📋 Case Study
Iron Ore Export Terminal Conveyor Reliability Upgrade
Chronic belt splice failures (>22 unscheduled stoppages/yr) causing demurrage penalties and stockpile congestion
🏗️ Project Overview
Port-based dry bulk terminal in Pilbara, Western Australia
🎯 Challenge
Chronic belt splice failures (>22 unscheduled stoppages/yr) causing demurrage penalties and stockpile congestion
🔧 Design Approach
Adopted RCD-driven transfer chute redesign + infrared splice temperature monitoring + dynamic tension control system
📐 Design Diagram
AI-generated project design illustration
📐 Key Calculations
Splice Fatigue Life
N = C × (Δσ)^−m
Result: 1.8M cycles
Validated 3× life extension over legacy splices
Tension Variation Allowance
ΔT/T_nom ≤ 5%
Result: 4.2%
Prevented edge wear and mistracking
📊 Results
Failures reduced to 3/yr; $2.1M annual demurrage savings; OEE increased from 78% to 92%💡 Lessons Learned
- •Real-time tension feedback is non-negotiable for long conveyors
- •Splice inspection must include thermal imaging at full load
✅ Key Takeaways
- 1Real-time tension feedback is non-negotiable for long conveyors
- 2Splice inspection must include thermal imaging at full load