Asset on a Page

Current Asset: B1

Printed On: 2/22/2012
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Asset Information
Asset Criticality Rating: 324 
Age: 29  years
Economic Life Remaining: 20  years
Outloading Rate: 0  tph

Conveyor Information
N/A

Component Sub Component Condition Issue Action
Electrical Man Overboard (MOB) System Unhealthy Reliability issues with sirens. Implementation of trial siren by December 2013.
Berth Access Ladder Healthy
Hook Release / Take Up System Unhealthy Ageing field devices, switchgear, control and enclosures etc. Cable deterioration in places, although serviceable On condition replacement of enclosures and switchgear on condition.
Cathodic Protection System Healthy Oil filled cathodic protection transformers in service. Replace oil filled units with air filled.
Structural Integrity Concrete Decks Unhealthy Berth 1 Roadway water proof seal deterioration. Reinstate deck seal by July 2012.
L7 & L8 columns & Tripper rails Unhealthy Corrosion Spot repair by December 2012.
Dolphins Unhealthy Corrosion Spot repair by December 2012.
Piles Unhealthy Corrosion Spot repair by December 2012.
L5/L6 Drive tower Poor Severe Corrosion on Tower Bracing. Inspect and repair tower bracing by April 2012.
Headstocks Unhealthy Corrosion Spot repair by December 2012.
Rail Girders Unhealthy Corrosion Spot repair by December 2012.
Availability Click here to view big chart
Asset Costs Click here to view big chart
Risks
Risk Mitigation Treated Risk Score
Collapse due to Crane overloading Procedure for the application of Live Loads, Inspections, Supervision, Work Permit system, Load Lift Plans and Work Method Statements 3
Partial Structural Collapse due to Corrosion, seismic event, structural modifications, or fatigue Inspections, Corrosion Protection Program, Structural Maintenance, Cathodic Protection, modification process 1

Asset on a Page

Current Asset: B2

Printed On: 2/22/2012
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Asset Information
Asset Criticality Rating: 318 
Age: 15  years
Economic Life Remaining: 34  years
Outloading Rate: 0  tph

Conveyor Information
N/A

Component Sub Component Condition Issue Action
Electrical Berth Access Ladder Healthy
Cathodic Protection System Healthy Oil filled cathodic protection transformers in service. Replace oil filled units with air filled.
Man Overboard (MOB) System Unhealthy Reliability issues with sirens. Implementation of trial siren by December 2013.
Hook Release / Take Up System Unhealthy Ageing field devices, switchgear, control and enclosures etc. Cable deterioration in places, although serviceable On condition replacement of enclosures and switchgear on condition.
Structural Integrity Dolphins Unhealthy Corrosion Spot repairs across whole of structure by July 2013.
Concrete Decks Poor Cracking and Corrosion Repair by December 2012.
Piles Unhealthy Corrosion Spot repair by December 2012.
L7/L8 Drive Tower Unhealthy Corrosion Spot repairs across whole of structure by July 2013.
Rail Girders Unhealthy Corrosion Spot repair by December 2012.
L7 & L8 columns & Tripper rails Unhealthy Corrosion Spot repair by December 2012.
Headstocks Unhealthy Corrosion Spot repair by December 2012.
Availability Click here to view big chart
Asset Costs Click here to view big chart
Risks
Risk Mitigation Treated Risk Score
Collapse due to Crane overloading. Procedure for the application of Live Loads, Inspections, Supervision, Work Permit system, Lift Load Plans and Work Method Statements 3
Collapse as a result of Concrete Degradation Inspections and Concrete Remediation Program 1
Partial Structural Collapse due to Corrosion, seismic event, structural modifications, or fatigue Inspections, Corrosion Protection Program, Structural Maintenance, Cathodic Protection, modification process 1

Asset on a Page

Current Asset: B3

Printed On: 2/22/2012
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Asset Information
Asset Criticality Rating: 317 
Age: 8  years
Economic Life Remaining: 41  years
Outloading Rate: 0  tph

Conveyor Information
N/A

Component Sub Component Condition Issue Action
Electrical Berth Access Ladder Healthy
Cathodic Protection System Healthy
Hook Release / Take Up System Healthy
Man Overboard (MOB) System Unhealthy Reliability issues with sirens. Implementation of trial siren by Dec 2013.
Structural Integrity Rail Girders Unhealthy Corrosion Spot repair by December 2012.
Headstocks Unhealthy Corrosion Spot repair by December 2012.
L17 Columns & Tripper Rails Unhealthy Galvanic Corrosion Remove SS bolts and spot repair tripper rail flange corrosion.
Concrete Decks Unhealthy Corrosion Treat strand exit points by July 2013.
Dolphins Poor Galvanic Corrosion Repair stair tread supports by July 2012.
Piles Unhealthy Corrosion Spot repair by December 2012.
Availability Click here to view big chart
Asset Costs Click here to view big chart
Risks
Risk Mitigation Treated Risk Score
Collapse due to Crane overloading. Procedure for the application of Live Loads, Inspections, Supervision, Work Permit system, Lift Load Plans and Work Method Statements. 3
Partial Structural Collapse due to Corrosion, seismic event, structural modifications, or fatigue Inspections, Corrosion Protection Program, Structural Maintenance, Cathodic Protection, modification process 1

Asset on a Page

Current Asset: B4

Printed On: 2/22/2012
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Asset Information
Asset Criticality Rating: 317 
Age: 3  years
Economic Life Remaining: 46  years
Outloading Rate: 0  tph

Conveyor Information
N/A

Component Sub Component Condition Issue Action
Electrical Hook Release / Take Up System Healthy
Berth Access Ladder Healthy
Man Overboard (MOB) System Unhealthy Reliability issues with sirens. Implementation of trial siren by December 2013.
Cathodic Protection System Healthy
Structural Integrity Headstocks Healthy
Rail Girders Healthy
L17 Columns & Tripper Rails Healthy
Concrete Decks Healthy
L17 Drive Tower Poor Galvanic corrosion Remove SS from Drive floor main Welded Beams and repair flange corrosion by July 2012.
Piles Healthy
Dolphins Unhealthy Galvanic corrosion Arrest corrosion on stair tread supports welds by July 2013.
Availability Click here to view big chart
Asset Costs Click here to view big chart
Risks
Risk Mitigation Treated Risk Score
Collapse due to Crane overloading. Procedure for the application of Live Loads, Inspections, Supervision, Work Permit system, Lift Load Plans and Work Method Statements. 3
Partial Structural Collapse due to Corrosion, seismic event, structural modifications, or fatigue Inspections, Corrosion Protection Program, Structural Maintenance, Cathodic Protection, modification process 1

Asset on a Page

Current Asset: IL1

Printed On: 2/22/2012
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Asset Information
Asset Criticality Rating: 253 
Age: 29  years
Economic Life Remaining: 20  years
Inloading Rate: 5500  tph

Conveyor Information
S1 / S3

Component Sub Component Condition Issue Action
Electrical Substation Healthy
S3 Conveyor Drives Healthy
Conveyor Electrical / Control Healthy
S1 Conveyor Drives Healthy
Mechanical Vibratory Feeders Healthy
Wagon Vibrator Healthy
Conveyor Drives Healthy
Structural Integrity S1 Conveyor Unhealthy S1 Tunnel Section Localised corrosion in critical structure Replace Roller Frames and spot repair conveyor footings June 2013
S3 Transfer Tower Healthy
S3 Conveyor Unhealthy Localised corrosion in non critical areas on roof supports Coating repair on galleries scheduled to be completed by June 2014
S1 Transfer Tower Healthy
Reliability Click here to view big chart
Rate Click here to view big chart
Availability Click here to view big chart
Asset Costs Click here to view big chart
Risks
Risk Mitigation Treated Risk Score
Conveyor belt fire due to hot work, coal carry back, belt misalignment, idler/pulley/wash roller overheating, electrical overload, electrical fault Earth leakage protection, trip switches and overload protection, preventative maintenance programme, hot work system in place, fire fighting equipment training and fire supression in certain coveyor drive towers, belt rip detection, condition monitoring, belt cleaning systems installed and maintained. 14
To Production or Corporate Reputation as a result of Belt Tear Inspections on Belt Condition regularly undertaken,RR Grizzlies, Magnets, Metal Detector (S1), Full length Spares, and Belt Rip detection 9
Partial structural collapse due to errosion of footings Inspections on condition and repair of eroded footings 1
Partial structural collapse due to corrosion Inspections, corrosion protection programme and structural maitnenance 1

Asset on a Page

Current Asset: IL2

Printed On: 2/22/2012
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Asset Information
Asset Criticality Rating: 247 
Age: 15  years
Economic Life Remaining: 34  years
Inloading Rate: 5500  tph

Conveyor Information
S2 / S4

Component Sub Component Condition Issue Action
Electrical Conveyor Electrical / Control Unhealthy Ageing field devices and enclosures On condition replacement of equipment.
S4 Conveyor Drives Healthy
S2 Conveyor Drives Healthy
Substation Healthy Ageing switchgear and controls Assessment of switchboard to determine priority by December 2012.
Mechanical Conveyor Drives Healthy
Vibratory Feeders Healthy
Wagon Vibrator Healthy
Structural Integrity S4 Transfer Tower Healthy
S2 Conveyor Unhealthy Localised corrosion in critical areas on roof supports and trestles Structural & coating repair on galleries & trestles scheduled to be completed by June 2014
S4 Conveyor Unhealthy S2 Tunnel Section Localised corrosion in critical structure Spot repair conveyor footings June 2013
S2 Transfer Tower Healthy
Reliability Click here to view big chart
Rate Click here to view big chart
Availability Click here to view big chart
Asset Costs Click here to view big chart
Risks
Risk Mitigation Treated Risk Score
Conveyor belt fire due to hot work, coal carry back, belt misalignment, idler/pulley/wash roller overheating, electrical overload, electrical fault Earth leakage protection, trip switches and overload protection, preventative maintenance programme, hot work system in place, fire fighting equipment training and fire supression in certain coveyor drive towers, belt rip detection, condition monitoring, belt cleaning systems installed and maintained. 14
To Production or Corporate Reputation as a result of Belt Tear Inspections on Belt Condition regularly undertaken,RR Grizzlies, Magnets, Metal Detector, Full length Spares, and Belt Rip detection 9
Partial structural collapse due to errosion of footings Inspections on condition and repair of eroded footings 1
Partial structural collapse due to corrosion Inspections, corrosion protection programme and structural maitnenance 1

Asset on a Page

Current Asset: IL3

Printed On: 2/22/2012
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Asset Information
Asset Criticality Rating: 247 
Age: 3  years
Economic Life Remaining: 46  years
Inloading Rate: 7500  tph

Conveyor Information
S11 / S13

Component Sub Component Condition Issue Action
Electrical Conveyor Electrical / Control Healthy
S11 Conveyor Drives Healthy
S13 Conveyor Drives Healthy
Substation Healthy
Mechanical Conveyor Drives Healthy
Wagon Vibrator Healthy
Belt Feeder Drives Healthy
Structural Integrity S11 Conveyor Healthy
S11 Transfer Tower Healthy
S13 Transfer Tower Healthy
S13 Conveyor Unhealthy Localised corrosion construction defects Spot Repairs by June 2013
Reliability Click here to view big chart
Rate Click here to view big chart
Availability Click here to view big chart
Asset Costs Click here to view big chart
Risks
Risk Mitigation Treated Risk Score
Conveyor belt fire due to hot work, coal carry back, belt misalignment, idler/pulley/wash roller overheating, electrical overload, electrical fault Earth leakage protection, trip switches and overload protection, preventative maintenance programme, hot work system in place, fire fighting equipment training and fire supression in certain coveyor drive towers, belt rip detection, condition monitoring, belt cleaning systems installed and maintained. 14
To Production or Corporate Reputation as a result of Belt Tear Inspections on Belt Condition regularly undertaken,RR Grizzlies, Magnets, Metal Detector, Full length Spares, and Belt Rip detection 9
Partial structural collapse due to errosion of footings Inspections on condition and repair of eroded footings 1
Partial structural collapse due to corrosion Inspections, corrosion protection programme and structural maitnenance 1

Asset on a Page

Current Asset: J1

Printed On: 2/22/2012
~/Images/asset_25.jpg
Asset Information
Asset Criticality Rating: 325 
Age: 29  years
Economic Life Remaining: 20  years
Outloading Rate: 0  tph

Conveyor Information
N/A

Component Sub Component Condition Issue Action
Electrical Cathodic Protection System Healthy
Structural Integrity Headstocks Unhealthy Corrosion Spot repair program to be completed by June 2014
Piles Unhealthy Corrosion Spot repair program to be completed by June 2014
Roadway Poor Concrete cracking Longitudinal cracks in soffit to be inspected by December 2012.
Availability Click here to view big chart
Asset Costs Click here to view big chart
Risks
Risk Mitigation Treated Risk Score
Collapse due to Crane overloading Procedure for the application of Live Loads, Inspections, Supervision, Work Permit system, Lift Load Plans and Work Method Statements 3
Partial Structural Collapse due to Corrosion Inspections, Corrosion Protection Program, Structural Maintenance, Cathodic Protection 1

Asset on a Page

Current Asset: J2

Printed On: 2/22/2012
~/Images/asset_26.jpg
Asset Information
Asset Criticality Rating: 325 
Age: 3  years
Economic Life Remaining: 46  years
Outloading Rate: 0  tph

Conveyor Information
N/A

Component Sub Component Condition Issue Action
Electrical Cathodic Protection System Healthy
Structural Integrity Headstocks Healthy
Piles Healthy
Roadway Healthy
Availability Click here to view big chart
Asset Costs Click here to view big chart
Risks
Risk Mitigation Treated Risk Score
Collapse due to Crane overloading Procedure for the application of Live Loads, Inspections, Supervision, Work Permit system, Lift Load Plans and Work Method Statements 3
Partial Structural Collapse due to Corrosion Inspections, Corrosion Protection Program, Structural Maintenance, Cathodic Protection 1

Asset on a Page

Current Asset: OL1

Printed On: 2/22/2012
~/Images/asset_22.jpg
Asset Information
Asset Criticality Rating: 346 
Age: 29  years
Economic Life Remaining: 20  years
Outloading Rate: 7200  tph

Conveyor Information
L1 / L3 / SB1 / SP1 / L5 / BF5 / BF7

Component Sub Component Condition Issue Action
Electrical Sample Plant Electrical Healthy
Substation Healthy
Conveyor Electrical / Control Healthy
Conveyor Drives Healthy
Surge Bin Instrumentation / Control Healthy
Mechanical Conveyor Drives Healthy
Structural Integrity L5 Galleries Poor Localised corrosion in critical areas Ongoing spot repairs required on top chords to prevent loss of stability by March 2012.
L1 Tower Healthy
Surge bin 1 Unhealthy Corrosion Coating spot repairs required by October 2012.
L3 Conveyor Unhealthy Localised advanced corrosion on all roof support structure Gallery coating repairs scheduled to align with ongoing SL1 Shutdowns to June 2014
L1 Conveyor Unhealthy Localised corrosion in non critical areas on roof supports Advanced corrosion on the L1 Tripper section Tripper section structural repairs complete by December 2011 and coating repairs scheduled August 2012
Reliability Click here to view big chart
Rate Click here to view big chart
Availability Click here to view big chart
Asset Costs Click here to view big chart
Risks
Risk Mitigation Treated Risk Score
Conveyor belt fire due to hot work, coal carry back, belt misalignment, idler/pulley/wash roller failure Inspections, Hot work permit system in place, belt cleaning systems installed and maintained, condition monitoring, fire fighting equipment training, fire supression in drive towers 19
To Production or Corporate Reputation as a result of Belt Tear Inspections on Belt, idler and pulley Condition regularly undertaken, Magnets, Metal Detector and Belt Rip detection, Belt Loop Detection, full length spares except L5 9
Partial structural collapse of L5 Inspections, Corrosion protection programme, structural maintenance, Dissmilar metal study 5
Partial structural collapse of Surge Bin 1 Inspections, corrosion protection program, bollards, structural maintenance 3

Asset on a Page

Current Asset: OL2

Printed On: 2/22/2012
~/Images/asset_23.jpg
Asset Information
Asset Criticality Rating: 346 
Age: 12  years
Economic Life Remaining: 37  years
Outloading Rate: 7600  tph

Conveyor Information
L2 / L4 / SB2 / SP2 / L6A / L6 / BF6 / BF8

Component Sub Component Condition Issue Action
Electrical Conveyor Electrical / Control Healthy
Sample Plant Electrical Healthy
Conveyor Drives Healthy
Surge Bin Instrumentation / Control Healthy
Substation Healthy
Mechanical Conveyor Drives Healthy
Structural Integrity L6 Conveyor Unhealthy Gallery bottom cords isolated area of advanced corrosion Coating Repairs scheduled to be completd by June 2012
Surge bin 2 Unhealthy Corrosion / perforated structural members Repair steelwork and repair coatings by December 2012.
L6A Conveyor Unhealthy Corrosion Repair coatings by July 2013.
L4 Conveyor Poor Corrosion Repair conveyor gallery hangers by April 2012. Repair coatings by July 2013.
L2 Tower Healthy
L2 Conveyor Unhealthy Localised corrosion in non critical areas on roof supports and L1 Tripper section Tripper coating repairs scheduled to align with next SL2 shutdown scheduled before June 2012
Reliability Click here to view big chart
Rate Click here to view big chart
Availability Click here to view big chart
Asset Costs Click here to view big chart
Risks
Risk Mitigation Treated Risk Score
Conveyor belt fire due to hot work, coal carry back, beltr misalignment, idler/pulley/wash roller failure Inspections, Hot work permit system in place, belt cleaning systems installed and maintained, condition monitoring, fire fighting equipment training, fire supression in drive towers 19
To Production or Corporate Reputation as a result of Belt Tear Inspections on Belt, idler and pulley Condition regularly undertaken, Magnets, Metal Detector and Belt Rip detection, Belt Loop detection, Full Length Spares except L6 9
Partial structural collapse of Surge Bin 2 Inspections, corrosion protection program, bollards, structural maintenance 3
Partial structural collapse of L6 Inspections, corrosion protection programme, structural maintenance, Dissmilar metal study 1

Asset on a Page

Current Asset: OL3

Printed On: 2/22/2012
~/Images/asset_24.jpg
Asset Information
Asset Criticality Rating: 346 
Age: 3  years
Economic Life Remaining: 46  years
Outloading Rate: 8650  tph

Conveyor Information
L11 / L11A / L13 / SB3 / SP3 / L15A / L15 / BF15 / BF17

Component Sub Component Condition Issue Action
Electrical Substation Healthy
Surge Bin Instrumentation / Control Healthy
Conveyor Electrical / Control Healthy
Sample Plant Electrical Healthy
Conveyor Drives Healthy
Mechanical Conveyor Drives Healthy
Structural Integrity L13 Conveyor Healthy
L15 Conveyor Unhealthy Galvanic Corrosion Spot Repair December 2013
L15A Conveyor Healthy
L11A Conveyor Healthy
L11/11A tower Healthy
L15A Tower Healthy
L11 Conveyor Healthy
Reliability Click here to view big chart
Rate Click here to view big chart
Availability Click here to view big chart
Asset Costs Click here to view big chart
Risks
Risk Mitigation Treated Risk Score
Conveyor belt fire due to hot work, coal carry back, beltr misalignment, idler/pulley/wash roller failure Inspections, Hot work permit system in place, belt cleaning systems installed and maintained, condition monitoring, fire fighting equipment training, fire supression in drive towers 19
To Production or Corporate Reputation as a result of Belt Tear Inspections on Belt, idler and pulley Condition regularly undertaken, Magnets, Metal Detector and Belt Rip detection, belt loop detection and full length spares (except L15) 9
Partial structural collapse Inspections, corrosion protection programme, structural maintenance, Dissmilar metal study 2

Asset on a Page

Current Asset: RL1

Printed On: 2/22/2012
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Asset Information
Asset Criticality Rating: 268 
Age: 5  years
Economic Life Remaining: 24  years
Reclaim Rate: 5300  tph

Conveyor Information
Yard Conveyor: R1

Component Sub Component Condition Issue Action
Electrical 415V MCC Healthy
11kV Transformer Healthy
Electric Motors Healthy
VVVF Drives Healthy
Yard Conveyor Electrical Unhealthy Ageing field devices and enclosures etc On condition replacement of ageing equipment.
PLC and Control Systems Healthy
11kV Trailing Cable Healthy
Mechanical Elevator Conveyor Drives Healthy
Boom Conveyor Drives Healthy
Bucket Wheel Drives Healthy
Bogies Healthy
Luff Hydraulics Healthy
Tripper Healthy
Slew bearing Healthy
Yard Conveyor Drives Healthy
Structural Integrity Slew Unhealthy Coating failures Spot repairs by January 2013.
Portal Unhealthy Coating failures on reeler platform. Spot repairs by January 2013.
Boom Unhealthy Galvanic corrosion on boom lower chord. Coating failures. Redesign spill tray mounts and repair boom by July 2013. Spot repairs by January 2013.
Mast, Rocker, Suspension and Rods Unhealthy Coating failures Spot repairs by January 2013.
Bogies / Equalisers Healthy
CW Boom Unhealthy Coating failures Spot repairs by January 2013.
Ropes Healthy
Reliability Click here to view big chart
Rate Click here to view big chart
Availability Click here to view big chart
Asset Costs Click here to view big chart
Risks
Risk Mitigation Treated Risk Score
Yard Machine Collapses due to structural fatigue, corrosion or critical component failure Structural integrity checks,critical settings programme, preventative maintenance inspections, corrosion protection programme. 14
Yard Machine Fire caused by coal build up, housekeeping, hot work, conveyor idlers/pulleys/washrollers overheating, damaged electircal cable, electrical system overload, earth leakage, smoking, electrical component failure Earth leakage, overload and trip switch protection, MCC design, housekeeping audits,Fire alarms, fire suppression in substations, preventative maintenance programme, hot work system in place, condition monitoring, lubrication schedules in place, fire fighting equipment training, skirts/scrapers installed and maintained to minimise coal spillage 9
To Production or Corporate Reputation as a result of Equipment Damage due to Belt Tearing Inspections on Belt Condition, Full Length Spares and Belt Rip Detection 5
Yard machine collision SIL 2 rated Anti-collision Collision avoidance system installed and maintained, software change management system in place, trained and competent operators and maintainers. 3
Uncontrolled movement caused by High Wind Events Rail clamps, Long Travel Brakes, Wind monitoring, Buffers, PMs on Controls 3

Asset on a Page

Current Asset: RL2

Printed On: 2/22/2012
~/Images/asset_15.jpg
Asset Information
Asset Criticality Rating: 267 
Age: 12  years
Economic Life Remaining: 17  years
Reclaim Rate: 5500  tph

Conveyor Information
Yard Conveyor: R7

Component Sub Component Condition Issue Action
Electrical 11kV Trailing Cable Healthy
VVVF Drives Healthy
11kV Transformer Healthy
415V MCC Healthy
Conveyor Electrical / Control Healthy
PLC and Control Systems Healthy
Electric Motors Healthy
Mechanical Bucket Wheel Drives Healthy
Boom Conveyor Drives Healthy
Elevator Conveyor Drives Healthy
Bogies Healthy
Tripper Healthy
Luff Hydraulics Healthy
Slew bearing Healthy
Yard Conveyor Drives Healthy
Structural Integrity Slew Unhealthy Coating failures Spot repairs by July 2013.
Bogies / Equalisers Healthy
Boom Unhealthy Coating failures Spot repairs by January 2013.
L-Frame Unhealthy Coating failures Spot repairs by July 2013.
Portal Healthy
CW Boom Unhealthy Coating failures on boom. Spot repairs by January 2013.
Stays Unhealthy Coating failures on rear stays Spot repairs by January 2013.
Reliability Click here to view big chart
Rate Click here to view big chart
Availability Click here to view big chart
Asset Costs Click here to view big chart
Risks
Risk Mitigation Treated Risk Score
Yard Machine Collapses due to structural fatigue, corrosion or critical component failure Structural integrity checks,critical settings programme, preventative maintenance inspections, corrosion protection programme. 14
Yard Machine Fire caused by coal build up, housekeeping, hot work, conveyor idlers/pulleys/washrollers overheating, damaged electircal cable, electrical system overload, earth leakage, smoking, electrical component failure Yard Machine Fire caused by coal build up, housekeeping, hot work, conveyor idlers/pulleys/washrollers overheating, damaged electircal cable, electrical system overload, earth leakage, smoking, electrical component failure 9
To Production or Corporate Reputation as a result of Equipment Damage due to Belt Tearing Inspections on Belt Condition, Full Length Spares and Belt Rip Detection 5
Yard machine collision SIL 2 rated Anti-collision Collision avoidance system installed and maintained, software change management system in place, trained and competent operators and maintainers 3
Uncontrolled movement caused by High Wind Events Rail clamps, Long Travel Brakes, Wind monitoring, Buffers, PMs on Controls 3

Asset on a Page

Current Asset: RRP1

Printed On: 2/22/2012
~/Images/asset_16.JPG
Asset Information
Asset Criticality Rating: 253 
Age: 29  years
Economic Life Remaining: 20  years
Unloading Rate: 5500  tph

Conveyor Information
C1

Component Sub Component Condition Issue Action
Electrical Substation Healthy obtained by December 2013.
Trigger / Hopper Instrumentation Unhealthy Ageing field devices and enclosures etc. Certification to hazardous areas standard required on some electrical equipment. On condition replacement of ageing equipment and certification
Dust Prevention Healthy
Wagon Vibrator Healthy
Conveyor Electrical Healthy
Magnet Healthy
Mechanical Conveyor Drives Healthy
Structural Integrity Rail Girders Unhealthy Corrosion Spot Repair June 2013
C1 Conveyor Healthy
Below rail line Hoppers & Feeders Unhealthy Localised corrosion rail Girders critical structure Spot Repair June 2013
RRP1 Building above rail line Healthy
Reliability Click here to view big chart
Rate Click here to view big chart
Availability Click here to view big chart
Asset Costs Click here to view big chart
Risks
Risk Mitigation Treated Risk Score
Conveyor belt fire due to hot work, coal carry back, belt misalignment, idler/pulley/wash roller overheating, electrical overload, electrical fault Earth leakage protection, trip switches and overload protection, preventative maintenance programme, hot work system in place, fire fighting equipment training, belt rip detection, condition monitoring, belt cleaning systems installed and maintained. 14
To Production or Corporate Reputation as a result of Belt Tear Inspections on Belt Condition regularly undertaken,RR Grizzlies, Full length Spares, and Belt Rip detection 9
Flooding due to inundation Pumps selection, Pit Design, Drainage realignment, High Level water alarm 5
Rail Beam Failure due to structural collapse as a result of structural deterioration 6 monthly inspections and a Corrosion Protection Program. Modify Rail Beam end. 1

Asset on a Page

Current Asset: RRP2

Printed On: 2/22/2012
~/Images/asset_17.JPG
Asset Information
Asset Criticality Rating: 247 
Age: 15  years
Economic Life Remaining: 34  years
Unloading Rate: 5500  tph

Conveyor Information
C2

Component Sub Component Condition Issue Action
Electrical Magnet Healthy
Substation Healthy
Trigger / Hopper Instrumentation Unhealthy Ageing field devices and enclosures etc. Controlability issues in hopper On condition replacement of ageing equipment.
Dust Prevention Unhealthy Ageing field devices and enclosures etc. On condition replacement of ageing equipment.
Wagon Vibrator Healthy
Conveyor Electrical Healthy
Mechanical Conveyor Drives Healthy
Structural Integrity Rail Girders Poor Fatigue cracks on beam end seal plates Increase testing frequency to 6 monthly and repair rail beam ends by December 2012.
RRP2 Building above rail line Healthy
C2 Conveyor Healthy
Below rail line Hoppers & Feeders Healthy
Reliability Click here to view big chart
Rate Click here to view big chart
Availability Click here to view big chart
Asset Costs Click here to view big chart
Risks
Risk Mitigation Treated Risk Score
Conveyor belt fire due to hot work, coal carry back, belt misalignment, idler/pulley/wash roller overheating, electrical overload, electrical fault Earth leakage protection, trip switches and overload protection, preventative maintenance programme, hot work system in place, fire fighting equipment training, belt rip detection, condition monitoring, belt cleaning systems installed and maintained. 14
To Production or Corporate Reputation as a result of Belt Tear Inspections on Belt Condition regularly undertaken,RR Grizzlies, Full length Spares, and Belt Rip detection 9
Flooding due to inundation Pumps selection, Pit Design, Drainage realignment, High Level water alarm 5
Rail Beam Failure due to structural collapse as a result of structural deterioration 6 monthly inspections and a Corrosion Protection Program 1

Asset on a Page

Current Asset: RRP3

Printed On: 2/22/2012
~/Images/asset_18.JPG
Asset Information
Asset Criticality Rating: 247 
Age: 3  years
Economic Life Remaining: 46  years
Unloading Rate: 7500  tph

Conveyor Information
BF11

Component Sub Component Condition Issue Action
Electrical Trigger / Hopper Instrumentation Healthy
Wagon Vibrator Healthy
Conveyor Electrical Healthy
Dust Prevention Unhealthy Exhaust fans creating issues during start up Installation of soft start/variable speed drive or similar by July 2014.
Magnet Healthy
Substation Healthy
Mechanical Conveyor Drives Healthy
Structural Integrity RRP3 Building above rail line Healthy
Rail Girders Healthy
Below rail line Hoppers Belt Feeder BF11 Healthy
Reliability Click here to view big chart
Rate Click here to view big chart
Availability Click here to view big chart
Asset Costs Click here to view big chart
Risks
Risk Mitigation Treated Risk Score
Conveyor belt fire due to hot work, coal carry back, belt misalignment, idler/pulley/wash roller overheating, electrical overload, electrical fault Earth leakage protection, trip switches and overload protection, preventative maintenance programme, hot work system in place, fire fighting equipment training, belt rip detection, condition monitoring, belt cleaning systems installed and maintained. 14
To Production or Corporate Reputation as a result of Belt Tear Inspections on Belt Condition regularly undertaken,RR Grizzlies, Full length Spares, and Belt Rip detection 9
Flooding due to inundation Pumps selection, Pit Design, Drainage realignment, High Level water alarm 5
Rail Beam Failure due to structural collapse as a result of structural deterioration 6 monthly inspections and a Corrosion Protection Program. Modify Rail Beam end. 1

Asset on a Page

Current Asset: SL1

Printed On: 2/22/2012
~/Images/asset_7.jpg
Asset Information
Asset Criticality Rating: 324 
Age: 29  years
Economic Life Remaining: 10  years
Load Rate: 7200  tph

Conveyor Information
L7 / L9

Component Sub Component Condition Issue Action
Electrical PLC and Control Systems Healthy
3.3kV Trailing Cable Healthy
3.3kV Transformer Healthy Transformer in serviceable condition, although gas filled insulation no longer supported resulting in de-rating of transformer if overhaul or repair was required Transformer overhaul eventually required
Electric Motors Healthy
VVVF Drives Healthy
415V MCC Unhealthy Old switchboard with insulation breakdown identifed in areas. Ageing switchgear and controls. Assessment of switchboard to determine priority by December 2013.
Mechanical SL1 Boom Drive Healthy
L7 Drive Healthy
Luff Rope Winch Drive Healthy
Shuttle Winch Drive Healthy
Structural Integrity A-Frame Unhealthy Coating failures Spot Repair by July 2013
L7 Tripper Poor Cracks in Stair Support Coating failures Repair by November 2011 Spot Repair by July 2012
Winch Deck Unhealthy Severe Corrosion Spot Repair by January 2013
Drive Floor Unhealthy Coating failures Spot Repair by July 2012
L9 Conveyor Unhealthy Coating failures Spot Repair by July 2012
Boom Unhealthy Corrosion Spot Repair by October 2012
Mast / Backstay Poor Severe Corrosion Spot Repair by January 2012
Bogies / Equalisers Healthy
Reliability Click here to view big chart
Rate Click here to view big chart
Availability Click here to view big chart
Asset Costs Click here to view big chart
Risks
Risk Mitigation Treated Risk Score
Shiploader Collapses due to structural fatigue, corrosion or critical component failure Structural integrity checks,critical settings programme, preventative maintenance inspections, corrosion protection programme. 14
Shiploader Fire caused by coal build up, housekeeping, hot work, conveyor idlers/pulleys/washrollers overheating, damaged electircal cable, electrical system overload, earth leakage, smoking, electrical component failure Earth leakage, overload and trip switch protection, MCC design, housekeeping audits,Fire alarms, fire suppression in substations, preventative maintenance programme, hot work system in place, condition monitoring, lubrication schedules in place, fire fighting equipment training, skirts/scrapers installed and maintained to minimise coal spillage, fire suppression on Ship loader booms 14
Shiploader collides with shiploader collision avoidance, trained and competent operators 10
To Production or Corporate Reputation as a result of Belt Tear Inspections on Belt Condition regularly undertaken,Magnets, Metal Detector, Full length Spares, and Belt Rip detection 9
Uncontrolled movement caused by High Wind Events Rail clamps, Long Travel Brakes, Wind monitoring, Buffers, PMs on Controls 3

Asset on a Page

Current Asset: SL2

Printed On: 2/22/2012
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Asset Information
Asset Criticality Rating: 318 
Age: 13  years
Economic Life Remaining: 26  years
Load Rate: 7600  tph

Conveyor Information
L8 / L10

Component Sub Component Condition Issue Action
Electrical 3.3kV Transformer Healthy
3.3kV Trailing Cable Healthy
VVVF Drives Healthy
415V MCC Healthy
PLC and Control Systems Healthy
Electric Motors Healthy
Mechanical Luff Rope Winch Drive Healthy
SL2 Boom Drive Healthy
L8 Drive Healthy
Shuttle Winch Drive Healthy
Structural Integrity Winch Deck Unhealthy Corrosion Spot repairs by December 2013
Bogies / Equalisers Healthy
Drive Floor Unhealthy Corrosion Spot repairs by December 2014
Boom / Shuttle Poor Corrosion excessive from Inspect and repair by December 2011
L10 Conveyor Healthy
L8 Tripper Healthy
A-Frame Unhealthy Localised corrosion Inspect and repair by December 2013
Mast / Backstay Poor Localised corrosion Inspect and repair by June 2012
Reliability Click here to view big chart
Rate Click here to view big chart
Availability Click here to view big chart
Asset Costs Click here to view big chart
Risks
Risk Mitigation Treated Risk Score
Shiploader Collapses due to structural fatigue, corrosion or critical component failure Structural integrity checks,critical settings programme, preventative maintenance inspections, corrosion protection programme. 14
Shiploader Fire caused by coal build up, housekeeping, hot work, conveyor idlers/pulleys/washrollers overheating, damaged electircal cable, electrical system overload, earth leakage, smoking, electrical component failure Earth leakage, overload and trip switch protection, MCC design, housekeeping audits,Fire alarms, fire suppression in substations, preventative maintenance programme, hot work system in place, condition monitoring, lubrication schedules in place, fire fighting equipment training, skirts/scrapers installed and maintained to minimise coal spillage, fire suppression on Ship loader booms 14
Shiploader collides with shiploader collision avoidance, trained and competent operators 10
To Production or Corporate Reputation as a result of Belt Tear Inspections on Belt Condition regularly undertaken,Magnets, Metal Detector, Full length Spares, and Belt Rip detection 9
Uncontrolled movement caused by High Wind Events Rail clamps, Long Travel Brakes, Wind monitoring, Buffers, PMs on Controls 3

Asset on a Page

Current Asset: SL3

Printed On: 2/22/2012
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Asset Information
Asset Criticality Rating: 324 
Age: 8  years
Economic Life Remaining: 31  years
Load Rate: 8650  tph

Conveyor Information
L17 / L19

Component Sub Component Condition Issue Action
Electrical PLC and Control Systems Healthy
VVVF Drives Healthy
3.3kV Trailing Cable Healthy
3.3kV Transformer Healthy
415V MCC Healthy
Electric Motors Healthy
Mechanical L17 Drive Healthy
Shuttle Winch Drive Healthy
Luff Rope Winch Drive Healthy
SL3 Boom Drive Healthy
Structural Integrity A-Frame Unhealthy Corrosion Coating repair by December 2012.
Winch Deck Unhealthy Corrosion Coating repair by December 2012.
Bogies / Equalisers Unhealthy Corrosion Coating repair by December 2012.
Mast / Backstay Poor Corrosion Coating repair with particular attention to masthead to backstay welds by April 2012.
L17 Tripper Unhealthy Corrosion Coating repair by December 2012.
Drive Floor Unhealthy Corrosion Coating repair by December 2012.
L19 Conveyor Healthy
Boom Poor Luffing ropes close to fatigue limit. Corrosion Increased monitoring freq to monthly visual and plan to change when valley breaks are detected. Coating repairs by October 2012.
Reliability Click here to view big chart
Rate Click here to view big chart
Availability Click here to view big chart
Asset Costs Click here to view big chart
Risks
Risk Mitigation Treated Risk Score
Shiploader Collapses due to structural fatigue, corrosion or critical component failure Structural integrity checks,critical settings programme, preventative maintenance inspections, corrosion protection programme. 14
Shiploader Fire caused by coal build up, housekeeping, hot work, conveyor idlers/pulleys/washrollers overheating, damaged electircal cable, electrical system overload, earth leakage, smoking, electrical component failure Earth leakage, overload and trip switch protection, MCC design, housekeeping audits,Fire alarms, fire suppression in substations, preventative maintenance programme, hot work system in place, condition monitoring, lubrication schedules in place, fire fighting equipment training, skirts/scrapers installed and maintained to minimise coal spillage, fire suppression on Ship loader booms 14
To Production or Corporate Reputation as a result of Belt Tear Inspections on Belt Condition regularly undertaken,Magnets, Metal Detector, Full length Spares, and Belt Rip detection 9
The risk of Structural Collapse as a result of Corrosion on the Boom / Mast / Back Stay Regular inspections, 04-05 Design Audit and Corrosion Protection Program, and address the specific corrosion in the Boom, Mast and Back Stay as well as address the corrosion issues identified. 3
Uncontrolled movement caused by High Wind Events Rail clamps, Long Travel Brakes, Wind monitoring, Buffers, PMs on Controls 3

Asset on a Page

Current Asset: SR1

Printed On: 2/22/2012
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Asset Information
Asset Criticality Rating: 289 
Age: 29  years
Economic Life Remaining: 0  years
Stack Rate: 4520  tph
Reclaim Rate: 3700  tph

Conveyor Information
Yard Conveyor: R2

Component Sub Component Condition Issue Action
Electrical Electric Motors Healthy Motors serviceable. DC motors no longer available. Relying on repaired/overhauled motors
Yard Conveyor Electrical Unhealthy Ageing field devices and enclosures etc On condition replacement of ageing equipment.
VVVF Drives Unhealthy Old technology. Drives are DC. Not in line with current DBCT standard Replace machine by 2013.
PLC and Control Systems Healthy 30 year old technology, although integrated into current control system Replace machine by 2013.
415V MCC Unhealthy Old switchboard with insulation breakdown identifed in areas. Replace machine by 2013.
11kV Trailing Cable Healthy
11kV Transformer Unhealthy Transformer in serviceable condition, although gas filled insulation no longer supported resulting in de-rating of transformer if overhaul or repair was required Replace machine by 2013.
Mechanical Bucket Wheel Drives Healthy
Boom Conveyor Drives Healthy