Cape Lambert operations recently conducted a $1.75 million major shutdown of Car Dumper One’s primary crusher to change the concave liners and rebuild the spider assembly and apron feeder.
Planning and preparation for the shutdown started in November 2006, with a project manager appointed in February 2007 and a full-time planner in April 2007.
The specialised tooling to be used was structurally inspected, repaired and tested to ensure it met all Rio Tinto Iron Ore and national safety standards.
The expertise of Steve Palmer’s clean-up team in operating the 315 excavator made short work of the dump hopper clean out, completing the task ahead of schedule.
With the crusher shutdown split into five major components and additional work scheduled within the plant, a decision was made to refurbish the spider assembly off-site in Karratha. This decision proved to be safe, efficient and cost effective.
A major complication arose when, for the first time in the 35-year history of the crusher, the mantle was stuck in the crusher and could not be removed.
After brainstorming potential causes, the team successfully removed the mantle, along with some damaged components jammed on the shaft.
Repairs were made at the workshop and the mantle was successfully reinstated and has run without fault since.
Learnings had also been taken from other Rio Tinto Iron Ore sites and the new concave liners are now constructed from a harder-wearing material, which should extend their life and thus reduce future maintenance costs.
Most importantly, no serious injuries were sustained during the job.
This article was first published in Coastal News [September 2007, Issue No. 2] – Rio Tinto’s Coastal Division Newsletter.