Projects & Automation Solutions
Solution Note
Integrated Solution for Mining
Conveyor Monitoring
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Honeywell’s BeltAIS™ conveyor health monitoring solutions help mining, minerals and
metals operations enhance equipment effectiveness, improve reliability and uptime,
and reduce maintenance costs.
Conveyor belts play a central role in the mining, processing,
careful planning to ensure the work is conducted without
storage and transportation of bulk materials. It is essential that
excessive process disruptions.
they operate efficiently with maximum availability and with a
minimum of downtime. This is because at industrial sites such as
mines, ports, cement plants and iron & steel mills, material
handling constitutes a major component of the production and
maintenance costs.
Material handling has often been viewed as beginning where the
process ends and thus, not adding value to the product. However
material such as iron or copper ores and coal is hard on
conveyor belt systems. It is often labour intensive or difficult to
monitor on line all areas associated with conveyors. This can
result in inadequate maintenance strategies and possible
catastrophic production losses.
Figure 1. Conveyor maintenance can be
costly and time-consuming.
An effective conveyor health monitoring solution extends the
service life of conveyors, and proactively identifies areas in need
of attention before operations are impacted. This ultimately
Managing the health of belt conveyors is complex, with numerous
contributes to saving a company time and money by better
measurement requirements for complete monitoring of the
managing resources and avoiding a costly shutdown affecting
system, including:
•
Cover defect detection
production.
•
Edge damage detection
•
Splice damage detection
•
Belt rip detection
reliability to achieve operational objectives, as well as reduce
•
Drive health monitoring
maintenance costs. This places an increased emphasis on
•
Pulley health detection
Overall Equipment Effectiveness (OEE) for critical components
•
Material off-loading and chute blocking
such as conveyor systems.
•
Idler health monitoring
Bulk material transportation is tough on conveyors, resulting in
•
Belt wear
continual maintenance and parts replacement, and significant
•
Internal defects detection
production and financial losses. In many cases, service and
•
Wander detection
repair requires specialized outside assistance and necessitates
•
Steel cord damage detection
Rigorous Operating Challenges
Industrial organizations are under pressure to improve equipment
Integrated Solution for Mining Conveyor Monitoring
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Until recently, no single solution or technology could satisfy all of
actual health status of conveyor equipment, users from
these requirements.
operations, maintenance, reliability and other departments gain a
consistent understanding, enabling effective planning and
execution of maintenance. BeltAIS minimizes the total cost of
ownership of conveyors by improving maintenance predictability
and reducing operational downtime due to faults.
BeltAIS: Total Conveyor Health Monitoring
BeltAIS (Belt Asset Inspection System) enables industrial sites to
coordinate all key functions involved in managing their bulk
material transportation infrastructure. With BeltAIS, plants can
improve conveyor belt maintenance, and at the same time,
increase production efficiency and reliability.
Figure 2. Conveyor defects can result in unplanned
downtime and lost production.
Rather than rely on multiple standalone monitoring solutions,
users can employ BeltAIS to maintain a continuous, online view
of conveyor operations and perform a wide range of monitoring
Choosing the Right Solution
There are a number of monitoring solutions which address
specific aspects of a conveyor system. These point solutions can
provide more measurements but may not assist in prioritization or
integration with other point solutions. In an increasingly resource
and analysis functions. The system provides an intuitive, userfriendly interface to the conveyor that improves the effectiveness
of plant maintenance and operations personnel.
The BeltAIS product suite is being developed to include:
•
Cover Defect Monitoring – a video-based decision
support system, which adapts Honeywell’s pulp & paper
web monitoring solutions to detect problems associated
with the surface of a conveyor belt, such as rips, splices
and other defects.
•
Idler Monitoring – a patented in-belt plug monitoring the
health of all idlers on a conveyor from a single device in
real time.
•
Belt Wear Monitoring – an adaptation of Honeywell’s
technologies to cost effectively measure the belt wear
online.
constrained environment, industrial operations need an
integrated solution combining state-of-the-art measurement
technologies with decision support capabilities for optimal
conveyor health.
The Honeywell BeltAIS™ solution suite allows mining, minerals
and metals facilities and other production sites to minimize the
impact of conveyors on their overall equipment effectiveness.
This is designed to detect, monitor and report on the health of the
conveyor belt and associated components. With visibility into the
Integrated Solution for Mining Conveyor Monitoring
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Figure 3: Honeywell’s integrated solution for conveyor health monitoring.
The BeltAIS conveyor monitoring solutions integrate with
existing Honeywell products such as:
• Equipment Health Monitor - vibration and temperature
wireless multiplexer particularly suited to large pulleys and
drives
• Field Advisor - software and tools to configure and manage
the execution of field tasks by mobile workers
• Digital Video Manager™ - video monitoring system that can
be integrated into the control system for monitoring diverse
operations
• Asset Manager™ - total plant health assessment decision
support system providing integration of all BeltAIS and other
third party solutions
• OneWireless™ Network – wireless system that allows cost
effective means to monitor instruments and devices for the
conveyor.
Figure 4: Conveyor health assessment system integrates and analyzes
data from many different conveyor health tools.
Integrated Solution for Mining Conveyor Monitoring
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Global Support from an Industry Leader
Honeywell is a leading supplier of automation solutions to the
Mining, Metals & Minerals (MMM) industries, with a worldwide
presence and broad application experience. Honeywell systems
and solutions optimize production for a wide range of mining,
metals and minerals (MMM) operations from alumina through
copper, coal and steel as examples.
Our process automation solutions can help you reduce operating
and maintenance costs, improve reliability, and increase
production efficiency. We also provide comprehensive pre- and
post-sales support, as well as value-based solutions that help
drive business success.
Honeywell can provide its products and services anywhere in the
world. MMM production facilities might be in remote locations
near raw materials or energy sources, but Honeywell has offices
in most countries and regions backed by Global Centers of
Excellence to provide timely and comprehensive support.
Honeywell is a pioneer in process control and today, more than
8,000 technicians use collective expertise to work for customers
in 67 countries around the world. Our global development teams
are driven to the highest standards to meet customer product
requirements for ease of use and maintenance.
Honeywell also provides world-class customer support via our
Global Technical Assistance Center (TAC).
For More Information
Learn more about how Honeywell’s BeltAIS
solution can optimize conveyor health monitoring,
visit our website www.honeywellprocess.com or
contact your Honeywell account manager.
Honeywell Process Solutions
Honeywell
1250 West Sam Houston Parkway South
Houston, TX 77042
Honeywell House, Arlington Business Park
Bracknell, Berkshire, England RG12 1EB
Shanghai City Centre, 100 Junyi Road
Shanghai, China 20051
www.honeywellprocess.com
SO-12-53-ENG
August 2012
© 2012 Honeywell International Inc.