The ASIA Miner - Reporting Important Issues to Mining Companies in the Asia Pacific Region
Issue link: https://asiaminer.epubxp.com/i/830355
52 | ASIA Miner | Volume 14 • Issue 2 | 2017 Supplier News By Bernd Küsel, CBG Germany MINING conveyor belts are subjected to exceptionally great stress from material loading impact, from countless bends, from worn and failing conveyor parts, and from foreign objects that may slit or penetrate it. Failure or severe damage of the belt of- ten has dramatic consequences. It is es- sential to detect such failures immediately when they occur, in order to be able to take appropriate measures before things get worse. Monitoring systems based on radio- graphic technology, similar to those used in medical diagnostics, are well on the way to revolutionising the safety and operating effi- ciency of conveyor belts. This article describes the CBGuard system. Benefits Having a conveyor belt permanently mon- itored obviates the need for time-con- suming, insufficient visual inspections and temporary system shutdown. Repairs are performed at the optimum point of time - not unnecessarily early and not too late. The monitoring unit is permanently and exactly informing about the severity of inju- ries and deficits. This allows damages to be remediated within the scope of scheduled maintenance stops. With visual evalua- tion this would give reason for immediate, non-scheduled repair and conveyor down- time. The CBGuard system measures the exact belt thickness and yields timely information about the upcoming need for a replace- ment. Hence, maximum lifetime can be ob- tained from the conveyor belt. Exact, continuous status reports not only offer cost benefits, they also increase safe- ty. Arising damages, not still visible from the outside, can be eliminated in a timely man- ner. Serious damages, for instance broken or corroded steel cords, trigger an alarm, which advises the belt operator to carry out the repair as soon as possible. The X-ray unit is an important part of the preventive maintenance program. Extremely critical failures like the com- mencing opening of a belt splice or the slitting of the belt automatically stop the belt drive. That way, dramatic consequen- tial damages, for personnel and plant, are avoided. The X-ray scanner digitises the entire belt - virtually every cubic millimetre of the belt is captured. That way, the X-ray system can be integrated into the Industrial Internet of Things. A reconciliation with the control units of other components is enabled. Since the X-ray also detects material build-up on the belt, it is possible to automatically de- mand corrections of the cleaning devices. In combination with other elements of the logistical chain, the optimal time of the next maintenance stop can be scheduled. The condition of the belt can be observed from any place in the world in real-time over the internet. Who needs it? The industry is in a new phase where the need for integration, innovation and holis- tic thinking to operate successful mines is replacing methodologies of the past. X-ray scanners are a central part in this new en- vironment and use of an X-ray belt scanner is recommended for all long or critical con- veyors. Originally, the request for an X-ray sys- tem came from underground coal mining, because a visual assessment of the con- veyor belt is difficult. Under the Safety First rules, belts were replaced, because it was assumed they were not reliable anymore. Assets were burned because of lack of in- formation. There are hundreds of X-ray sys- tems now operating in underground mining. Particularly important is the X-ray scanner for steel cord conveyor belts. Damages to such long and expensive belts can have catastrophic consequences. In most cases they are the lifelines of mines, power plants and ports. Mode of operation The software generates an intelligent, holis- tic analysis of any kind of threat to the belt. The current condition of the belt and the splices is compared with the target condi- tion. Any deviation triggers a customised action - from a warning to the automatic shutdown of the conveyor system. The CBGuard scanner is suited for a belt width of up to 3200mm, a belt thickness of up to 60mm and a velocity of up to 9 m/s. The device is very compact. It fits in al- most all conveyors. The preferred installa- tion place is in the bottom part of the con- veyor (the return run) as the belt needs to run flat (not troughed) through the device. A concrete foundation and a safety fence have to be provided. Only autho- rised, qualified personnel will have ac- cess to the system. The scanner itself is equipped with several safety devices. At the fence, about 2 metres away from the generator, the radiation is equal to the nor- mal environmental radiation. Before work on the device, it is switched off in the control room. When turned off, there is no radiation. The program is intuitive and very easy to use. Remote servicing is possible anytime. The scanner is almost wear-free, because it has no moving parts or contact with the belt. The device signals in good time when the X-ray tube, which normally has a lifetime of some years, is about to be replaced. Conclusion X-ray technology in combination with so- phisticated software has begun a triumphal march with regard to conveyor belt health monitoring. No other independently working system or technology is capable of provid- ing and processing such a wealth of de- tailed information. The reduction in operating cost and the increase in safety are most convincing ar- guments for the implementation of these state-of-the art scanners. The CBGuard X-ray monitoring system in use on a conveyor belt. Monitoring boosts conveyor belt safety and efficiency