Darren Barge Presentation - IQPC.com

Welcome from BMA

BMA Ownership Structure
Mitsubishi
50%
BMA Owners
50%
Council
Illawarra Coal
Operations
Peak Downs Mine Saraji Mine Goonyella Riverside Mine
Norwich Park Mine Blackwater Mine Gregory
Mine
Broadmeadow Mine
Hay Point Terminal Crinum Mine
Marketing
Singapore
Brisbane
The Hague
Other regional offices
BHP Billiton
Mitsui & Co
80% 20%
BHP Mitsui Coal P/L
Poitrel Mine
South Walker Creek Mine

Safety is priority number 1
Our Goal is zero harm
We are successful when each employee ends each day safely
The safety of our employees and contractors is an integral
part of our business
Environment
Minimising the environmental impact of our operations
remains a priority into the future.
Community
BMA is a proud contributor to the community

Norwich Park processing operation

Structure replacement project
The crushed Raw coal conveyor structure is critical as the
only means of stockpiling raw coal for plant feed.
The plant has a 1560 TPH name plate feed capacity with a
current 73% yield for coke product
In July 2006 ,I was faced by a report of a high potential major
structure risk.
The project was vital to the business success at Norwich Park
as well as the flow on effect to BMA.
Charter : to design and install a replacement structure to
enable safe and efficient operation and delivery of crushed
raw coal to the plant feed stockpile.
Incorporate leading practise designs to ensure the operations
and maintenance stakeholders for the project benefited from
the replacement.

Key stakeholders
Main structure design by Maintenance Technology Institute
,MTI by Dr Daya Dayawansa and Dr Brian Kerezsi.
Principle Contractor Fabrication and Installation
by McBryde Corporation.
Project management assistance
by RKF Engineering ,Paul Hallett
Independent design review for main structure
by ASPEC Engineering. Craig Meng
Electrical Engineering Design
by Welcon Technologies ,George Baker.
Electrical installation
by O'Donnell Griffin

Background details
Original design based on I beam main chords and extensive
use of back to back angles with spacers and a flexible
sealed joint approximately 10 mm wide

Maintenance & operation history
Due to the limited access to a large number of the
cross bracing a visual inspection from a distance
had been the process utilised for structural integrity
reporting and replacement planning.
Bracing replacement had been ongoing for two
years previous.
A dramatic change had been seen with a number of
critical members showing signs of deformation
between the angles.

Gathering thickness data
A program of thickness testing the entire structure during
scheduled maintenance periods was initiated and allowed a
team to access via the use of crane and dog box to ultra
sonic test all members in three position along the length of
structural members. Red denotes >50% loss.

Design modelling & failure mode
With the assistance of MTI a full design model was created to
reflect the actual stability and strength and potential failure
mode

Risk management during operation
Due to the time frame of a structure replacement a
operational risk management strategy had to be
initiated to ensure no people were put at risk.
A wind speed monitoring system was incorporated
to raise a full screen alarm page informing the
control room operator of actions required, retract
all machinery from stockpile area, raise telescopic
chute to maximum raised position stop feed to
ROM.
Personnel were not allowed on the running system
at this stage of the project

Replacement design & objectives
The replacement of the main structure created a
fantastic opportunity to build a structure that would
not only be a replacement but allow the inclusion of
current best practise design and standards.
The structure utilised Square hollow sections as the
main chords and vertical bracing.
The Horizontal bracing was all round section to
minimise any potential coal build up.
All members were fully welded.

Benefits from the design
Incorporation of access stair way to allow close
inspection of all main chord nodes.
Reduce flat surface areas for any build up potential.
Pressure test points for the main chords for
conformation of seal integrity.
Inclusion of a maintenance level platform for the
telescopic chute probes sheaves and dust
suppression.
Top of belt covers to encapsulate and run back and
possible spillage.

Fabrication & Transport
All structure was fabricated off site and transported
in three major sections.
The transport to site was a challenge on its own but
with the use of house removal transport technology
we were able to minimise the amount of bridge and
electrical interference so the permits required were
greatly reduced.
S1 and S2 spans were pre piped and transported
ready to install.

On site assembly
The assembly took place on a pad area on the raw
coal stock pile where we had pre poured a series of
concrete piers with beams and levelling studs.
Once fully aligned the final welding was completed.
All walkway sections were fitted out with cable
ladder and pre wired.
Conveyor gantry sections were fitted out with
frames and rollers ready for lifting into final
position.

New structure ready for install
Structure on levelling beams.

Demolition
A large number of scenarios were calculated for the lifting
plan to lower the old structure.
The large uncertainty was how the structure would react once
taken from compression into a tension state
The final plan chosen was to cut the structure and lower in two
pieces.

Demolition Photos
S4 Span lowered ,Day 3.

Demolition Photos
S3 span lowered Day 4,preparing main column studs.

Installation & alignment
The main column frame was pre installed and the new structure
lowered into position for in situ welding of the S3 & S4 spans.
Alignment was set from the rear pin positions and survey
points.

Main structure lift and positioning
Main S3 & S4 positioning. day 7.

Installation of pre assembled galleries
Fitted with frames , rollers & cable ladders.

The work in progress
Head end platform and south walkway

Beltreco covers
The covers have eliminated spillage from run back.

Dry commissioning completed ,Day 19

First Coal Day 20 Wet commissioning

Zero Harm ,On Time ,On Budget

Questions Please
Any part of the presentation needing
clarification or further detail?