Project Summary

CPS designed and manufactured BHP’s South Flank overland conveyor (OLC) idler systems. With a combination of high-tolerance idler frames and composite roller technology, CPS has delivered one of the most advanced, reliable, and cost-efficient overland conveyors in the world.

“CPS is proud to have completed the supply of the South Flank overland conveyor idlers, on time and in budget, in April 2020 – the culmination of more than three years of collaboration with BHP and the single largest project undertaken by our business. We believe this represents one of

the most advanced, reliable and cost efficient overland conveyors in the world. On a more human level, manufacture of the conveyor rollers and frames required CPS production facilities to run over two shifts for nearly 10 months, and employ more than 50 additional local staff.” – Matt Einhorn, CPS Chief Financial Officer

Through early engagement with the client and engineers in 2016, CPS was able to develop a composite roller specification capable of long life and heavy duty OLC operation. CPS worked with BHP and Fluor on iterative design changes and modifications to optimise entire conveyor design (drives, belts, idlers, pulleys and structure). This included material development to suit 219mm diameter composite rollers which significantly reduced belt indentation power losses. The roll diameter, spacing and bearing combinations were optimised to reduce power draw.

Value Delivered

Over such extreme distances and in as harsh conditions as are found moving Iron Ore in Western Australia’s Pilbara region, every minute factor has a massive cumulative effect. This is where the precise engineering and manufacture of CPS’s Yeloroll HD composite roller technology

teamed with SKF bearings, custom grease development and triple labyrinth seals came into their own creating the smoothest conveyor belt traverse and longest roller life possible.

The idler sets were designed with ease of installation in mind and incorporated precision jigging points and alignment positions to reduce man-hours during construction and maintain ±0.5mm tolerances. The effect of each idler frame being so precisely aligned and constructed over such a long distance (combined with the superior Yeloroll HD rollers) provides a significant collective benefit - reducing mechanical drag losses by 25% in turn reducing power draw.