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MAXIMISING UPTIME: HOW TO REPLACE A CONVEYOR BELT IN ONE MOVE

The conventional method for replacing a conveyor belt is to change the sections one by one because it spreads out the periods of downtime and minimises impact on workflows. This seems sensible, particularly on large overland conveyors that transport materials over long distances and difficult terrain where accessibility may be a challenge. But cumulatively those stoppages add up to significant lost production time, however well-planned your maintenance regime. So, is it possible to gain a competitive advantage by changing the entire belt in one go?

By Alexander Unruh

 

Overland conveying systems are commonly used in industries such as minerals and mining, quarrying, cement production, power generation, and bulk terminal transportation. Their critical role in moving materials around the site means that any downtime directly affects productivity. Minimising downtime for belt replacement is key, but replacing multiple belt sections can be a time-consuming task. The number of belt sections involved depends on multiple factors, such as the length of the conveyor and belt strength: but each replacement requires a stoppage and careful planning. Multiple replacements also multiply the risk that something may go wrong.

The good news is that there is an alternative: the single-operation belt replacement method.

ONE OPERATION, MULTIPLE BENEFITS

Swapping out an entire belt in one move may sound fantastical, particularly when your overland conveyor is several kilometres long, but the benefits are considerable. Significantly shorter downtime contributes to lower overall costs and means your materials handling operation can be up and running again sooner. Replacing the belt in one go is also safer because there are fewer interventions altogether. There is also less likelihood of unplanned failures due to poor-quality belt splices or pressure to complete the task in a short maintenance window.

Essentially, this single-operation belt replacement process involves: 

  • Joining multiple belt rolls together adjacent to the conveyor system to form a complete belt with no disruption to normal operations 
  • Connecting the new belt to the old one 
  • Pulling the new belt into the system while simultaneously pulling the old one out using the existing drive unit and associated equipment.  

KEY SUCCESS FACTORS

If single-operation belt replacement sounds like the right solution for your conveyor system, there are three key parameters you need to consider: 

  1. Accessibility: room to work on the new belt assembly is the single most important requirement. There needs to be sufficient space next to the conveyor for the new belt to be laid out and prepared, and for stocking the necessary materials. The best assembly site will depend on the individual overland conveyor and environmental conditions (see below). If the belt sections need to be stored outdoors, the supplier should be informed so they can apply a special film to protect the sections from UV radiation.  
  2. Environmental conditions: the belt rolls are joined together using vulcanisation, a chemical process that bonds the rubber sections to make a strong and durable belt of the required length. The sections of a belt should be provided on a just-in-time basis to achieve the required quality: snow, frost, ice or rain will bring work to a halt. Success is dependent on maintaining suitable atmospheric conditions – first and foremost, temperature and humidity — throughout the process. In adverse weather conditions, it is crucial to set up a controlled environment, such as an air-conditioned tent. 
  3. Technical skills: the entire belt replacement process requires skilled technicians and service personnel to achieve the desired results. Ideally, the exercise should be supervised by an expert from the belt supplier to ensure quality workmanship. 

SUCCESS IN THE FIELD 

Single-operation belt replacement has been successfully undertaken at various sites globally. One cement manufacturer used the technique to replace its 3.5km long overland conveyor, which had reached the end of its service life. Single-operation belt replacement dramatically reduced downtime compared to section replacement. In another instance, the overland conveyor was 12.5km in length, but the technique achieved equally good results.

TAKEAWAY

Replacing a conveyor belt in one pass rather than in segments is particularly advantageous for extensive conveyor systems because it minimises downtime and reduces the risk of unplanned failures, ultimately leading to lower total costs and increased safety. Success depends on working with a skilled specialist to ensure that site and weather conditions are suitable for this technique, and that on-site personnel are adequately trained in the processes involved.
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