Transcript of Alex Harrison - Conveyor Technologies
- 1. Repair Methodology for Steel Cord Belts to Increase Life and
Reduce Operational Risk. Alex Harrison, RPEQ Conveyor Technologies
Pty Ltd 2014 Conveyor Technologies Pty Ltd. All Rights
reserved
- 2. 2014 Conveyor Technologies Pty Ltd. All Rights reserved
COLLECT DAMAGE INFORMATION BEST ACHIEVED BY REMOTE ACCESS TO A NDT
MONITOR Main Types of Damage : (a) Impact (b) Fatigue at Defects
The NDT Monitor : Dual Frequency E-M plus Magnetic Induction
- 3. Damage by Impact Belt damage is not always visible ! Steel
cables break due to Impact and/or Fatigue Fabrication Defects
- 4. Damage by Fatigue Manufacturing Defects Steel cord belts
contain defects from new. Steel cables break from : Bending
Fatigue, Flexing, Stress Concentrations at Defects Press-mark
Defects Edge cord defect
- 5. STEPS IN REDUCING RISK MAXIMISING BELT LIFE 2014 Conveyor
Technologies Pty Ltd. All Rights reserved Collect damage
information at regular intervals from a remote NDT belt monitor
(Belt Scan). Conduct a strain analysis on damage site. Determine
belt Safety Factor (SF) at damage sites, in order of severity.
Design a Repair for load-carrying, depends on damage shape and
cable-end distribution. Install repair and Test its Quality : Hot
vulcanized in-laid cable repair, with belt tension removed [1]. 1.
The Belt : Steel Cord Composite Construction (AS-1333) 2. Steel
cables share load and redistribute stress imbalance by Shear.
- 6. 2014 Conveyor Technologies Pty Ltd. All Rights reserved
RECORDING BELT CABLE DAMAGE Remotely Accessed NDT Belt Monitor.
Equipment shown was installed in 2001, Henderson Mine PC-3 belt ,
Colorado
- 7. 2014 Conveyor Technologies Pty Ltd. All Rights reserved
COLLECTING NDT DATA Steel cord belts remotely monitored annually =
150 In Australia : Queensland (12 / year) In North America : USA
(130 / year) Canada (8 / year Peru (1 installation) 4
- 8. RECORDING BELT CABLE REINFORCEMENT DAMAGE 2014 Conveyor
Technologies Pty Ltd. All Rights reserved Expand
- 9. EXPANDED DATA EVENT LOCATION AND TYPE 2014 Conveyor
Technologies Pty Ltd. All Rights reserved
- 10. RECORDING BELT CABLE DAMAGE 2014 Conveyor Technologies Pty
Ltd. All Rights reserved
- 11. SPLICE ADHESION MONITORING 2014 Conveyor Technologies Pty
Ltd. All Rights reserved 8-2014 : Damaged Splice Signature
8-2013
- 12. CORD PLANE DEFECT FATIGUE (Press-length Interval cord plane
buckles) 2014 Conveyor Technologies Pty Ltd. All Rights
reserved
- 13. EMBEDDED LOOP CAUSING CABLE FATIGUE
- 14. SELECT THE NDT SCAN INTERVAL : REMOTE ACCESS TESTING 2014
Conveyor Technologies Pty Ltd. All Rights reserved Corrosion and
Cable Break Growth 1 to 3 Months. (Annually too long) Impact damage
use other detection devices
- 15. REPAIR DESIGN REQUIRES ACCURATE DAMAGE ASSESSMENT COMPARING
NDT MONITORING SYSTEMS 2014 Conveyor Technologies Pty Ltd. All
Rights reserved bs1 = Belt Manufacturer Scan System Permanent
Installation ~ $70k, NR bs2 = Belt Manufacturer Scan System On-site
Personnel required ct = Conveyor Tech Remote Calibrated, Online
24/7 if needed bv = By verification on-site destructive testing of
detected events
- 16. CONVERT BELT CABLE DAMAGE LEVEL TO A STRAIN CONCENTRATION
Mechanical Model (Ti+1 Ti) = (Ti T/n) 2014 Conveyor Technologies
Pty Ltd. All Rights reserved BreakRubber ShearRubber Shear
CSFStrain Decaylength along cordsStrain Decay across beltMax
CSF
- 17. DAMAGE ANALYSIS STRESS AT DAMAGE SITE Edge Example (Maximum
Strain) 2014 Conveyor Technologies Pty Ltd. All Rights
reserved
- 18. DAMAGE ANALYSIS STRESS AT DAMAGE SITE Non-Edge Example (Up
to 30% below Edge Strain) 2014 Conveyor Technologies Pty Ltd. All
Rights reserved
- 19. 2014 Conveyor Technologies Pty Ltd. All Rights reserved
SAFETY FACTOR GRAPH : Belt will FAIL when SF < 1+ Tmax
(Start)
- 20. REPAIR DESIGN BASED ON SF ANALYSIS 2014 Conveyor
Technologies Pty Ltd. All Rights reserved
- 21. TYPICAL REPAIR AND SPLICE SIGNATURES (ST-5400 BELT) 2014
Conveyor Technologies Pty Ltd. All Rights reserved
- 22. SOME REPAIR METHODS and EXAMPLES 2014 Conveyor Technologies
Pty Ltd. All Rights reserved Break Pattern (7 breaks) Repair
Pattern 1 (3, 3, 4, 3) Near Dege DOT 35 " 35 " 35 " Repair Pattern
2 (2, 3, 2, 3, 3) Near Dege DOT 35 " 35 " 35 " 35 " Break Pattern
Repair Pattern 1 (2, 2, 3, 2) Near Dege DOT 35 " 35 " 35 " Repair
Pattern 2 (2, 2, 1, 2, 2) Near Dege DOT 35 " 35 " 35 " 35 "
- 23. POST-REPAIR SIGNATURE ANALYSIS Basis for Overlap Length
____________________________________________________________ Small
Cables Straight Overlap (Edge Breaks Centre-Breaks 2014 Conveyor
Technologies Pty Ltd. All Rights reserved Parent Belt Cords Break
In-laid Cable 48 inches 5.4 mm 5.4 mm 5.4 mm 2.6 mm 5 Broken Cables
At Edge (5 In-laid cables needed) 5 Non-edge Broken Cables (6
In-laid cables needed) Edge Signature Off-edge Signature
- 24. BELT LIFE EXTENSION EXAMPLES 2014 Conveyor Technologies Pty
Ltd. All Rights reserved Life Extension factor : LE = A/A1 = No.
Months since Scanning First Commenced No. Months to 1-st Critical
Damage Event A1 is also the time when the belt would have failed if
un-monitored.
- 25. 2014 Conveyor Technologies Pty Ltd. All Rights reserved
Thank You 6th Annual Conveyors Conference Sept. 22-24, 2014,
Brisbane, Qld