Alex Harrison - Conveyor Technologies

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.

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

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

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.

Engineering

Alex Harrison - Conveyor Technologies