Published in March 2005 Australian Longwall Magazine
Newcastle-based company Rescan came into existence following the collapse of conveyor monitoring company Gulf Conveyor Holdings. Headed by Peter Thorpe and three ex-Gulf employees, the new company is 40% owned by IPower Solutions and has no remaining links with Gulf.
The company has developed a remote conveyor monitoring system (rescan) that conducts non-destructive testing of steel cord conveyors. The technology, which works by inducing longitudinal magnetism of the steel cords, has been used by at least four other companies worldwide and does not infringe on technologies offered by other companies.
“It has been designed around software products you can buy off the shelf, and, as such, is a very cost-effective alternative to other options,” said managing director Thorpe.
“The early detection, mapping and monitoring of anomalies allow maintenance engineers to plan maintenance windows in advance and extend the service life of conveyors.”
The first system was successfully installed and tested at Centennial Coal’s Munmorah Mine. Since then, units have been or are being installed in Tasmania, the Hunter Valley in New South Wales and the Bowen Basin in Queensland.
The autonomous system is permanently installed and allows interrogation (through a phone connection or LAN) of steel cord conveyors without stopping production.
Using a magnetic flux leakage device, the rEscan system monitors the belting at variable speeds for cord breakage, corrosion, cord repairs and internal lay-up of any splices. Each system is supplied in a stainless steel enclosure.
Advances in computer software have made it possible to monitor more than one conveyor system from each main computer enclosure. Currently, rEscan is capable of monitoring four belts with each computer; theoretically, monitoring 16 belts is possible and will be trialled in the near future.
Stage two of the product’s development will see the system monitoring conveyors 24/7 and alerting on-site personnel and Rescan (by email) of changing conditions. Thorpe expects the 24/7 option to be available by the end of 2005.
At present, data generated by the system is analysed by Rescan personnel and a report sent to the client.
The company is also in the process of developing video imaging capabilities, lateral tracking, rip detection and laser cover profiling, driven in part by mines’ need to monitor belt health.
“Maintenance managers want to be able to video the belt for a full cycle in a non-carry area and carry out visual inspections from a desktop without stopping the production cycle,” Thorpe said.
rEscan can also perform a full condition examination on steel cord, fabric re-enforced and solid woven conveyors. The company offers services such as splice x-ray, oil and vibration analysis, thermography and structural condition audits.
In addition, it offers full electrical and mechanical conditions audits on conveyor systems, including its support structure, loading and discharge points, drives, substations and all connected electrical apparatus.
