REMA Tip Top’s advanced technology solutions have saved an Australian gold miner from significant financial losses.
REMA Tip Top was approached by a leading gold miner in the Kalgoorlie region with a critical challenge: frequent unplanned downtime in their plant facility caused by belt rips. This downtime disrupted their operations and resulted in significant financial losses and efficiency drops.
To address this issue, REMA Tip Top proposed implementing an advanced belt rip detection technology. This solution aimed to proactively monitor the integrity of conveyor belts and enhance operational efficiency.
Two days after commissioning, the Loopless Rip Detection system successfully detected its first belt rip and the conveyor stopped within 1.5 metres, preventing significant damage and operational disruption. This case study details the challenges faced, the innovative solutions implemented, and the measurable outcomes of this critical event.
Project background
Belt rips are a significant issue in conveyor belt systems, causing unplanned downtime that can bring an entire plant to a standstill. Statistics indicate that over 90 per cent of all longitudinal rips occur in the loading area, making it a critical point of failure. Traditional condition monitoring solutions, such as the ‘Fishing Line’ method and Rip Detection Systems with sensor loops, have been employed to address these issues in the past.
However, they come with inherent limitations: The fishing line method uses a piece of string beneath the conveyor’s carry side, attached to an electrical switch. It Activates if material penetrates the belt and touches the string.
Rip Detection Systems with Sensor Loops use sensor loops embedded in the conveyor belt at regular intervals. They require a minimum cover thickness of 6mm. Sensor loops have a finite lifetime and may work intermittently as they near the end of their life. They are susceptible to damage, causing false alarms.
Recognising these limitations, the customer sought a more reliable and efficient solution. They approached REMA Tip Top for cutting-edge technology that would not only detect belt rips but also effectively mitigate unplanned downtime.
Smart solution
REMA Tip Top proposed the implementation of a Loopless Rip Detection system. This innovative solution leverages intelligent mathematical algorithms (AI-based) to detect anomalies in motor current and voltage, eliminating the need for sensor loops or other sensing elements inside the conveyor belt. Unlike traditional systems, it requires no sensor loops, reducing the risk of damage and false alarms. It uses intelligent algorithms to detect anomalies accurately. It is accessible via Ethernet for multiple users and has readily available data because it uses existing input data from the conveyor.
REMA Tip Top can ensure the system can be integrated into almost any conveyor system.It also has a range of extendable add-ons, including Drive Monitoring, Massflow Calculation, Electrical Network Analysis, and maintenance support. It also has an emergency response where output relays can connect to PLC to stop the belt in emergencies.
By implementing this advanced Loopless Rip Detection system, REMA Tip Top aimed to provide the customer with a robust solution that ensures operational continuity and reduces unplanned downtime.
Tough challenge
In the mining industry, conveyor systems are critical for the efficient transport of materials. However, these systems are prone to frequent belt rips, which can cause significant operational disruptions. For the customer, the primary challenges included frequent belt rips and operational disruptions. Over 90 per cent of belt rips occurred in the loading area, leading to unplanned downtime and operational inefficiencies.
These belt rips often resulted in halting operations, sometimes bringing the entire plant to a standstill. The financial impact of these disruptions was substantial, including repair costs and lost productivity.
Traditional methods such as the ‘Fishing Line’ technique and sensor loop systems had several drawbacks, including susceptibility to damage and false alarms, finite sensor lifetimes, and requiring regular maintenance and replacements and a requirement for a minimum belt cover thickness, limiting their applicability.
Simple implementation
REMA Tip Top introduced an advanced Loopless Rip Detection system tailored to address these challenges in the mining industry.
To do this, REMA Tip Top conducted a detailed assessment of the client’s existing conveyor system to customise the solution. This involved integrating AI-based algorithms to detect anomalies in motor current and voltage without requiring sensor loops.
This led to a seamless installation of the Loopless Rip Detection system with integration with the client’s existing conveyor systems, ensuring compatibility and minimal disruption during implementation.
As a result, the customer can carry out real-time monitoring, including real-time alerts. The Implementation of real-time monitoring capabilities was made possible due to the Ethernet being accessible to multiple users.
The configuration of output relays to connect to PLCs for emergency stoppages helped enhance safety measures for the customer’s workers. Their system also included extended functionalities, including drive monitoring, massflow calculation, electrical network analysis, and maintenance support. These add-ons provided comprehensive insights and support for the client’s operational needs.
Rewarding results
The deployment of the Loopless Rip Detection system resulted in significant improvements for the customer.
Because the Loopless Rip Detection system successfully detected its first belt rip, the incident only resulted in a rip length of around a metre. This rapid detection and response significantly minimised potential damage, showcasing the system’s effectiveness in real-world conditions.
This provided the customer with several key benefits including reduced downtime, improved reliability and cost savings.
The notable decrease in unplanned downtime ensures continuous operations as well as enhanced productivity and efficiency, leading to substantial cost savings.
The AI-based detection system enhanced the improved reliability and provided accurate and timely alerts, reducing false alarms. The absence of sensor loops eliminated common points of failure, increasing the system’s reliability.
The customer achieved cost savings due to lower maintenance and operational costs due to the durable and efficient design of the Loopless Rip Detection system. It is expected that there will be long-term cost benefits from reduced downtime and minimal ongoing maintenance requirements.
The Loopless Rip Detection System can detect and mitigate belt rips early, significantly reducing associated costs. Based on statistical information, the average costs for a 200-metre-long belt rip are as follows:
Downtime costs: Approximately AUD 123,000
Service costs: Approximately AUD 82,000
Belt costs: Approximately AUD 41,000
While the event cannot be entirely prevented, its impact can be minimised. These figures are averages, and actual costs can vary depending on the specific customer and application. The Rip Prevent System helps significantly lower these costs by preventing extensive damage and reducing downtime.
The customer reported high satisfaction with the system’s performance and impact on their operations.
“The Loopless Rip Detection System has drastically improved our operational efficiency. The real-time alerts and rapid response have prevented potential catastrophes, saving us both time and money. We highly recommend this technology for any mining operation,” they said.
The successful implementation showcased the potential of this technology for broader applications in the mining and bulk-handling industries.
