1570W D li j t1570W Dragline projectGoedgevonden Colliery

Presented by D. Nothnagel

INDEX

• Introduction

• Planning• Planning

• Safety

Sit ti• Site preparation

• Boom down

• Planned repairs

• Challenges

2

Introduction

• History of machine – Rietspruit Mine- 5 Seam Mine- GGV Mine

• Dragline walk – 16km walk 5Seam to GGVg- 11 x power lines- 1 x public roadp- 1 x river - 1 x gas pipeline

3

g p p

Planning of repairs

• Assessment of required repairs ssess e t o equ ed epa s

• Manufactured spares – Tub Manufactured spares Tub - Back legs & lugs- Electrical equipment Electrical equipment

• Tracking of progress

• unplanned

4

Safety

• JHA, risk assessment & controls

• Permit system & Pto's

• Safety drive – scratch cards

• Achievements & rewards – 93 241 man hrs

• One incident – fall from stairs 1.5m- low blood pressure

5

low blood pressure

Project structure

Xstrata

OPS Manager

Xstrata

Engineer

ImpactBucyrus

BucyrusImpact

MechanicalMechanical

Tub

Bucyrus

Electrical

6

Site preparation

7

Site preparation

• Wooden oodelogs

• Plinths

• Tent

8

Boom down

• 17TH August ugust2009

• 56mm steal rope

• 523m long

• Drag circuit

9

Lesson learned from another operation – how not to do the operation how not to do the

job !

10

Planned repairs:Planned repairs:New dragline tub

11

Tub Manufacturing

• Manufactured by a u actu ed byBucyrus

• 4 Months

• Coded welders

• Part AA5 & AA10 in 3rd

ring

12

Tub assembly on site

• Parts AA1- AA4a ts

• 12 Coded welders12 Coded welders

• 3 Months3 Months

• Procedure• Procedure

13

Segment welding

ID % Complete Task Name Duration Start Finish

19 19% EF Segment 17 days Sat 09/04/18 Tue 09/05/0520 50% Pre heat 1 day Sat 09/04/18 Sun 09/04/1921 100% Block weld 5 days Sun 09/04/19 Fri 09/04/2422 25% Filler welding 9 days Fri 09/04/24 Sun 09/05/03

M E B M E B M E B M E B M E B M E B M Ed Quarter 3rd Quarter 4th Quart

22 25% Filler welding 9 days Fri 09/04/24 Sun 09/05/0323 0% Back gouge 1 day Sun 09/04/19 Mon 09/04/2024 0% Grind 1 day Mon 09/04/20 Tue 09/04/225 0% UT 1 day Tue 09/04/2 Wed 09/04/2226 0% Filler weld 8 days Wed 09/04/22 Thu 09/04/3027 0% Capping 2 days Thu 09/04/30 Sat 09/05/0228 0% Grinding 10 days Wed 09/04/22 Sat 09/05/0229 0% Painting 3 days Sat 09/05/02 Tue 09/05/0530 19% DE Segment 17 days Fri 09/04/24 Mon 09/05/1131 50% Pre heat 1 day Fri 09/04/24 Sat 09/04/2532 100% Block weld 5 days Sat 09/04/25 Thu 09/04/3033 25% Filler welding 9 days Thu 09/04/30 Sat 09/05/09g y34 0% Back gouge 1 day Sat 09/04/25 Sun 09/04/2635 0% Grind 1 day Sun 09/04/26 Mon 09/04/2736 0% UT 1 day Mon 09/04/27 Tue 09/04/2837 0% Filler weld 8 days Tue 09/04/28 Wed 09/05/0638 0% Capping 2 days Wed 09/05/06 Fri 09/05/0839 0% G i di 10 d T 09/04/28 F i 09/05/08

14

39 0% Grinding 10 days Tue 09/04/28 Fri 09/05/0840 0% Painting 3 days Fri 09/05/08 Mon 09/05/1

Tub after assembly

15

Machining & alignment

• Special micrometer for Spec a c o ete oalignment

• Machining for rails

16

Lathe and discard

17

Aligning & drilling the lower Aligning & drilling the lower rails

18

Installing rack & rollers

19

Upper rail installation

• GPS alignment on G S a g e t oupper and lower rail

• Special equipment for safe installation

• Hooks for extra support

20

Tub installation completed

21

Drag assembly

22

Refurbish drag assembly

23

Line boring

• All bearing landings bea g a d gswas line bored

• Bearing landing welded

• Landing machined

• Equipment used

24

Swing gearboxes

25

Removing Back legs

• 160t crane – reach

• Back leg=13t

• Top pins stuck

26

Back leg lugs

• Welding and grinding = 4weeks

27

New back legs & lugs

28

Sandblasting of boom

• Top flight

• Sandblasting and painting

29

Boom repair

• Repairs done on A,B,C apex cores

• Clusters

30

Boom complete

31

Electrical upgrade

• Removing of all cabling and e o g o a cab g a dpanels

• New PLC replacing old technology

• New DC drives replacing exciter set

32

New MCC in subs

33

MV upgrade

• New MV switchgear –e s tc geaAlstom

• 2 New 10MVA skids

• Interlock protection between links & Transformer

34

Advantage of electrical upgrade

• Easier fault finding – PLC

• Improved response on controls

• Safety – MCC panels

• 100% Improved protection on circuits

• Permanent condition monitoring

35

Challenges

• Weathereat e

• TimeTime

• Overhead linesOverhead lines

• Centre pintle crack• Centre pintle crack

36

Centre pintle crack

37

Centre pintle repair

38

Conclusion

• Planning27 December 2009

• Safety

• Site preparation

• Boom down

• Planned repairs

39

• Challenges & Success

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