Retrofit Resilience: How Noggrann Eliminated Catastrophic Conveyor Failures.

The Challenge

In early 2024, a major mining refinery in the Pilbara contacted Noggrann to address a series of equipment failures which were made by other manufacturer. Their existing conveyors were failing at an alarming rate under full production loads. In some sections, the lines lasted only five days before a total system shutdown occurred.

The combination of abrasive material, high chain-pull requirements, and extreme operating temperatures created a "perfect storm" for the underspecified hardware. On-site, the maintenance teams were battling several specific issues:

Drive Cog Tracking: The chain frequently jumped the drive cog and caused immediate mechanical damage.

Chain Snapping: Frequent tensile failures occurred during bogged starts when the system tried to move under full load.

Accelerated Wear: Excessive chain stretch and component thinning were visible within weeks of commissioning.

The Noggrann Approach

Instead of pushing for a costly and time-consuming CAPEX replacement, we focused on a targeted engineering solution. Our team conducted a thorough technical assessment of the existing layout. We worked closely with the Hapman team to analyze line speeds, pipe diameters, and the specific characteristics of the material being moved.

To avoid the cost and downtime of a full infrastructure overhaul, we implemented a surgical retrofit:

Infrastructure Recovery: We kept the existing pipework and drive boxes to minimize unnecessary site works.

Heavy-Duty Internals: We replaced the failing components with a custom-engineered Hapman chain and sprocket assembly. These parts were specifically treated to withstand the abrasive refinery environment.

The Result: Proven Longevity
The retrofit was commissioned as a trial to test its durability against the harshest conditions in the Pilbara. After more than a year of continuous operation, the system has delivered:

Zero Unplanned Downtime: The five-day failure cycle was eliminated immediately. There has not been a single failure since the installation.

Operational Reliability: Maintenance teams have shifted from firefighting constant repairs to routine monitoring.

Full-Site Rollout: Based on this success, the client has approved the upgrade of all remaining conveyor lines to the Noggrann and Hapman standard.