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Tracking Correction Services Massively Reduce Downtime and Boost Productivity in Iron Ore Mine

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In severe cases, belt mistracking can lead to edge damage caused by the belt contacting surrounding structure, potentially causing unplanned downtime, lost revenue, and reduced belt lifespan.

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The Challenge

A conveyor for our client, a major iron ore operator in WA was dealing with mistracking, which was causing significant belt edge damage and subsequent unscheduled downtime due to the tripping of conveyor belt rip detection and belt drift switches.

Any downtime in a mining environment can potentially cause significant lost throughput and revenue for the operation.

In 2024 alone, over 26 hours of unscheduled downtime was caused by belt related incidents relating to this belt. With operational efficiency at risk, the client reached out to Fenner Conveyors for a solution.

The Solution

Our service team were tasked with the scoping, alignment, and installation of conveyor components to mitigate the belts mistracking and reduce unscheduled downtime.

These works focused on frame adjustments; marking and measuring for squareness, adjusting carrying and return frames, and the installation of guide rollers on the GTU carriage to constrain and centralise the system.

A number of other works were also completed to ensure Active Tracking Protection:

  • Return Tracker Installation: Remove existing return frame, install return tracker frame, adjust to OEM specs, complete QA/QC documentation and commissioning
  • Trough Tracker Installation: Install trough tracker frame and guide roller support arms, adjust to OEM specs
  • Return Transition Frames Replacement: Install new 5° and 10° V-return transition frames, relocate existing frames with guide rollers, mark and measure for squareness
  • Return Frame Installs: Install return guide frames and rollers, remove existing frames, level and set new frames
  • Guide Roller Installation: Install guide rollers and mounting brackets, mark and drill mounting holes, adjust to design specifications
  • Flat Return Frame Installs: Install flat return frames as part of system upgrades

The Results

Following the work performed by the service team, total unscheduled downtime for the following year was reduced to just 8.5 hours, a reduction of over 65%, demonstrating the success and effectiveness of the improvement package. In addition, these corrective measures help to maximise the lifespan of the belt, by reducing edge wear and ensuring optimal performance.