Past Projects: Click A Project For More Information
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- Remove the operators from the exposure to product dust.
- Improvement in packing plant throughput.
- Automate the process, thus make the packing less labour intensive and more comfortable for operators.
- Conceptual Design
- Preliminary Design & Cost Estimate
- Detailed Design
- Project management of manufacture & factory acceptance testing
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Past Projects - Uranium Packing Plant
Client:
Energy Resources Australia
Location:
Ranger Mine, Northern Territory, Australia
Energy Resources Australia is the world’s third largest producer of uranium oxide (U3O8). It operates the Ranger mine in the Northern Territory, approximately 260 km East of Darwin. The U3O8 product is sold under strict security provisions to ensure it is used in commercial power generation. The product packing line is an automated process that packs the product into 205L drums without human intervention.
Project Scope:
Mechanical design review & Project Management of a fast track project to Manufacture, Test, Install & Commission a new automated packing process.
Key Benefits:
Successful implementation of a new packing line that was running behind schedule. Significant year-end accounting improvements resulted from meeting the original project deadline. Vast reduction in the exposure of personnel to product dust, thus providing a safer working environment. Reduction in the number of operators required to pack product.
Images of final packing plant solution:
Past Projects - Uranium Oxide Concentrate
Client:
Western Mining Corporation (Now: BHP)
Location:
Olympic Dam, South Australia, Australia
The Olympic Dam mine is a large poly-metallic underground mine located in South Australia, 550 km NNW of Adelaide. It is the fourth largest copper deposit and the largest known single deposit of uranium in the world. The existing UOC Packing Plant was installed when the Olympic Dam operations were originally commissioned some 15 years prior to the project being initiated and WMC were investigating the feasibility of upgrading the facility.
Project Scope:
Services Provided by CABS:
Assortment of images from packing plant & surrounding plant:
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- Exisiting Operational Plant - Design solutions had to be integrated into exisiting plant
- Limited Shutdown Time - As the plant was still operational, shutdown windows to execute modifications were limited
- Limited Funds - Complete new chute solution was not economically viable.
- Determine the root causes of spillage.
- Identify solutions to eliminate the problem.
- Model & draft required design changes.
- Prepare a specification & scope of fabrication & installation.
- Provide engineering & project management during the fabrication & installation of designed solutions.
- Provide assistance during commissioning.
- Eliminated the cost of lost product & clean up of spillage.
- Eliminated the environmental impact of the spillage of product into the water.
- Increased spillage free output capacity of system from 2200tph to over 4000tph.
- Fixed belt tracking issue.
- Harsh nature of ore being mined, with large rock size and very large fall height.
- Water content of ore. Due to being an underground mining operation, the ore has a very high water content, which when mixed with clay causes considerable build-up and blockage issues
- Funding constraints meant the scope of the chute replacement had to be minimised.
- Determine the root causes of spillage and high chute wear.
- Develop a concept for a new chute and undertake DEM; and
- Physical scale modelling to achieve proof of concept.
- Confirmation that it was possible to design a transfer chute that could control the ore flow.
- And is able to withstand the high impact & wear duty in this application.
- The DEM provided visual confirmation the concept would work.
- Using 3D modelling software a scale model of the transfer chute was built & used to refine the chute design.
- The design was simplified and developed to fabrication detail drawings.
- The modifications were implemented in three stages over three shutdowns.
- Plant performance was improved and maintenance burden reduced.
- Below is a video comparison between the DEM & Physical modelling.
- The next video shows a comparison between the DEM of the original chute & CABS final chute design.
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- Replacing the transfer chute on the coarse ore apron feeder to CO1 conveyor transfer chute.
- Design, fabrication, delivery & installation of a new transfer chute to conveyor CO1.
- This project had a life time of 12 months.
- Along-side the rapidly degrading condition of the transfer, poor chute performance was also a problem that required investigation, with build-up, blockage and poor loading issues.
- Develop detailed cost estimation & projection.
- Modifications of drawings to improve installation methods & times.
- Design of installation aids.
- Scheduling & planning.
- Pre-shutdown works.
- Safety planning & coordination.
- Conduct Preparation works in the area.
- Shutdown works (Chute Installation & Conveyor Repairs).
- The client was looking for ways to improve the performance of the operation when loading bauxite.
- Specifically, the transfer chute regularly blocks when exporting bauxite and a reliable alternative to the current chute is required.
- The ultimate objective of this project is to design and install a new chute that can operate without adversely impacting the shiploading operation.
- The clients stated criteria for the design were:
- Operation of the transfer chute at 1800 tph with bauxite at the expected operating range of moisture content and clay content without blocking.
- Additional key criteria that CABS believe should be included were:
- Control of ore flow in the chute
- Minimising high energy impacts (wear); and
- Minimising stagnant areas which promote build-up and blockages. Controlled ore flow at loading points with:
- Limited scatter;
- Good surcharge angles;
- Centralised loading;
- Low skirt pressure;
- Good ore stream to belt impact velocity with low belt wear;
- Good dust control; and
- No spillage.
- Ease of maintenance of major components, such as the use of rotable transfer chute components.
- Good access for inspection, operation and hose-out.
- The objective of this particular scope of work is to explore the range of material characteristics which are likely and determine whether the chute concept which CABS has developed will be capable of operating with the range of products likely to be experienced.
- Concept Development
- Refinement of Chute (Detailed DEM Analysis) Including:
- Material characterisation tests
- Model calibration
- Chute flow modelling of extremes and most likely material
- Refinement of the transfer chute design to enable operation in all ranges of material
- Check range of operating flow rates
- Optimisation of chute detail.
- Preliminary & Detail Design
- Fabrication Detail Development
- Installation Guide Development
- All objectives achieved or exceeded.
- Impact plate.
- Intermediate cone.
- Soft loading moving rear wall.
- Feed chute.
- Skirts.
- Installation.
- On-going Maintenance.
- Ergonomics.
- HSE Risks.
- Downtime.
- Cost.
Past Projects - Outloading Spillage Elimination
Client:
Fremantle Ports
Location:
KBT, Fremantle, Western Australia
Fremantle Ports is a Western Australian Government trading enterprise that strategically manages the Port of Fremantle. The port is the State’s biggest general cargo port and Australia's fourth largest container port. The Kwinana Bulk Terminal, or KBT, is located in Kwinana approximately 40km south of Perth and handles cement clinker, coal, gypsum, nut coke, iron ore and slag.
The client was suffering high volumes of spillage, high skirt wear, belt tracking and reduced production capacity (caused by spillage).
Project Constraints:
Project Scope:
Key Benefits:
Fremantle Ports
Location:
KBT, Fremantle, Western Australia
Fremantle Ports is a Western Australian Government trading enterprise that strategically manages the Port of Fremantle. The port is the State’s biggest general cargo port and Australia's fourth largest container port. The Kwinana Bulk Terminal, or KBT, is located in Kwinana approximately 40km south of Perth and handles cement clinker, coal, gypsum, nut coke, iron ore and slag.
The client was suffering high volumes of spillage, high skirt wear, belt tracking and reduced production capacity (caused by spillage).
Project Constraints:
The three major constraints of this project were:
Project Scope:
Key Benefits:
Past Projects - Argyle Diamond Spillage & Chute Blockage Investigation
Client:
Rio Tinto Argyle Diamond Mine
Location:
Arygle Diamond Mine, East Kimberley, Western Australia
Rio Tinto owns and operates the Argyle diamond mine in the remote East Kimberley region of Western Australia. The mine has been operating since 1983 and has produced more than 800 million carats of rough diamonds. It is one of the world's largest supplier of diamonds and the world's largest supplier of natural coloured diamonds.
The conveyor transfer was suffering high spillage, extreme chute and skirt wear, belt tracking problems, severe belt wear, surging causing dangerous belt spillage, and chute blockages.
Project Constraints:
Project Scope:
Outcomes:
Rio Tinto Argyle Diamond Mine
Location:
Arygle Diamond Mine, East Kimberley, Western Australia
Rio Tinto owns and operates the Argyle diamond mine in the remote East Kimberley region of Western Australia. The mine has been operating since 1983 and has produced more than 800 million carats of rough diamonds. It is one of the world's largest supplier of diamonds and the world's largest supplier of natural coloured diamonds.
The conveyor transfer was suffering high spillage, extreme chute and skirt wear, belt tracking problems, severe belt wear, surging causing dangerous belt spillage, and chute blockages.
Project Constraints:
The three major constraints of this project were:
Project Scope:
Outcomes:
Past Projects - CO1 6000 TPH Transfer Chute Replacement
Client:
Robe River Iron Associates
Location:
Cape Lambert, Western Australia
Robe River Iron Associates is Australia's third largest Iron Ore exporter.
The operation at Cape Lambert at the time of this project exported 30mtpa of Sinter Fines and Lump iron ore.
Project Scope:
Key Benefits:
CABS also developed systems to assist with safe installation & future maintenance:
CABS managed the fabrication of the chute:
CABS also managed the demolition & installation:
Robe River Iron Associates
Location:
Cape Lambert, Western Australia
Robe River Iron Associates is Australia's third largest Iron Ore exporter.
The operation at Cape Lambert at the time of this project exported 30mtpa of Sinter Fines and Lump iron ore.
Project Scope:
Key Benefits:
CABS also developed systems to assist with safe installation & future maintenance:
Past Projects - Outload Blockage Elimination & Increase of Throughput
Client:
Fremantle Ports
Location:
KBT, Fremantle, Western Australia
Fremantle Ports is a Western Australian Government trading enterprise that strategically manages the Port of Fremantle. The port is the State’s biggest general cargo port and Australia's fourth largest container port. The Kwinana Bulk Terminal, or KBT, is located in Kwinana approximately 40km south of Perth and handles cement clinker, coal, gypsum, nut coke, iron ore and slag.
Problems:
Project Objectives:
Project Methodology:
Key Benefits:
Fremantle Ports
Location:
KBT, Fremantle, Western Australia
Fremantle Ports is a Western Australian Government trading enterprise that strategically manages the Port of Fremantle. The port is the State’s biggest general cargo port and Australia's fourth largest container port. The Kwinana Bulk Terminal, or KBT, is located in Kwinana approximately 40km south of Perth and handles cement clinker, coal, gypsum, nut coke, iron ore and slag.
Problems:
Project Methodology:
Key Benefits:
Past Projects - SLD2/SLD3 Boom Loading Transfer Re-Design
Client:
Rio Tinto Iron Ore
Location:
Cape Lambert, Western Australia
Cape Lambert is a port facility operated by Rio Tinto Iron Ore in the Pilbara region of Western Australia. It is located 40 kilometres north of Karratha. The port at Cape Lambert is comprised of five car dumpers, eight shipping berths, nine stackers, six reclaimers and four ship loaders. The output capacity of the port is approximately 205 Mt/a.
Objectives:
The overall objective of this project is to develop a chute which is easy to maintain and takes less downtime when wear elements require replacement for Shiploader 2 & 3. Furthermore the new design shall reduce belt wear and skirt wear.
Surge capacity of the existing chute was inadequate & required improvement:
Project Scope:
CABS utilised DEM (Discrete Element Modelling) for optimisation of chute flow/design:
CABS also developed systems to assist with safe installationa & future maintenance:
CABS managed the fabrication of the chute:
Post installation:
Rio Tinto Iron Ore
Location:
Cape Lambert, Western Australia
Cape Lambert is a port facility operated by Rio Tinto Iron Ore in the Pilbara region of Western Australia. It is located 40 kilometres north of Karratha. The port at Cape Lambert is comprised of five car dumpers, eight shipping berths, nine stackers, six reclaimers and four ship loaders. The output capacity of the port is approximately 205 Mt/a.
Objectives:
The overall objective of this project is to develop a chute which is easy to maintain and takes less downtime when wear elements require replacement for Shiploader 2 & 3. Furthermore the new design shall reduce belt wear and skirt wear.
Surge capacity of the existing chute was inadequate & required improvement:
Project Scope:
1. Re-design & Replacement of the following components:
2. Develop change-out system and maintenance aids considering:
CABS utilised DEM (Discrete Element Modelling) for optimisation of chute flow/design:
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- Stage 1: Preliminary investigations
- Stage 2: Detailed Analysis and Reporting
- Stage 3: Development of medium & long term conceptual solutions into preliminary designs & detailed implementation cost estimates
- Stage 4: Detailed design & implementation of medium & long term solutions
- CABS undertook an in-depth, comprehensive review of the entire circuit (both on-site & in the office of downtime data).
- This included the screen houses, overland conveyors, transfer chutes, wharf conveyors & shiploader transfers & loading systems.
- A comprehensive report was then developed, with cost estimates, outlining each issue identified.
- These were then worked through with the client & broken into individual projects & prioritised based on importance & return on investment.
- The projects, which were executed by both the client internally & CABS (where a more in-depth design is required), have resulted in a significant reduction in spillage, increasing circuit reliability & reduced environmental impact (from spillage falling into & contaminating the ocean.
- Indepth review & analysis of downtime data to identify key areas which were causing production loss.
- Indepth review & analysis of operational data to identify key areas which were causing production loss.
- Identification of tune-up possibilities to reduce cycle time & increase production.
- Hydraulic system upgrades/tune ups to increase production.
- Apron feeder speed control adjustments to decrease out-loading delays & increase production.
- Onsite plant condition & reliability reviews with identification of key areas for overhaul, repair & upgrade to effectively & economically increase production.
- CABS provided detailed but easy to understand reporting on all investigations to the client & provided emphasis on key areas where rectifications/improvements could be made by the client internally (reducing costs).
- CABS also provided further support for identified projects which required more indepth engineering
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- Review of the performance of a recently installed clay washing plant to identify areas where the performance & safety of the plant could be improved.
- Preparation of proposals and cost estimates for improvements identified.
- Site commissioning engineer for the implementation of the replacement control system PLC & software
- Responsible for the technical design of modifications to the hydraulic system of the ore car positioner to prevent repeated pump failures.
- Modifications to the speed control system of the positioner drive to simplify & improve performance.
- Specification of the control system requirements for the positioner; &
- Overall integration of the electrical & mechanical systems of the complete dumping & crushing facility during commissioning.
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- Project management of the technical analysis & design of modifications to upgrade an existing boom structure to ensure compliance with the new design code for bulk handling machines, AS4324.
- Review of previous design audit.
- Determination of boom load cases.
- Supervision of Finite Element Analysis (FEA) of boom; and
- Design structural and mechanical modifications for the installation to comply with AS4324.
- Oversee the dismantling & transhipment of an 800 tonne, 60 x 89 Gyratory primary crusher from USA to Australia.
- Project manage overhaul & installation.
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- Preliminary design and cost estimate.
- Capital Expenditure justification.
- Project Management of design, supply and commissioning.
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- Conceptual & preliminary design & costing of a test facility for an iron ore processing plant.
- Detailed design.
- Manufacturing & construction management.
- Commissioning & test programme operation.
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Past Projects - Shiploader Circuit Spillage Review
Client:
Rio Tinto Iron Ore
Location:
Cape Lambert, Western Australia
Cape Lambert is a port facility operated by Rio Tinto Iron Ore in the Pilbara region of Western Australia. It is located 40 kilometres north of Karratha. The port at Cape Lambert is comprised of five car dumpers, eight shipping berths, nine stackers, six reclaimers and four ship loaders. The output capacity of the port is approximately 205 Mt/a.
Project Scope:
Key Benefits:
Rio Tinto Iron Ore
Location:
Cape Lambert, Western Australia
Cape Lambert is a port facility operated by Rio Tinto Iron Ore in the Pilbara region of Western Australia. It is located 40 kilometres north of Karratha. The port at Cape Lambert is comprised of five car dumpers, eight shipping berths, nine stackers, six reclaimers and four ship loaders. The output capacity of the port is approximately 205 Mt/a.
Project Scope:
Key Benefits:
Examples of problems identified & subsequently resolved/rectified by the project.
Belt tracking:
Increased chute wear:
Poor skirt control of ore during loading:
Ship Loading:
Belt tracking:
Increased chute wear:
Poor skirt control of ore during loading:
Ship Loading:
Past Projects - Car Dumper Circuit Review & Optimisation
Client:
Rio Tinto Iron Ore
Location:
Cape Lambert, Western Australia
Cape Lambert is a port facility operated by Rio Tinto Iron Ore in the Pilbara region of Western Australia. It is located 40 kilometres north of Karratha. The port at Cape Lambert is comprised of five car dumpers, eight shipping berths, nine stackers, six reclaimers and four ship loaders. The output capacity of the port is approximately 205 Mt/a.
Project Scope:
To provide engineering consultancy services to attend site to conduct an operation and maintenance review to the CD1 circuit.
Project Objective:
The objective of the work is to review the operation of the CD1 plant & identify opportunities for improvement, either in terms of operational performance, maintainability or reliability.
Key Project Outcomes:
Rio Tinto Iron Ore
Location:
Cape Lambert, Western Australia
Cape Lambert is a port facility operated by Rio Tinto Iron Ore in the Pilbara region of Western Australia. It is located 40 kilometres north of Karratha. The port at Cape Lambert is comprised of five car dumpers, eight shipping berths, nine stackers, six reclaimers and four ship loaders. The output capacity of the port is approximately 205 Mt/a.
Project Scope:
To provide engineering consultancy services to attend site to conduct an operation and maintenance review to the CD1 circuit.
Project Objective:
The objective of the work is to review the operation of the CD1 plant & identify opportunities for improvement, either in terms of operational performance, maintainability or reliability.
Key Project Outcomes:
General images from the review:
Belt tracking issue:
Belt tracking issue:
Past Projects - Process Plant Optimisation Review
Key Project Details:
Past Projects - Iron Ore Stacker / Reclaimer Control System Upgrade
Key Project Details:
Past Projects - Control System Upgrade on Ore Car Dumping Facility
Key Project Details:
Past Projects - Shiploader Discharge Boom Analysis
Key Project Details:
This project involved the following phases:
Past Projects - Primary Crusher: New Mexico
Key Project Details:
Past Projects - Water Treatment Plant for Power Station Demin Water Supply
Key Project Details:
Past Projects - Feasibility Study: Iron Ore Secondary Processing
Key Project Details:
Preparation of the conceptual design, costing & feasibility of an ore secondary processing plant
Preparation of the conceptual design, costing & feasibility of an ore secondary processing plant
Past Projects - Optimisation Project
Key Project Details:
Conduct process performance analysis & debottle necking analysis on an ore stacking and shiploading operation.
Conduct process performance analysis & debottle necking analysis on an ore stacking and shiploading operation.
Past Projects - Car Dumper Mass Balance Study
Key Project Details:
Mass Balance & dynamic analysis of the rotating car dumper barrel to optimise the drive.
Mass Balance & dynamic analysis of the rotating car dumper barrel to optimise the drive.
Past Projects - Iron Ore Process Test Facility
Key Project Details:
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- Determine the cause of failure.
- Identify solutions to eliminate the problem.
- Prepare a specification and scope of repair.
- Provide engineering inspections during the overhaul.
- Witness factory testing.
- Return to service of the gearbox at less cost, longer life & greater reliability than a new gearbox of original design.
- Several gearbox design improvements were identified & implemented as a result of CABS investigation
- This contributed to improved reliability & operational performance.
- Allowance for site inspection, tooling confirmations & contractor/client liaison.
- Design of replacement thrust roller preload screw.
- Design of support wheel boss repairs.
- Safety & preparation activities.
- Weld procedure & welder qualifications.
- Work instructions.
- Contractor shutdown Scope of Work.
- Wheel overhaul specification.
- Revisions of up to five drawings, detailing repairs & changes.
- Complete repair of wheel & hub,
- Repair of Thrust Roller bolts, &
- Development of Overhaul Procedure to avoid future failures.
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- Examine the failed components.
- Prepare calculations where required.
- Identify causes of failure & possible solutions &
- Prepare a report of the findings.
- Investigation into & identification of cause of failure of Apron Feeder chains.
- Cause of failure of the links identified &
- Recommendations provided on how to eliminate root causes.
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- Investigation into cause of failure of leach agitators.
- Expediting of manufacture of replacement agitator shafts.
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Past Projects - Failure Analysis & Repair of Reclaimer Bucketwheel Gearbox
Client:
Robe River Iron Associates
Location:
Cape Lambert, Western Australia
Robe River Iron Associates is the third largest Iron Ore exporter in Australia. The Cape Lambert Operation is located approximately 1500 km Northwest of Perth in the remote Pilbara region of Western Australia. The client suffered catastrophic failure of the output shaft of a bucketwheel gearbox.
Project Scope:
Key Benefits:
Assortment of images from project:
Past Projects - Tertiary Crusher Hydraset Failure
Key Project Details:
Investigation & rectification of a recurring hydraset seal failure on the tertiary crusher.
Investigation & rectification of a recurring hydraset seal failure on the tertiary crusher.
Past Projects - Failure Analysis & Repair of Car Positioner Wheel (Axle/Hub/Thrust Rollers)
Client:
Rio Tinto Iron Ore
Location:
Cape Lambert, Western Australia
RTIO is the third largest Iron Ore exporter in Australia. The Cape Lambert Operation is located approximately 1500 km Northwest of Perth in the remote Pilbara region of Western Australia. The objective of the project was to design, draft & prepare for the execution of repairs to the damaged support wheel boss.
Project Scope:
Key Benefits:
Assortment of images from project:
Past Projects - Chain Link: Fatigue Analysis
Client:
Robe River Iron Associates
Location:
Pannawonica, Australia
Robe River Iron Associates is the third largest Iron Ore exporter in Australia. The Pannawonica Operation is located approximately 1400 km Northwest of Perth in the remote Pilbara region of Western Australia. The client suffered multiple Apron Feeder chain failures (Approx. 7 over 4 years).
Project Scope:
Key Benefits:
Assortment of images from project:
Past Projects - Griffin: Coal Bucket Lug
Key Project Details:
Identify the cause of the failure of bucket back attachment lugs & recommendations for the path to long term solution of the problem.
Identify the cause of the failure of bucket back attachment lugs & recommendations for the path to long term solution of the problem.
Past Projects - Leach Agitator Shaft Failure
Key Project Details:
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- Stay rope & socket integrity inspections.
- Working rope inspections, including sheaves, wire rope, winch & brake systems.
- Stay rope fatigue analysis &
- Inspection interval optimisation.
- Development of specialised inspection tooling &
- Development of Procedures to maximise efficiency.
- Development of Electronic Inspection Apps utilising the latest technology for accurate & timely reporting.
- Risk assessment of defects;
- Serious defect notification;
- Incomplete inspection notifications;
- Short form defect notification reporting;
- Exception reporting;
- Long form detailed inspection reports.
- Engineering, Planning & project management of difficult rope replacement projects.
- Corrosion mitigation services (Rope Cleaning & application of Protectant).
- Balance machine mechanical inspections
- Inspections include: Ring Bearings, Bogies, Boom & Long Travel Breaking Systems & more
- Inspection interval optimisation
- Development of specialised inspection tooling & Procedures to maximise efficiency
- Development of Electronic Inspection Apps utilising the latest technology for accurate & timely reporting
- Risk assessment of defects;
- Serious defect notification;
- Incomplete inspection notifications
- Short form defect notification reporting
- Exception reporting
- Long form detailed inspection reports
- In-depth investigation into task
- Identification of risks/hazards
- Identification of safety controls to eliminate hazards/risk
- Development of procedure (in an efficient order)
- Identification of required tooling (including any special/custom tooling requiring development)
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Past Projects - Rope Inspections
Client:
Multiple clients throughout the Pilbara (RTIO, BHP etc.)
Services Provided by CABS:
Our systems include:
Comprehensive reporting includes:
Additional Rope Services Provided by CABS:
Images from our inspections:
Past Projects - Mechanical Inspections
Client:
Multiple clients throughout the Pilbara (RTIO, BHP etc.)
Services Provided by CABS:
Our systems include:
Comprehensive reporting includes:
Additional Services Provided by CABS:
Engineering, Planning and project management of defects/issues requiring repair
Images of some issues found during inspections:
Past Projects - SWP Development
Client:
Multiple clients throughout the Pilbara (RTIO, BHP etc.)
As part of our Engineering, Maintenance, Inspection & Repair projects, CABS often create SWPs (Safe Work Procedures), overhaul specifications or installation guides which identify the potential risks involved with the task & the safe way to complete the task in an efficient manner.
CABS offer SWP development as a standalone service or integrated into the delivery of an engineered maintenance repair.
We investigate & gain an understanding of the task, identify possible risks & hazards & develop an efficient procedure for undertaking the tasks involved; including any tooling, control/safety systems, efficient order of steps & resources required.
SWPs are required for all types of tasks from complex one type task (installations/repair procedures etc.) through to routine maintenance (repetitive tasks where reliable repeatability is required or where complacency can become an issue when identifying risks & hazards).
Services Provided by CABS:
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- Apron Feeder Drives originally stored & shipped on their side.
- High Risk two crane roll required to transition drive for removal & installation. (see images)
- Heavy, bulky access platforms which are not fit for purpose & provide limited maintenance access to drive & chute.
- Wheels on existing platforms are seized & cannot be moved by single maintainer.
- Causes issues for production team during clean up (bob cat access & washdown).
- Design a completely new access system incorporating new fit-for-purpose transport frames.
- Transport frames stay attached & act as frames for maintenance access platforms.
- All additional access to drives & chutes undertaken via permanent [access from above] platforms.
- Walkways can be easily removed when required for chute change outs & require zero floor foot print. (see bottom image)
- All areas safely accessible by single maintainer.
- High Risk roll of drive eliminated.
- Risk of drive hydraulic pipe damage eliminated by not having to take drives on & off the transport frame when undertaking changeout.
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- Mantle removal is high risk work.
- Working at heights issues and high risk of fall.
- Scaffolding required to hook up mantle to overhead crane & then must be removed prior to mantle removal.
- Designed crow’s nest to allow safe easy hook-up to overhead crane.
- No working at heights during installation.
- Crow’s nest stays in place when mantle is removed.
- Designed to also allow access when mantle is in maintenance cradle.
- Allows quick & easy inspection & overhaul.
- Hazardous working conditions in surge bin of the primary crusher.
- (Extreme heat, poor air supply, poor ventilation, dusty, poor lighting, high humidity)
- Liner change outs / repairs require extended periods of grinding, welding and even thermal lancing.
- Leaving opening uncovered eliminates work front in crusher due to high risk of working above.
- (Dropped objects and Falling from heights).
- Problem analysed and platform designed.
- Eliminated HSE issues:
- - Working at Heights above,
- - Dropped objects from above &
- - Surge bin working environment.
- Increased air flow, ventilation & light.
- Enabled simultaneous work fronts (above in crusher and below in surge bin).
- Design of procedures and tooling including barriers, platforms, monorails & transport frames.
- Elimination of multiple HSE exposure (Working at Heights, Lifting etc.)
- Stream line of methodology allowing reduced shutdown time & cost savings.
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- Servicing/overhaul of Screens in workshop is problematic and slow.
- Required access causes HSE issues.
- Existing procedure requires working at heights and slow, costly scaffolding.
- Developed light weight, aluminium, roll up platform.
- Easily manoeuvrable platform.
- Platform provides simultaneous multi-level access.
- The sinter fines screens at Cape Lambert Port operation requires scaffolding to provide fall protection before screen deck maintenance can be undertaken.
- This imposes delays & logistical problems during maintenance shutdowns that impact the costs of the shutdown &
- Reduces the time available for maintenance.
- Visit site to inspect the screen & understand the aspects of the job and requirements of the barrier system.
- Develop a concept which will provide the requirements.
- Criteria specified:
- 1. Easy deployment (permanent installation is preferred).
- 2. Light weight.
- 3. Elimination of the need for scaffolding.
- Maintenance Aid for Apron Feeder Pan & Drive Changeouts.
- A trolley that can take the weight of the Apron Feeder drive & allow it to be rolled back from the rigid coupling.
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- Design of a ladder to be incorporated within the scalper oversize chute supporting structure that safely provides visual inspection access to the secondary crusher bowl.
- Design a small platform to inspect the Tertiary crushers that is able to be removed for maintenance.
- The root cause of a failure of Car Dumper trunion support concrete protection liner & subsequent 5.5 days lost production resulting from a bogged crusher was a failure to act & develop a maintenance method for the end ring deflector rubbers.
- There was no simple access method available to permit in-time maintenance of the end ring deflector rubbers.
- Neglect over many years resulted in gradual degradation of the trunion support protection liners to the point where the liner fixings failed & the complete liner fell & jammed in the crusher causing a crusher bog.
- The extent of the damage to the end ring deflectors was so extensive that the repair scope was beyond the will & capability of the organisation to implement in the downtime windows available.
- An on-going maintenance system & modifications were developed by CABS & implemented during the Dumper repair works.
- The solution has provided a system which enables on-going maintenance in the regular maintenance windows available.
Past Projects - Apron Feeder Maintenance Platforms
Client:
Rio Tinto Iron Ore
Location:
Cape Lambert, Western Australia
Problems:
Images of Solution:
CABS have completed many Maintenance Aid projects in & around Primary Crushers.
Please pick from one of the above Crusher Areas
Past Projects - Mantle Removal & Overhaul Access
Client:
Rio Tinto Iron Ore
Location:
Cape Lambert, Western Australia
Project Focus Area:
Mantle Removal and Overhaul Access
Problems:
CABS Solutions:
Past Projects - Surge Bin & Primary Crusher
Client:
Rio Tinto Iron Ore
Location:
Cape Lambert, Western Australia
Project Focus Area:
Surge Bin / Primary Crusher
Problems:
Work Area Before Installing New Ring
Work Area After Installing New Ring
Past Projects - Crusher Works (Safe Access)
Spider Transport/Overhaul Cradle
Client:
Rio Tinto Iron Ore
Location:
Cape Lambert, Western Australia
Project Focus Area:
Crusher Works - Barriers, Platforms, Monorails & Transport Frames
Problems:
HSE issues around mantle removal, surge bin, crusher access & safe transport of equipment for overhaul.
CABS Solutions:
Elimination of Liner Lifting via installation of rail & lifting carriage
Engineered Cover which closes as it lowers around the Spider to eliminate Fall risk.
Crusher Safety Ring - Easy to install & eliminates Fall risk.
Past Projects - Screen Maintenance Platforms
Client:
Rio Tinto Iron Ore
Location:
Cape Lambert, Western Australia
Problems:
CABS Solutions:
Past Projects - On-Deck Screen Access
Client:
Rio Tinto Iron Ore
Location:
Cape Lambert, Western Australia
Problems:
Scope:
CABS Solutions:
CABS developed designs for multiple safety barrier systems for the Sinter fines screens which eliminate the Fall risks & the need for scaffolding.
Past Projects - Gearbox Trolley
Client:
Rio Tinto Iron Ore
Location:
Cape Lambert, Western Australia
Problems:
CABS Solutions:
Design & Fabrication of a compact, balanced trolley for easy drive manoeuvring.
Past Projects - Crusher Inspection Access
Client:
Rio Tinto Iron Ore
Location:
Cape Lambert, Western Australia
Scope:
CABS Solutions:
Design & Fabrication of safe access platforms.
Past Projects - Car Dumper On-Going Maintenance Access
Client:
Robe River Iron Associates
Problem:
Solution
Previously access was difficult & took along time due to scaffolding requirements, leading to a lack of maintenance which resulted in a costly failure & significant downtime.
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- Drive Modules were not standardised and lacking proper overhaul specifications.
- Severe Drive-Rack Spine cracking was identified. Caused by the improper maintenance overhaul.
- Overhaul of Positioner Arm Bearings and Pins was required.
- Overhaul of Positioner Towing points was required due to severe misalignment.
- Replacement of wheels and guide rollers was required.
- Over multiple shutdowns undertake investigations into each issue.
- Analyse & identify the root causes of each problem.
- Develop engineered solutions to resolve each issue.
- Draft modifications & tooling required & fabricate where necessary.
- Project Manage execution work of all shutdown repairs.
- Car positioner now runs with a reduced cycle time.
- With reduced wear on other components (i.e. rail, bearings, racks etc.)
- Required regular maintenance time greatly reduced now the drive modules are standardised and hold down method enhanced.
- Elimination of HSE hazards related to awkward positions required for fitting of of the drive modules.
- Wear on ore cars is reduced due to smoother more controlled operation.
- Operational reliability and uptime greatly improved.
- Modules continually overhauled incorrectly & to a poor standard.
- Varied and poorly maintained hold down pattern.
- Non-standard modules leading to module interchangeability issues (units needed to be tracked to ensure correct module was ready for change out.)
- Multiple lengthy over runs during shutdowns.
- Additionally modules were not being setup correctly & wear & tear resulted in the drive pinions dropping below the rack, causing contact between the pinions & spine structure resulting in significant damage.
- CABS also repaired the spine damage; see corresponding project detail for more information on the spine repairs.
- Investigate all root issues existing with Drive Modules. Improve hold down configuration.
- Standardise the design of all module frames.
- Develop complete overhaul specification.
- Overhauled module drive pinions no longer contact spine structure.
- Created specification to include sections which eliminates pinion / spine contact from re-occurring.
- Module change out time significantly reduced eliminating the potential for shutdown over runs.
- Hold down arrangement re-designed to allow easy access and standardised resulting in significantly reduced change out time.
- Investigate all root causes of the cracking.
- Investigate and assess severity of damage and develop repair method.
- Project Manage repairs in conjunction with other positioner overhaul works.
- Budget constraints did not allow replacement of the spine structure, thus a repair method had to be developed.
- The steel required specialist weld procedures.
- The work area was covered in grease and hydraulic oil despite extensive clean down.
- The spine itself was full of oil and the steel and cracks consistently leached oil during welding despite significant cleaning and pre-heating.
- Gaining access to the area where the cracks existed required complete disassembly of the rack/spine structure.
- Limited shut time was available for the repair works.
- The bearings, bushes and pins of the car positioner indexing arm had not been overhauled in the past 5+ years due to the high degree of difficulty existing with the job, surrounding areas & limited shutdown time available.
- The result was severe slack had developed in the bearings & pins causing inconsistent and uncontrolled operation of the index arm.
- This in turn was causing damage to the arm cylinders and ore car couplings.
- Develop removal method which fit into the available shutdown window.
- Develop contingency plans for all possible issues and design & prepare adequate tooling and procedures to mitigate the risk of these issues occurring.
- Develop work method for contractor.
- Project Manage shut execution of arm overhaul.
- Assess each component as it is removed & identify if replacement part is required.
- Budget constraints did not allow complete replacement of the arm.
- Many of the components had to be fabricated & delivered to site in a short amount of time.
- Some required fabrication & or overhaul on site during the shutdown & this had to be planned for without the possibility of inspection.
- The steel required specialist weld procedures if cracks were identified.
- The work area was covered in grease & hydraulic oil despite extensive clean down.
- Limited crane access. Limited shut time was available for the repair works.
- Other works were scheduled simultaneously with the arm change-out.
- Available parts provided did not meet tolerances & required in-situ modification.
- Limited prior knowledge regarding arm removal & overhaul was available.
- Overhaul was completed in shut window provided within budget & without any HSE incidents.
- In the field machining was undertaken successfully greatly reducing required shutdown time.
- Once overhauled the operation of the arm is now controlled and smooth.
- This has resulted in lower impact loads & less wear on the cylinders, ore car couplings & arm itself.
- After many overhauls the towing points of the drive modules were found to be severely misaligned.
- This was resulting in Pinion to Rack misalignments and the Drive Module towing point pins having to be forced on an angle so they could be installed.
- This contributed to delays during module change outs & was putting additional loading on the pins greatly increasing the chances of a pin shearing in half if a shock load is delivered.
- Reports of broken pins occurring have been made in the past.
- Analyse misalignment and determine required position of towing point.
- Develop repair method including new bore/sleeve sizes and tolerances.
- Develop boring alignment jig for contactor.
- Project manage shut execution of towing point overhaul.
- Available shut time was limited & the boring operation in this situation had not been attempted before.
- Gaining access to towing points required significant removal of other components.
- Boring to required tolerances was achieved & installation of the drive module & pin was smooth and easy.
- Adverse loading of the towing pins has been eliminated & thus the risk of a pin breakage occurring has been greatly reduced.
- This has significantly increased the reliability of the car positioner.
- The guide rollers of the positioner were overdue for changeout.
- The high wear was causing the positioner to float on the rails due to increased clearances caused by the wear.
- This was resulting in higher duty & wear of the other components such as wheels, rack, rail & drive pinions.
- Develop removal method of guide rollers & changeout other worn components such as wheels.
- Project manage shut execution of replacement of components.
- No prior knowledge existed around the removal of the guide roller structure or rollers themselves.
- The weight of each roller was in excess of 500kg.
- The design of the roller assembly and structure meant that a number of other components had to be removed in order to gain access to remove the rollers.
- Shut time was limited & the task needed to be undertake in conjunction with a number of other work fronts making the scheduling/timing of the task difficult.
- The positioner guide rollers now have the correct clearances.
- Thrust is now translated into the appropriate components & the floating of the positioner has been significantly reduced.
- This will greatly reduce wear on other components.
- An audit of the existing shiploader luffing system, identification of the areas of risk & equipment requiring replacement.
- Development of concepts for rectification of the problem areas identified in the audit.
- Costing estimates & preparation of Capital Expenditure Justification.
- Detailed design.
- Specification and Tender document preparation, contract award & contract management for the manufacture of the upgrade equipment.
- Site project management for installation, including complete control system upgrade; &
- Commissioning.
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- Crusher Seal Plates (Complete Overhaul/Replacement incl. fabrication management)
- Lip Liners (Complete Overhaul incl. Specialised procurement& modifications)
- Mantle Overhaul (incl. changeout, inspection & repairs)
- Spider Overhaul
- Hydraset Overhaul (incl. plate refurbishment)
- Concave Replacement
- Surge Bin & Gear Case (Overhaul & Repairs)
- Mantle Bore (crack repairs)
- Eccentric Overhaul
- Crusher Gearset (15 year long mesh correction project with successful results)
- Extreme wear on positioner arm. (The above photo should be a flat surface)
- Excessive clearance on thrust surfaces.
- Only short available shutdown window.
- No spare Arm to change out & no method to repair thrust surfaces.
- Investigate issues, develop solution & corresponding work procedure.
- Develop execution method & provide pre-shut support to contractor.
- Supply contractor for execution of planned works onsite & project manage site works.
- Provide post-execution support and reporting.
- CABS developed methodology which allowed machining of the Positioner Arm on site & positioner thrust surfaces in-situ, reducing the shutdown duration.
- Pre-shut preparations & working with the contactor allowed for pre-site testing & development of custom tooling arrangement to achieve rapid setup of machine & square, accurate machining of damaged face.
- Once positioner thrust surfaces were machined replaceable wear plates were installed to eliminate the problem from re-occurring & improving maintenance access in the future.
- Access to the rubber buffers was difficult and too time consuming.
- Maintenance was not possible in the shutdown times allocated.
- The rubber buffers wore out and were not replaced.
- Damage resulted including major structural damage.
- Design a semi-pre-fabricated repair & developed a repair procedure within the shutdown time available.
- Increase the strength of the end ring with a different design.
- Design a customised platform to provide rapid & safe access during the shutdown which reduced the shutdown to an acceptable outage time, &
- Provided on-going maintenance facility which would facilitate regular maintenance.
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- Degraded condition of the rope due to harsh coastal environment (salt/water/sand blasting etc.)
- Considerable consumption of the outer protective coating applied by the manufacturer.
- Difficult work environment (wharf) with limited access and limited working area for EWP.
- Limited shut time to complete works.
- Develop tooling for rope cleaning, lubrication application and appropriate clean-up.
- Investigation, selection and supply of lubricant.
- Development of work procedure.
- Supply and manage equipment, EWP & sub-contractor for execution of lubrication works.
- Successful completion of the rope lubrication in the allocated time.
- Increased safety from dropped objects and control of environmental contamination.
- Effective management of sub-contractor.
- Poor protective coating provided by manufacturer.
- Harsh coastal environmental operating conditions (salt/water/sand blasting etc.)
- High risk of consumption of the outer protective coating applied by the manufacturer.
- Limited shut time to complete works.
- Furthered development of tooling for rope cleaning, lubrication application & appropriate clean-up.
- Investigation, selection & supply of lubricant.
- Development of work procedure.
- Supply equipment, EWP & manage sub-contractor for execution of lubrication works.
- Successful rope lubrication of each machine in the fleet in the allocated time.
- Increased safety from dropped objects & control of environmental contamination.
- Effective management of contractor.
- Existing chutes were worn out & require replacement.
- Chutes require re-design to improve ore flow & wear life.
- Ore flow.
- Extended wear life.
- Increased accessibility.
- Detail design of new chute & drafting of required Engineering & Fabrication drawings.
- Fabrication management.
- Installation tender management.
- Shutdown planning & optimisation of installation schedule & methodology.
- Execution of shutdown incl. supply & management of sub-contractor labour.
- Commissioning support & post shut review/reporting.
- CABS utilised 3D modelling & DEM (Discrete Element Modelling) to improve the ore flow through the chute.
- Wear of the existing chute was analysed & additional liners added to improve chute life.
- CABS were able to directly engage the labour contractor which allowed for an established chain of management.
- This in turn allowed for CABS to manage the labour supervisors directly & guide them through the installation process.
- Pre-shut preparations working with the contactor on equipment prep, installation procedure & execution safety procedures & documentation.
- Shut-execution works & post shut commissioning, review & reporting.
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Past Projects - Car Positioner Repairs & Overhaul
Client:
Rio Tinto Iron Ore
(Robe River Iron Associates)
Location:
Cape Lambert, Western Australia
Robe River Iron Associates is the third largest Iron Ore exporter in Australia. The Cape Lambert Operation is located approximately 1500 km Northwest of Perth in the remote Pilbara region of Western Australia. The client was suffering from multiple issues which were causing unreliable operation of the car positioner. These included:
Project Scope:
Key Benefits:
Upon resolution of all issues the following has been achieved:
See more information of each project stream using links above.
Past Projects - Drive Module Overhaul
Project Focus Area:
Drive Module Overhaul
Problems:
Project Scope:
CABS Solutions:
Module before overhaul:
Past Projects - Rack Spine Structure Cracking
Project Focus Area:
Rack Spine Structure Cracking
Problem:
The pinions of the Drive Modules were found to have dropped below the rack and had made contact with the spine structure and causing significant damage.
Project Scope:
Project Constraints:
Key Benefits From CABS Solution:
Due to the severity of the damage to the spine, serious potential existed for the complete top of the spine structure to break free if shock loaded. Repairs re-instated the structural integrity of the spine and were completed within the small shutdown window available.
Spine cracking before repairs:
Past Projects - Car Positioner Indexing Arm
Project Focus Area:
Car Positioner Indexing Arm
Problems:
Project Scope:
Project Constraints:
Key Benefits From CABS Solution:
Arm Before Overhaul:
Past Projects - Drive Module Towing Point Misalignment
Project Focus Area:
Drive Module Towing Point Misalignment
Problems:
Project Scope:
Project Constraints:
Key Benefits From CABS Solution:
Towing point prior to re-alignment:
Past Projects - Auxiliary Maintenance
Project Focus Area:
Auxiliary Maintenance
Problems:
Project Scope:
Project Constraints:
Key Benefits From CABS Solution:
Guide Roller structure prior to removal:
Past Projects - Shiploader Luffing System Replacement
Project Summary:
This project spanned four years and involved the following stages:
Client:
Robe River Iron Associates
Location:
Cape Lambert, Western Australia
Robe River Iron Associates is Australia's third largest Iron Ore exporter. The operation at Cape Lambert exports 30mtpa of Sinter Fines and Lump iron ore. All product exported by Robe is loaded onto ships via the single shiploader. The shiploader is controlled by an operator at the end of the boom. Peak loading capacity is 10,500 tph.
Project Scope:
Project management, structural & mechanical design & supervision of the luffing system, then commissioning engineer for the entire project including the control system replacement.
Key Benefits:
Compliance with new design standard, AS4324. A safe and reliable luffing system. Improved reliability and availability.
Past Projects - Primary Crusher Shutdown
Client:
Rio Tinto Iron Ore
Location:
Cape Lambert, Western Australia
Over the past 20 years CABS have been involved in & conducted numerous overhaul & repair projects on the Primary Crusher at Cape Lambert.
The following is an brief exhibit of some of these projects.
Projects Undertaken by CABS on the Primary Crusher:
Images of some of the project areas CABS have been involved in:
Lip Liners
Mantle Overhaul & Bore Crack Repairs
Spider Overhaul
Hydraset & Plate Overhaul
Gearcase Overhaul
Crusher Gear Set Inspection & Mesh Correction
(This project was undertaken over a period of 15 years with a successful end result & the mesh being corrected).
After in-depth investigation CABS identified the correction required, managed the machining & subsequent final mesh correction confirmation
Crusher Pinion Inspection & Overhaul
Crusher Gear Set Damage From Poor Meshing
Crusher Gear Set Mesh Investigation
Past Projects - Turn Key Project: Investigate, Design, Execute & Post Execution Support
Client:
Rio Tinto Iron Ore
Location:
Cape Lambert, Western Australia
Turn Key Project: Investigate, Design, Execute & Post Execution Support
Problems:
Project Scope:
CABS Solution:
Past Projects - Dumper End Ring Repairs
Client:
Rio Tinto Iron Ore
Location:
Cape Lambert, Western Australia
Problems:
CABS Solution:
Customised platform to provide rapid & safe access during the shutdown
Past Projects - Shiploader Rope Lubrication
Cleaning of the Shiploader Ropes
Client:
Rio Tinto Iron Ore
Location:
East Intercourse Island, Western Australia
Problems:
Project Scope:
CABS Solution:
Cleaning of Ropes
Rope Condition Pre-Lubrication
Contamination Control
Rope Lubrication Underway
Rope Condition Post Lubrication
Past Projects - Roy Hill Balance Machine Fleet: Rope Lubrication
Simultaneous Work Fronts: Rope Lubrication
Client:
Roy Hill
Location:
Port Hedland, Western Australia
Problems:
Project Scope:
CABS Solution:
Cleaned Rope Condition
Cleaning of Ropes
Contamination Control
Lubrication Application Device
>
Successfully Lubricated Rope
Past Projects - Secondary Screen Feed Chute Redesign & Installation
Client:
Rio Tinto Iron Ore
Location:
Cape Lambert, Western Australia
Turn Key Project: Investigate, Design, Execute, Post Execution Support
Problems:
Project Scope:
Review of existing design & re-design of chute to include improvements in the following areas:
CABS Solution:
Poor Ore Stream – Biased Flow
Chute Old & Worn Out.
Chute Requires Replacement. Worn Through.
Fabrication Management
Fabrication Delivery Management
Onsite Installation
Management of Sub-Contractor
Post Installation Commissioning & Review. Note Improved Centralised Ore Stream
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- Excessive Ore build-up under the car dumper.
- The ore builds to such an extent that it can contact the dumper barrel.
- To prevent damage to the dumper, non-scheduled shutdowns are required whilst the build-up is washed away.
- Build-up has caused approximately 120 hours of lost production.
- At $24 per tonnes, 5000 tph specific dumping rate, this represents $14.4m of lost revenue.
- The frequency of ore with higher clay & moisture content is set to escalate as more material is mined below the water table.
- Trials of an alternative High Pressure water blast method.
- Detailed design & costing of a remote controlled track mounted extendable boom device with high pressure lance.
- Implementation of the most effective cleaning system to significantly reduce the downtime.
- CABS developed a remote control water cannon & oversaw its installation on the west side of the car dumper to control ore build-up under the dumper.
- The cannon elevation & slew is controlled manually via a wireless remote control.
- The CD1 wash down pump draws water from the fire service.
- Monitoring systems were installed to automatically shutdown the pump if there is a demand on the fire service water.
- Excessive build-up on the Fines Screens.
- Normal maintenance hosing not adequate to clear build-up.
- Conduct an inspection of Fines Screens & develop conceptual layouts for a water cannons.
- Cannon position to provide good cleaning action.
- Easily accessible for maintenance.
- Positioned so it does not interfere with normal screen maintenance access.
- Assess suitability of existing pumping systems.
- Preliminary Pipe run from water supply to cannons.
- Detail design of Water Cannon, High Impact Nozzles & required piping modifications.
- Management of manufacture & supply.
- Design & supply of cameras, lighting & automation control system.
- On-site Installation and commissioning.
- Design & supply for automated Water Cannon (complete with lights and camera).
- Integration of automation control into clients existing system.
- Provision of operating manual.
Past Projects - Primary Crusher Water Cannon
Client:
Rio Tinto Iron Ore
Location:
Cape Lambert, Western Australia
Problems:
Project Scope:
CABS Solution:
Video of Water Cannon Design
Primary Crusher Dump Hopper Experiencing Excessive Build-up
Examples of Build-Up in Primary Crusher Dump Hopper
Investigation & Design of optimal nozzle.
Manufactured Design with Modified OEM Design to Increase Safety
Water Cannon Installed With Control
Commissioning of New Water Cannon
Past Projects - Secondary Screen Water Cannon
Client:
Rio Tinto Iron Ore
Location:
Cape Lambert, Western Australia
Problems:
Project Scope:
The conceptual design should consider the following:
CABS Solution:
Video of Final Water Cannon Design
Secondary Screens Experiencing Excessive Build-up
Design of Water Cannon using CAD.
Commissioning of New Water Cannon