Data-driven tracking eliminates belt misalignment in bulk conveying
At a chemical plant, ScrapeTec's e-PrimeTracker correlated conveyor tracking data with process operational technology to identify the root cause of sporadic belt misalignment shutdowns.
Sporadic conveyor shutdowns at chemical production facility
At a chemical production site, sporadic belt misalignment repeatedly triggered automatic shutdowns of a central conveyor system. As part of a critical main conveying line, each stoppage directly impacted upstream and downstream bulk handling processes. Troubleshooting proved difficult due to complex operating conditions, including two closely spaced loading points and a travelling tripper car with variable discharge positions.
Digital sensor integration on the return belt
To identify the underlying cause, a ScrapeTec e-PrimeTracker was installed on the return side, 18 metres from the tail pulley. The device combines mechanical belt correction with digital sensors and a processing unit. Belt tracking measurement data was correlated with plant operational technology (OT) data, such as motor current and loading point activation status, using the ScrapeTec Analytic Engine.
Root cause identified through process data correlation
Systematic analysis first ruled out mechanical defects in drum alignment, belt condition, and bearings. By correlating e-PrimeTracker data with OT process logs, engineers discovered a clear temporal link: dynamic activation and impulsive material loading at the second loading point generated belt movements that caused the shutdowns.
Targeted stabilisation of belt tracking
Identifying the precise process trigger enabled targeted engineering measures to stabilise belt tracking. The e-PrimeTracker provided immediate mechanical correction while allowing continuous verification of corrective actions under real operating conditions, significantly reducing unplanned downtime.
