Conveyer belting company Fenner South Africa reports that its latest belt replacement process, which is believed to be a first for South Africa, has been deliverd to a colliery mine in Mpumalanga.

"The new replacement process, which is safety driven, will ensure a reduction in
conveyor belt downtime, at the same time ensuring a more consistent and reliable supply of
coal on the 7 km overland conveyor system from the mine to the adjacent power station," Fenner national marketing and sales manager Clive Demont explains.

Last year, a survey was requested by the mine, to establish if there was a way to
improve the overall belt reliability and at the same time extend belt life. "Fenner’s in depth survey revealed that there were some short comings in the existing conveyor components, which is now in the process of being rectified. 

"These changes will ensure that the replacement steel cord DynaFlight belt will improve the overall reliability, thereby reducing downtime to a minimum," he explains.

With the assurance of improved operational activities, Fenner South Africa was awarded the
R23-million contract to manufacture the upgraded 14 km steel cord DynaFlight belt.

Applying the latest belt replacement methodology, Fenner started the process in late November, 2012. By early January over 7 km had been spliced, flaked and stacked in one continuous length. This length of belting is stacked at the specially designated Fenner site, adjacent to the current operational conveyor system, between the mine and the power dtation. 

"To date no interruptions have been experienced to the supply of coal to the power station," Demont says.

It is estimated that  the 31 splices would be completed by the end of March, in readiness to safely install the new belt. "This full replacement process climaxes with the pull-in
process of the steel cord DynaFlight belt and the final splice – total downtime, only six days,
compared to the estimated 35 days downtime," he adds.

In support of the new belt and other belt systems in the country, Fenner South Africa’s cost
saving life cycle management system is prescribed. "This cradle-to-the-grave system has also been welcomed by other mines, as it ensures the life cycle programme follows a systematic procedure for the life of the belt, from design audits, system surveys, belt tension verification, dynamic analysis and optimum belt specification," Demont states.

This programme also includes an 'around-the-clock' ongoing comprehensive scanning procedure that is implemented throughout the belt’s life – all this contributing to overall belt reliability.

In addition, the monitoring of the belts’ manufacturing and commissioning phases are the other services that Fenner offers, which once again helps to extend belt life. “Once in use, the conveyor system is continuously inspected and, if necessary, corrective measures made to avoid downtime," Demont concludes.