From scrap to riches

After identifying complexities and risks with the installation of an inclined downhill conveyor, the Kemerton Lithium Plant (KLP) project team agreed something needed to be done to aid conveyor belt pulling activities.  

The complexities of the job included pulling of an enclosed conveyor belt which would require access via confined space entry, sidewalls encompassing the belt with the possibility of the belt getting caught on return idlers and space limitations at the tail pulley requiring the belt to be pulled in a downhill direction.  

Using a learning from a previous belt change on another train at KLP, the team designed and fabricated a purpose-built trolley on site using scrap steelwork and materials at a cost of $200 including labour.  

The trolley has removed the need for confined space entry, by removing the possibility of the belt getting caught on the return idlers. The trolley has also significantly reduced manual handling risks by negating the need for handling the return idlers above grade and simplified the rigging arrangement for pulling the belt.  

The trolley design not only improved safety but reduced the installation time of the belt from five days, down to two days, and had a total cost saving of approximately $15,000.  

For this innovative idea, the team have been nominated for the 2021/2022 Managing Directors Safety Innovation Award.  

Well done team on this simple, effective and cost-efficient solution!