Initial breakdown call & belt calculations completed.
Sunday
Plan for methodology of recovery.
Monday
Plan confirmed. Fenner service team set up works. 3 Splice kits urgently provided.
Wednesday
Preparation for works continue. Splice kits arrive.
Thursday
A further 12 Fenner Conveyors service employees arrive to step up preparations.
Friday
Work commences to recover the system.
Saturday
Winder equipment and counterweights are set up.
Sunday
Belt arrives from Kwinana - 7 days after the breakdown call. new belt set up to be installed whilst removing damaged section.
Monday
Belt pull 1 of 2 on damaged section begins.
Tuesday
Belt pull 2 of 2 complete. First 3 splices commenced.
The Challenge
Our client is one of the largest producers of Iron Ore in the world. Located in Western Australia’s Pilbara region, a key system of the client's is 24Km long and the key link between two of the client's mines.
During a shift, the overland conveyor system had an emergency breakdown, resulting from a (non-Fenner Conveyors) tail pulley failing causing belt damage along the main conveyor system. Breakdowns like this bring the entire operation to a halt, and thus Fenner Conveyors was engaged to remediate the emergency situation quickly and efficiently to save the client downtime.
It was important for the Fenner Conveyors team to complete urgent belt recovery works, including a belt pull, insert and splicing as quickly and as safely as possible to get the system back up and running.
The Solution
Belt pull calculations completed to understand the requirements to build a recovery plan.
Supplies were fast tracked to ensure we were ahead of schedule.
Emergency splice kits manufcatured and air frieghted to site.
Increased number of employees to prepare for major works and to recover the system.
Diagnostic support through the use of MFL and Belt Guage scans. These scans were used to compare previous base line results to asses the degree of damage. The iBelt technology and the diagnostic bracket enabled a health check of the entire length of the belt, including cord health and cover damage.
The Results
The job was one shift ahead of schedule and had the system operational 4th February 2024.
Zero quality or splicing issues.
The system was remediated ahead of schedule and had the system operational 23 days after the emergency call out.
The client was extremely satisfied with the performance of the team involved to get their system up and running again.
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