and commissioning, specialised welding and cutting, crane operation and rigging, painting and blasting services,” he said.

“We’ve long spoken about our desire to provide total industrial solutions that are aligned to our customers’ operating challenges and the establishment of this new infrastructure capability is evidence of this commitment.”

The new partnership is in effect from January 1, 2020.

Flexco ready to present bulk handling products, expertise at CONEXPO

Bulk handling, Equipment maintenance, Mineral processing, Mining equipment, Mining events, Mining services, , , , , ,

Flexco says it will address splicing, cleaning, tracking, and belt slippage needs at the upcoming CONEXPO-CON/AGG 2020 event, held in Las Vegas, on March 10-14, 2020, in addition to discussing the future of belt conveyor technology for heavy duty applications in various industries.

The company’s booth at the event will feature a full-size conveyor, as well as interactive displays to help attendees better understand the features and benefits of Flexco product solutions, it said. Live demonstrations of conveyor rip repair and 45-degree fastener installation, using the Flexco Bolt Solid Plate Fastening system, will also take place.

Flexco will be showcasing a variety of products designed to increase efficiency and decrease downtime.

The Flexco Wash Box is designed to deliver superior cleaning efficiency in applications where the conveyor must be very clean or when head-end cleaning is not enough. Mounted on the return side of the belt, hinged doors are available on each side for easy inspection.

The Y-Type™ Secondary Cleaner (pictured) will also be highlighted on the booth this year. With standard and heavy-duty options available, the Y-Type offers multiple blade options and easy maintenance at an affordable price, according to Flexco.

And, if miners are having dust containment issues at the load zone, the company says they should stop by the Flexco booth for more information on the Flexco Enclosed Skirt System and Dual Seal Polyurethane Skirting.

At this year’s booth, Flexco also plans to introduce its new TUG™ HD® Belt Clamps, designed to secure the belt for repair, meeting the most stringent safety test standards. Available in 5.4 t and 7.3 t versions, TUG HD Belt Clamps provide even tensioning across the entire belt width for ultimate strength, according to the company. Modular components, meanwhile, allow for increased versatility and portability.

The Flex-Lifter™ Belt Lifter, 900 Series Belt Cutter, and Cordless Electric Belt Cutter round out the group of products designed for safer belt conveyor maintenance that will be highlighted on the Flexco booth this year.

Martin Engineering on confined safe entry for chutes, silos and hoppers

Bulk handling, Equipment maintenance, Mining equipment, Mining maintenance, Mining safety, , , , , ,

Martin Engineering, a global innovator in the bulk material handling industry, is urging operators to locate safe access points before attempting to unblock chutes, silos and hoppers in order to prevent potential accidents on site.

As the company says, many factors can cause bulk materials to adhere to the sides of chutes, silos and hoppers – including humidity, moisture content, size/texture of the raw material or increased production volume – resulting in lost capacity or clogging.

Ongoing accumulation reduces flow and eventually stops production in order to address the issue, causing expensive downtime and requiring extra labour to clear the obstruction.

Martin Engineering Product Engineer, Daniel Marshall, said: “Clearing extensive build up often involves confined space entry, but the consequences of untrained staff entering a chute, silo or hopper can be disastrous, including physical injury, burial and asphyxiation.

“Without proper testing, ventilation and safety measures, entering vessels containing combustible dust could even result in a deadly explosion.”

What is confined space entry?

The US Occupational Safety and Health Administration (OSHA) defines “confined space” as an area not designed for continuous employee occupancy and large enough for an employee to enter and perform assigned work, but with limited or restricted means for entry or exit. “Permit-required confined space” means a confined space that has one or more of the following characteristics:

  • The vessel contains or has the potential of containing a hazardous atmosphere such as exposure to explosive dust, flammable gas, vapour, or mist in excess of 10% of its lower flammable limit;
  • Atmospheric oxygen concentration below 19.5%, or above 23.5%;
  • There is the potential for material to engulf, entrap or asphyxiate an entrant by inwardly converging walls or by a door which slopes downward and tapers to a smaller cross-section; or
  • Contains any other recognised serious safety or health hazards.

Entering a confined space

Working in confined spaces typically requires special personnel training, safety harness and rigging, extensive preparation and added personnel for a ‘buddy system’.

Marshall continued: “Systems designed to minimise permit-required confined spaces can provide a significant return on investment and the best time to reduce the amount of confined-space entry for component maintenance and replacement is during the specification and design stages of a project.”

Many manufacturers offer systems and products that can reduce the need for confined space entry.

Examples would include:

  • Modular chute designs with abrasion-resistant liners;
  • Chutes that hinge open and lay down for liner replacement;
  • Skirtboards with external liners;
  • Belt cleaners that can be serviced without confined space entry;
  • Flow aids such as air cannons and vibrators to reduce build up; and
  • Modular air cleaners for specific locations rather than centralised dust collection.

Global regulations, standards and best practices

Rules regarding confined space entry vary greatly depending on the country, even down to the state, province or prefecture level. As always, regional and local codes should be identified and followed, but general rules can be drawn from regulations established in major industrial markets such as Australia/New Zealand, Canada and the United States. Commonalities between governmental regulations provide employers with a measured approach to safety.

Prior to starting the job, these procedures include:

  • Review the permit and the job-specific work procedures;
  • Gather and inspect all necessary PPE;
  • Test and/or calibrate any safety gear, test instrumentation or communication tools;
  • If a current Job Safety Analysis or safety check list does not exist, perform a risk assessment;
  • Hold a pre-job meeting making sure all workers are aware of the hazards and safe work practices;
  • Conduct proper tests for toxins, vapour, dust levels, oxygen levels and material-specific hazards;
  • Perform as much cleaning and maintenance as possible outside of the vessel;
  • Post completed confined space entry permit outside of the vessel;
  • Isolate contaminants and moving parts to prevent the accidental introduction of materials; and
  • Proper lock-out/tag-out/block-out/test-out procedures must be completed and documented prior to entry.

During the procedure, they include:

  • Perform maintenance/cleaning using non-toxic substances such as water and avoid using heat/fire in the confined space. Never use oxygen to purge a confined space, as this can create a fire and explosion hazard;
  • Provide ventilation if possible;
  • Select personal protective/safety equipment such as safety helmet, gloves, hearing protectors, safety harness and lifeline and breathing apparatus;
  • Assign a trained observer to monitor the procedure and internal conditions, and provide escape assistance if needed; and
  • Practice fast evacuation of the confined space.

“Over time, well-designed access improves safety and saves money,” Marshall said. “Safe access that is carefully located and adequately sized will increase dependability and also reduce the downtime and associated labour required for maintenance.”

He advises that companies consider equipment designs which minimise the need for confined space entry, including improved access doors, vibrators, air cannons or silo cleaning services.

“Conveyor systems that are properly outfitted with appropriate cleaning and material discharge equipment create a safer workplace, while experiencing longer life and less downtime,” he concluded.

Superior’s Prime Mine Duty Pulley to be unveiled at CONEXPO

Bulk handling, Equipment maintenance, Mining events, , , , ,

Superior Industries is to debut a new conveyor drum pulley at the upcoming CONEXPO-CON/AGG 2020 show in Las Vegas, it has confirmed.

One of a dozen new products the company will introduce during the trade show on March 10-14, the Prime™ Mine Duty Pulley is a drum-style conveyor pulley manufactured in diameters from 4 in (10 cm) to 30 in (76 cm) and face widths of 12 in to 78 in.

It is designed and built with a solid steel end disc, which eliminates welding at the hub of the pulley, according to Superior, which said the applications include aggregate and mine duty conveyors using fabric belts that frequently start and stop under full loads.

Alan Schmidgall, a Vice President with Superior, said: “Our Prime Mine Duty Pulley has many of the same design characteristics of Mine Duty 2.0 and Super Duty drum pulleys, but its optimised design yields a lower weight. That means we can offer a more economically friendly option and include many of the features our customers said they require.”

The Prime Mine Duty Pulley is one of four standard, pre-engineered conveyor pulley models available from Superior. Other designs include CEMA, Mine Duty 2.0 and Super Duty. Superior also offers custom-engineered pulleys from its Core Systems® Design team.