Correa de Sacrificio

CORREA DE SACRIFICIO
Correa de SacrificioTAG 31110-CTR-001 Equipos Auxiliares Asociados Tareas de Mantenimiento Relevantes

Capacidad 7046 tmph Enrollador de cinta Cambio de Poleas
Velocidad 2,5 m/s Tecle 15 t maniobras polea de cabeza Cambio de Cinta
Tipo de Cinta EP-1800 Cambio de Polines
Largo 45,5 m Cambio de Raspadores
Ancho 96” Cambio de Revestimientos del Chute de descarga
Numero de poleas 2
Polines de Carga xx
Polines de retorno x
Motor Eléctrico
1 | 30th Nov. 2016 | Maintainability Workshop Greg Schalck / Lars Ullmann

1.3 Diverse Lifting Equipment, Monorails and Hoists
31110-TCL-004
Electrical Hoist
(for Sacrificial Conveyor Head End)
31110-TCL-004
Electrical Hoist
(15t for Sacrificial Conveyor Head End)

Maintainability Workshop (30%) Objectives & Agenda
1. 31640-GPT-001 Bridge Crane Tail 50 metric ton, 31640-GPT-002 Bridge Crane Head 50
metric ton, diverse lifting equipment operational areas and space
2. Disassembly and installation of feeding and discharge chutes of the transport system
(31110-ACT-001 Belt Feeder, 31110-CTR-001 Sacrificial Conveyor & 31640-CTR-001
Regenerative Conveyor)
3. Detailed disassembly and installation of main transfer chute from Sacrificial
Conveyor to Regenerative Conveyor (31110-CTR-001 Sacrificial Head End Chute),
Head End Chute DEM simulation videos
4. Belt installation and replacement (total and partial)
5. Main pulleys removal and installation
6. Reliability design considerations (indexing belt clamp description, belt rip detection,
antennas of the belt, LISTEC cables and maintenance vehicle)
7. Miscellaneous

3.1 31110-CTR-001 Sacrificial Conveyor Head End Chute
31110-CTR-001 Sacrificial Conveyor Head End Chute

disassembly/assembly is broken down into three sections:
3.1.1 Upper Rock Box Removal

3.1.2 Middle Chutes Removal
3.1.3 Bottom Chute Removal
3.1.4 Spoon Removal
3.1.5 General
Note:
the removal of the Sacrificial Head Chute Hood is handled
under 5.4 31110-CTR-001-05 Head Pulley as well

3.1.1 31110-CTR-001 Sacrificial Conveyor Head End Chute -
Upper Rock Box Removal
A. Animation / Images
Sacrificial Conveyor Head End Chute B. Maintenance of equipment (in situ)

Dust Hood / Cover not applicable, see 3.1.5
C. Disassembly steps (Assembly steps)
1. Disassemble dust collection duct and remove
2. Attach dust hood to lifting equipment / hoist
3. Unbolt flanged connection between dust hood and

upper rock box.
Sacrificial Conveyor Head End Chute
Upper Rock Box
4. Lift the dust hood and remove
5. Remove and clean out all material from upper rock

box
6. Remove all detachable side and back panels
7. Remove flexible seal between upper rock box and

middle chute
8. Attach upper rock box to hoist
9. Unbolt mounting brackets from structure

3.1.1 31110-CTR-001 Sacrificial Conveyor Head End Chute -
Upper Rock Box Removal
10. Lift upper rock box until box clears structure
11. Move upper rock in north direction to clear pulley
Note:
Assembly of upper rock box shall follow the reversed
sequence

3.1.2 31110-CTR-001 Sacrificial Conveyor Head End Chute –
Middle Chute Removal
B. Maintenance of equipment (in situ)

not applicable, see 3.1.5
1. Remove all material/ore from rock box
2. Remove flexible seal from top and bottom of middle

chute
i-beam
trolley
4. Jack-up middle chute and attach to 4 trolleys
5. Move middle chute in South direction to clear

structure
rock-
box 6. Attach middle chute to 4 chain hoists
7. Lift rock box slightly to detach from trolleys

Lifting
lugs
I beam trolley

Middle Chute Removal
8. Lower middle chute using the chain hoists and

position rock box on the steel structure
9. Remove chain hoists
10. Attach middle chute to bridge crane
11. Pick up rock box and move to laydown area
Note:
Railings are removable and need to be disassembled for
this procedure
Assembly of middle chute shall follow the reversed

sequence

Bottom Chute Removal A. Animation / Images

1. Remove all material/ore from rock box
2. Remove spoon (see section 3.1.4)
3. Remove flexible seal from top of the bottom chute
5. Jack-up bottom chute
6. Assemble 4 wheels and lower the chute till the

wheels are resting on the rail
7. Move bottom chute in South direction to clear

structure
8. Attach bottom chute to bridge crane
9. Pick up rock box and move to laydown area
Note:
this procedure
Assembly of middle chute shall follow the reversed
sequence

Spoon Removal A. Animation / Images

1. Remove and clean out any loose material/ore from

spoon
2. Remove impact idlers and allow belt to sag
3. Remove top of skirt board
4. Detach/unbolt spoon from bottom chute
5. Lower spoon onto rail
6. Move spoon in South direction to clear structure
8. Attach spoon to bridge crane
9. Pick up spoon and move to laydown area
Note:
this procedure
Assembly of spoon shall follow the reversed sequence

General
A. Animation / Images D. Material and Tools required
not applicable. See 3.1.1, 3.1.2, 3.1.3 and 3.1.4
1. Material and Tools by tkIS
The maintenance of the different chutes/rock boxes, I. Brigde Crane 31640-GPT-001
meaning the replacement of wear plates can be
performed once a rock box was disassembled and II. 4 Trolleys, 4 wheel assemblies
moved to the cavern ground level.
2. Material and Tools by Others
Alternatively the rock boxes can be completely I. Additional crane, lifting equipment for upper
removed from the mine and replace by spare chutes. rock box, dust hood removal
Available spare chute can minimize the downtime of
the mine II. Chain hoists
C. Disassembly steps (Assembly steps) III. Come-alongs, cable puller, Slings

not applicable. See 3.1.1, 3.1.2, 3.1.3 and 3.1.4
E. Estimated manpower resources and time
Manpower (per item and removal):
• 4 workers in the mine
• Transport team in addition
Time:
• Approximately 1 day

3.2 Head End Chutes DEM Simulation Videos
A. DEM Chute Simulations
1. Regenerative Conveyor Head End Chute Simulation

Videos:
3.1 25% case
3.2 50% case
3.3 75% case
3.4 100% case
2. Regenerative Conveyor Head End Chute Simulation

Videos (future 2000mm belt) :
4.1 25% case
4.2 50% case
4.3 75% case
4.4 100% case

4.2 31110-CTR-001-22 Sacrificial Conveyor Belt
(96” 4PLY 1800 PIW Fabric Belt 95m)
no animation available
31110-CTR-001-22
Sacrificial Conveyor Belt
not applicable
C. Belt installation
Sacrificial Belt installation and Replacement is split

into two sections:
4.2.1 Initial 31110-CTR-001-22 Sacrificial Conveyor

Belt Installation
4.2.2 Replacement of 31110-CTR-001-22

Sacrificial Conveyor Belt Installation

4.2.1 Initial 31110-CTR-001-22 Sacrificial Conveyor Belt Installation
C. Belt Installation
Motorized Belt
Reel Stand (uncoupled)
1. Remove Sacrificial Head End Chute Hood
Position new belt reel on motorized belt reel stand

and uncouple the belt reel stand motor
Position a air tugger or a winch at the tail end of the

Air Tugger Tail Carry / Head Head Chute conveyor
/Winch Pulley Return Idlers Pulley Rock Box
Install a temporary roller on top of the rock box to

avoid the belt scraping at sharp edges of the rock
box
1. Step (For easier representation the following images
don’t show the rock box & the roller)
Motorized Belt
2. Move the tail pulley in north direction to belt
installation position
Run cable of air tugger / winch through the return

strand of the conveyor
Connect the pulling equipment to the new sacrificial

Air Tugger
/Winch
Tail
Pulley
Carry /
Return Idlers
Head
Pulley
belt. Use belt pulling clamps, belt pull plates or
other devices
2. Step

Motorized Belt C. Belt Installation
3. Pull belt through the return strand all the way to the
tail end of the conveyor utilizing the air tugger or
winch
4. Move the pulling equipment (air tugger/winch) to

the head end of the conveyor and run the cable to
Air Tugger Tail Carry / Head
the tail end of the conveyor.
/Winch Pulley Return Idlers Pulley
As before, connect the cable of the pulling

equipment to the belt
3. Step
Motorized Belt
Tail Carry / Head Air Tugger

Pulley Return Idlers Pulley /Winch
4. Step

5. Pull the belt around the tail pulley on the carry side
Vulcanization
of the conveyor all the way to the vulcanization area
area
6. Clamp the belt so that the belt can’t move anymore
Move the pulling equipment to the South

Tail Carry / Head Air Tugger
Pulley Return Idlers Pulley /Winch
Unreel a sufficient length of belt from the belt reel,
cut the belt with a appropriate cutting tool (e.g.
knife)
Fold the belt, if required.

5. Step
Motorized Belt Remove idlers for the installation of the vulcanizer

Air Tugger
/Winch Belt Vulcanizer Top Transport the bottom part of vulcanizer to its
and Bottom Part
Belt Clamp installation position and mount it to the conveyor
belt steel structure
(special crane and/or lifting equipment required, by
others)
Tail Carry / Head

Pulley Return Idlers Pulley
6. Step

Air Tugger
/Winch Belt Vulcanizer Top
7. Pull the belt around the head pulley on the carry
Belt Clamp
and Bottom Part
side of the conveyor all the way to the splicing and
vulcanization area. Use the pulling equipment
8. Define and measure the required overall length of

the belt
Tail Carry / Head
Cut any excess belt if required and remove
Clamp the belt at the head end side so that the belt
can’t move anymore
7. Step
Perform splicing procedure and prepare belt for
Motorized Belt vulcanization following belt suppliers instruction
Belt Vulcanizer Top

and Bottom Part
Belt Clamp
Belt Clamp
Tail Carry / Head

8. Step

Belt Vulcanizer Top

9. Perform vulcanization of belt
and Bottom Part
Belt Clamp
Belt Clamp 10. Remove top part of the vulcanizer
Remove belt clamps and lift vulcanized belt

(use e.g. temporary frames, belt pulling pipes and
Tail Carry / Head
come-alongs)
Remove bottom part of the vulcanizer
Reinstall idlers and lower belt onto the carry strand

of the conveyor
9. Step
Motorized Belt Tension sacrificial conveyor belt by moving the tail

pulley back into his operating position
Belt Vulcanizer Top
and Bottom Part
Remove belt roller from rock box and re-install
chute cover
Tail Carry / Head

10. Step

D. Material and Tools required
1. Material and Tools by tkIS
I. Vulcanizer
II. Belt pulling pipe
III. Belt roller for rock box
2. Material and Tools by Others
I. Air tugger/el. winch, come-alongs: e.g. chain

hoists or cable puller, slings
II. Belt pull plates, belt pulling clamps
III. Belt cutting device, knife
IV. Temporary steel frames for belt lifting
V. Lifting crane for vulcanizer, e.g. mobile shop

crane

Manpower:
• 4 workers for belt repair in the mine
Time:
• Approximately 1-2 days

4.2.2 Replacement of 31110-CTR-001-22 Sacrificial Conveyor Belt
Motorized Belt A. Animation / Images
Reel Stand
no animations available

not applicable
C. Belt replacement
1. Bring motorized belt reel stand with empty belt reel

Tail Carry / Head
Rock box
Pulley Return Idlers Pulley in position
Release belt tension by moving tail pulley into belt

installation position
1. Step Remove Sacrificial Head End Chute Hood
Motorized Belt
Reel Stand
Install a temporary roller on top of the rock box to
avoid the belt scraping at sharp edges of the rock
Belt Clamp
box
Belt Clamp (For easier representation the following images
don’t show the rock box & the roller)
2. Clamp belt and cut

Tail Carry / Head
2. Step

Belt Pulling Belt Clamp Motorized Belt C. Belt replacement
Clamp Reel Stand
3. Fix belt pulling clamp at the of the cut belt and

Belt Clamp
connect with come-alongs at the belt reel stand
Carefully release belt clamps and remove them
Pull belt via belt pulling clamp and come-along to

Tail Carry / Head the motorized belt reel stand
4. Connect the old belt to the empty belt reel and start
winding up the old belt
3. Step
Motorized Belt
Reel Stand
Tail Carry / Head

4. Step

Motorized Belt C. Belt replacement
Reel Stand
5. Remove old belt utilizing the monorail and electrical

hoist
6. Belt replacement follows the steps under section

4.2.1 Belt Installation
Tail Carry / Head

D. Material and Tools required
Pulley Return Idlers Pulley see section 4.2.1

see section 4.2.1
5. Step
Motorized Belt
Air Tugger Tail Carry / Head Head Chute

/Winch Pulley Return Idlers Pulley Rock Box
6. Step = 1. Step (4.2.1)

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CORREA DE SACRIFICIO

Correa de SacrificioTAG 31110-CTR-001 Equipos Auxiliares Asociados Tareas de Mantenimiento Relevantes

1 | 30th Nov. 2016 | Maintainability Workshop Greg Schalck / Lars Ullmann

2 | 30th Nov. 2016 | Maintainability Workshop Greg Schalck / Lars Ullmann

3 | 30th Nov. 2016 | Maintainability Workshop Greg Schalck / Lars Ullmann

31110-CTR-001 Sacrificial Conveyor Head End Chute

3.1.1 Upper Rock Box Removal

4 | 30th Nov. 2016 | Maintainability Workshop Greg Schalck / Lars Ullmann

Sacrificial Conveyor Head End Chute B. Maintenance of equipment (in situ)

C. Disassembly steps (Assembly steps)

1. Disassemble dust collection duct and remove

2. Attach dust hood to lifting equipment / hoist

3. Unbolt flanged connection between dust hood and

5. Remove and clean out all material from upper rock

6. Remove all detachable side and back panels

7. Remove flexible seal between upper rock box and

8. Attach upper rock box to hoist

9. Unbolt mounting brackets from structure

5 | 30th Nov. 2016 | Maintainability Workshop Greg Schalck / Lars Ullmann

10. Lift upper rock box until box clears structure

11. Move upper rock in north direction to clear pulley

6 | 30th Nov. 2016 | Maintainability Workshop Greg Schalck / Lars Ullmann

B. Maintenance of equipment (in situ)

C. Disassembly steps (Assembly steps)

1. Remove all material/ore from rock box

2. Remove flexible seal from top and bottom of middle

3. Unbolt mounting brackets from structure

5. Move middle chute in South direction to clear

7. Lift rock box slightly to detach from trolleys

7 | 30th Nov. 2016 | Maintainability Workshop Greg Schalck / Lars Ullmann

8. Lower middle chute using the chain hoists and

9. Remove chain hoists

10. Attach middle chute to bridge crane

11. Pick up rock box and move to laydown area

Assembly of middle chute shall follow the reversed

8 | 30th Nov. 2016 | Maintainability Workshop Greg Schalck / Lars Ullmann

B. Maintenance of equipment (in situ)

C. Disassembly steps (Assembly steps)

1. Remove all material/ore from rock box

2. Remove spoon (see section 3.1.4)

3. Remove flexible seal from top of the bottom chute

4. Unbolt mounting brackets from structure

5. Jack-up bottom chute

6. Assemble 4 wheels and lower the chute till the

7. Move bottom chute in South direction to clear

8. Attach bottom chute to bridge crane

9. Pick up rock box and move to laydown area

9 | 30th Nov. 2016 | Maintainability Workshop Greg Schalck / Lars Ullmann

B. Maintenance of equipment (in situ)

C. Disassembly steps (Assembly steps)

1. Remove and clean out any loose material/ore from

2. Remove impact idlers and allow belt to sag

3. Remove top of skirt board

4. Detach/unbolt spoon from bottom chute

5. Lower spoon onto rail

6. Move spoon in South direction to clear structure

8. Attach spoon to bridge crane

9. Pick up spoon and move to laydown area

Assembly of spoon shall follow the reversed sequence

10 | 30th Nov. 2016 | Maintainability Workshop Greg Schalck / Lars Ullmann

C. Disassembly steps (Assembly steps) III. Come-alongs, cable puller, Slings

• 4 workers in the mine

• Transport team in addition