ESI Tech Services upgraded a 270m conveyor safety system, in collaboration with Pacific Automation and BIS Industries, at Karara Mine, in Western Australia.
Project background
The mine’s conveyor safety system had become increasingly unreliable, and with limited spares available, was deemed obsolete.
This was impacting operations and productivity, as the ageing equipment and cabling was subject to corrosion and, given the fluctuating weather, at risk of further deterioration.
Challenges
The project had several challenges, including the site’s remoteness and harsh conditions, and the absence of on-site fabrication facilities and team.
The remote site meant all materials and tooling had to be transported to site before the works started to ensure an efficient installation with no delays.
The challenge of working in high temperatures was exacerbated by having to wear additional heavy protective gear, including Versaflow helmets, to mitigate the risk silica dust exposure, making communication difficult, and the general working conditions taxing.
As there was no on-site fabrication team to help with brackets and conduit installation, ESI Tech Services’ team prepared all the parts in Perth and transported them to site. This included undertaking a detailed site survey and preparing AutoCAD drawings for the fabricator.
Having observed that the environment was corroding the structure, the team opted for a hot-dip galvanising coating for the bracket for durability and efficiency as they did not need to paint the brackets on site after installation.
Due to the ground conditions, the conveyor could not be accessed safely with an elevated work platform (EWP). This could pose risks to the workers and delay progress.
ESI Tech Services requested BIS drain the area and provide safe access by building hard, level ground to safely operate an EWP for our installation team to access the conveyor. This was completed before arriving on site, creating a safe and efficient installation environment.
Our solution
Our team provided both administrative and technical solutions.
To avoid future environmental impacts on the system, our team installed hot-dipped galvanised conduit for all cables. This provides mechanical protection from spillage in the cable installation areas, while keeping it safe from the elements and isolated from other services, preventing interference.
The new technology in the system provides live, accurate, fault-finding feedback to the PLC and local display, informing operators what has failed and where, minimising downtime in the case of a fault / alarm.
Outcome
Our team completed all the works safely, including zero harm / LTIs, and received positive feedback from the client, our partner, Pacific Automation, and the product manufacturer.
“The client is extremely pleased with the product. They highlighted the quality of the installation and appreciated the timeliness with which your team managed to complete the job, despite various challenges. Thank you for the excellent job you and your team have done.” – Johan Blignaut, Product Manager – Conveyor Control & Mining, Pacific Automation
To learn more about our electrical services and how we can enhance your operations, visit: https://esi-techgroup.com/electrical-instrumentation-services or email info@esi-techservices.com.