A full risk assessment and safety plan was put into place for changing out the conveyor system. Skilled operators were required at each of the drives. Te belt is pulled off the 100m to 130m long flaking piles from a relatively high tension at the start of each lap to nearly zero at the end of the lap. Tis causes problems as it propagates through the system reaching the powerful winders. A medium winder with 18.5kW, configured as a booster drive, was used to pull the belt from the pile and keep the tension of the new belt at a constant, very low, tension. Te belt supplier, Sempertrans, was able to supply large belt rolls of 921m in length from its factory in Poland to the site, reducing the number of splices in the belt from the original 100 down to 37. However, getting the large belt rolls from the port to the site was a challenge. Te belt rolls were shipped to the Chittagong port and then transported by truck the final 393km to the cement factory located near Chhatak, Bangladesh (as shown in Fig.1.). In addition to handling the racetrack

reals of new belting, while changing out the conveyor belt, large rolls of old belting need to be removed from the winder, loaded on a truck to take them out of the work area, and then offloaded from the truck to permanent storage. Te process was repeated every few hours as rolls of belting were removed from the system and required reliable, dedicated, high-tonnage cranes until the changeout was completed.

Each splice was done in an air- conditioned work area using the Almex SG1 control system with pressure and temperature dataloggers monitoring the cure cycle of each splice to ensure quality, as shown in Fig. 2. On completion, the belt was x-rayed to document the cord layout and check for porosity or cord movement in the splice. Te added benefit is that everyone involved

Replacing 24km of belting during second shutdown

FIG. 1 Profile of long belt conveyor and transport to site

pays extra attention while doing the splice to ensure that the cord layout and spacing are exactly to the splice design. Te belt was supplied with Emsys

SmartWires spaced every 200m to protect against belt rips and a BeltGard 1 system for online monitoring of cord damage. Te first round of splicing, flaking and pulling the belt onto the system proceeded so well that for the second round, all of the remaining 22km of belting was spliced together and pulled onto the system. To accommodate the extra length the three continuous flaked piles of belting were extended to 130m long. Tis eliminated the need for a third shutdown.

OVERCOMING CONCERNS When starting the project there were concerns about changing such long lengths in a single shutdown. Typical system downtimes include one to two

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FIG. 2. Splice temperature and pressure chart

days for the initial splice of the new belt to the old belt and between one and five days to change the entire belt. With proper planning, equipment and onsite expertise any length conveyor can be changed out in a single shutdown.

Te belt was changed out in two phases with the project completed on April 18, 2018 – a day ahead of schedule. Te logistics of getting the equipment, belting and labour to the site had both expected and unexpected hurdles. Ultimately, the project was a success and three years later the belt and splices are still in operation without incident.

Mark Derige & Dr Andrew I. Hustrulid are with the Almex Group. 35

0.0 2.5



10.0 12.5 15.0 17.5 20.0 22.5 25.0 Pressure Bar

Bottom Platen °C Temperature Probe Bottom Platen °C


0.0 17.0 34.0 51.0 68.0 85.0 102.0 119.0 136.0 153.0 170.0 Top Platen °C

Temperature Probe

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Top Platen Bottom Platen

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Temperature Probe Top Platen Bottom Platen Temperature Probe Top Platen Bottom Platen

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Temperature Probe Top Platen Bottom Platen Pressure

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