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Reducing shutdown times with a safer and faster way of changing underground belts

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Australia’s largest gold mining operations in NSW approached Belle Banne Belt Handling Equipment to develop a new methodology for splicing conveyor belt within the restricted space of underground mining.

The Challenge

Our client is an underground mine located 250kms west of Sydney. Their conveyor belts are inclined requiring high strength and tension and demand more time in splicing. Belle Banne engineers along with the client’s support, reviewed the process and developed a new splicing system for the shutdown, where each of these belts can be replaced in a similar and faster time frame as any surface conveyor system.

The Solution

  • The belts were pre-spliced in purposely mined out chambers using the BB flaking system over a period of weeks while the mine was in full production.
  • When ready to change, the old belt was spliced to the new using a shortened dummy (BB design) the system was powered by a superior hydraulic pony drive and the old belt was flaked out continuously as the new belt was pulled onto the system.
  • When the new belt was spliced, the next large belt was anticipated to be replaced in under 100 hours.
  • After the system was up and running the old belt was rolled up and skidded to the surface in individual rolls

The Results

  • Zero lost time injury-free.
  • BB met all the installation timetables, all completed on a 5 day window.
  • The client standardised all their range of equipment, including belt winders, turning frames, flaking stations and winches, all manufactured by Belle Banne.
  • The improved belt changing method has branched off into several other initiatives in the client’s site.
  • Belle Banne worked with the client in training their team on using the equipment.
  • Belle Banne Belt Handling Equipments original flaking system is now the benchmark around Australia.