Published in June 2008 Australian Longwall Magazine

ESS Engineering Services and Supplies have introduced the Keysafe Blade Removal System as standard on all its XHD and Durt Tracker primary cleaner blades, with the exception of a couple of special application blade types, after successful trials at the Newlands mine in Queensland.

Typically to change cleaner blades personnel must obtain confined space entry approvals and enter the confined chute on scaffolds. Alternatively, the cleaner support cross member and blades must be physically removed, weighing up to 150kg. These practices carry inherent risk.

The Keysafe system eliminates these risks as there is no confined space entry, elimination of the need to reach into chutes, heavy lifts, pinch point hazards and substantial time savings in blades replacement.

The Keysafe system is based on a keyhole cast into polyurethane belt cleaner blades. The Keysafe tool has a spade-shaped tip that inserts into the keyhole in the blade, allowing the blade to be grabbed and withdrawn from the conveyor chute.

The tool can then be used to withdraw the blades as long as access is available from one side of the conveyor chute. Most of the larger belts do not require any modification for the tool to be used, while some smaller belts can require the cleaner mount and mount bracket to be slightly notched to allow access for the tool. ESS has already modified all new cleaner mount brackets as standard.

The system is suitable for both surface and underground coal applications and, according to ESS Maitland branch manager Mark Whittaker, the only constraining factor is the amount of side access available.

The system can be used by anyone authorised to service the belt cleaners and while the keyhole in the blades comes standard, a mine can then purchase the tool if they are doing their own maintenance.

ESS Wollongong branch manager Gary Minch said the system had been a big hit with the service technicians in Wollongong, who say they have reduced blade change time by more than a third.

“There is now no need to lay on the belt and lean over and prise each blade with a screwdriver then smash them with a hammer or bar.

“The safety factor has been exemplified over bins and sizers where the shaft would normally have to be extracted or the blades laboriously bashed from one side with a heavy bar. The number of blades on the larger belt widths made this into a very heavy and fatiguing process. The Key Safe has erased all this,” Minch said.