All Member Open Forum

Hello Lesiba, 

Have you thought about the following that could cause a conveyor belt to rip in half, including:

1. Overloading: If the conveyor belt is carrying a load that exceeds its weight capacity, it can cause the belt to stretch beyond its limit and eventually break.

2. Misaligned pulleys: If the pulleys that guide the conveyor belt are not properly aligned, it can cause the belt to shift to one side, resulting in uneven wear and tear that can eventually lead to a tear.

3. Material build-up: If the conveyor belt is used to transport materials that have a tendency to stick, such as wet or sticky substances, it can cause material build-up on the belt, which can increase the weight and stress on the belt, eventually leading to a break.

4. Poor maintenance: If the conveyor belt is not properly maintained, such as lack of regular cleaning or lubrication, it can cause wear and tear that can weaken the belt over time, leading to a break.

5. Wear and tear: Over time, the constant friction and stress placed on the conveyor belt can cause it to wear out, weaken, and eventually break.

Thoughts?

Hello Lesiba,

Have you thought about the following that could cause a conveyor belt to rip in half, including:

1. Overloading: If the conveyor belt is carrying a load that exceeds its weight capacity, it can cause the belt to stretch beyond its limit and eventually break.

2. Misaligned pulleys: If the pulleys that guide the conveyor belt are not properly aligned, it can cause the belt to shift to one side, resulting in uneven wear and tear that can eventually lead to a tear.

3. Material build-up: If the conveyor belt is used to transport materials that have a tendency to stick, such as wet or sticky substances, it can cause material build-up on the belt, which can increase the weight and stress on the belt, eventually leading to a break.

4. Poor maintenance: If the conveyor belt is not properly maintained, such as lack of regular cleaning or lubrication, it can cause wear and tear that can weaken the belt over time, leading to a break.

5. Wear and tear: Over time, the constant friction and stress placed on the conveyor belt can cause it to wear out, weaken, and eventually break.

Thoughts?

Hello Lesiba 

I am quite interested in the case analysis, I would like to know the procedure used to inspect the belt condition. My guess the failure started earlier, but the symptoms of failure are very hard to be noticed. My suggestion is the belt should be replaced based on age only regardless of it is condition, and the belt supplier hundred percent will warrant that.  

Hello Lesiba,

It has been my experience that conveyor belting failures often occur very quickly once the initial fault occurs. A small puncture from a sharp piece of ore or a foreign object can propagate to a complete separation in just a few hours or even faster, depending on the age of the belt and operating conditions.
I noted you said the belt had been in service for possibly up to 5 years? I agree that conveyor belting should be replaced based on time in service. Your vendor should be able to help in determining the expected service life of your belting.
Just based on where the failure occurred, I would suspect that the splice failed. There are several "ends" on a laminated/vulcanized splice, not just the ones you can see externally. I would start there, but your vendor should be able to help with this as well.

Best of luck.

Hello Lesiba,

It has been my experience that conveyor belting failures often occur very quickly once the initial fault occurs. A small puncture from a sharp piece of ore or a foreign object can propagate to a complete separation in just a few hours or even faster, depending on the age of the belt and operating conditions.
I noted you said the belt had been in service for possibly up to 5 years? I agree that conveyor belting should be replaced based on time in service. Your vendor should be able to help in determining the expected service life of your belting.
Just based on where the failure occurred, I would suspect that the splice failed. There are several "ends" on a laminated/vulcanized splice, not just the ones you can see externally. I would start there, but your vendor should be able to help with this as well.

Best of luck.

------------------------------
Walt Coltrin MLA1, CMRT
Maintenance Planner/Scheduler
Nixa MO

Original Message:
Sent: 04-06-2023 06:38 AM
From: Lesiba Moja
Subject: Conveyor Belt Damage

Greetings Fellow Practitioners

Last week I had a scenario whereby a conveyor belt ripped in half causing a major down time. I've been tasked with the RCA but can't wrap my head around what could've caused this.

Any one experience this?

Hi Lesiba,

Did it rip along or across the belt?
I once experienced a similar case of a belt rip due to a collapsed pulley which then went on to cut the belt along as it moved. Also, another cause of the rip could be tramp metal cutting the belt, do you have any metal dictators installed to detect such?

Hi Shelton

It ripped across the belt. Yes there is a metal detector before the crushers but not after on the very belt.

Hi Lesiba,

Did it rip along or across the belt?
I once experienced a similar case of a belt rip due to a collapsed pulley which then went on to cut the belt along as it moved. Also, another cause of the rip could be tramp metal cutting the belt, do you have any metal dictators installed to detect such?

Dear Lesiba,
The case is interesting, and ultimately the contributions and comments from the colleagues is very good. On the other hand, I can share my own experience in the failure of a band, I suggest, like the colleagues, to evaluate the following:
1. Operative: Loads, sudden changes
2. Equipment: Cleaning system, rock encrustation, presence of metal, protection system against metals. tensioning system, age of the band, lifetime of the band.
3 Routine inspection: Scope of inspection, in the splice, band seals, wear rate, openings, detachment, rubber cuts and types of cut, follow-up to observations.

Regard

Vladimir Tasayco
Reliability Engineer 

Hi Shelton

It ripped across the belt. Yes there is a metal detector before the crushers but not after on the very belt.

Hi Lesiba,

Did it rip along or across the belt?
I once experienced a similar case of a belt rip due to a collapsed pulley which then went on to cut the belt along as it moved. Also, another cause of the rip could be tramp metal cutting the belt, do you have any metal dictators installed to detect such?

Was it a laced belt? I always dealt with these types of issues when I was working in Amazon Fulfilment Centers here in California.

Your issue might be tension way too tight.

Product getting stuck causing friction and very small punctures, bad lacing (no dog earing when installed), Tension issuses, etc.