Ausenco assumed responsibility of the operations and maintenance of the Isaac Plains Coal Handling and Preparation Plant (CHPP) in 2008 from an existing provider, taking on full responsibility from Run Of Mine (ROM) to train load out.
In order to commence operation of the plant Ausenco firstly had to finalise commissioning of the CHPP. During this process we identified a number of bottlenecks which prevented the plant from reaching its design capacity and anticipated production targets. A design review revealed that the crusher equipment was undersized resulting in frequent break downs. The operations and maintenance team assisted with the upgrade of the secondary sizer, allowing name plate throughput to be achieved in terms of tonnes per hour and equipment availability.
In addition, the operations and maintenance team identified performance issues with the teetered bed separator and subsequent modification to the teetered bed separator resulted in 2% yield improvement. Within six months from commencement we achieved full name plate production for the entire plant.
This enabled us to convert from a cost plus to a fixed/variable cost per tonne contract arrangement linked to key performance indicators within 12 months of operation. As part of our continuous improvement program Ausenco Rylson was engaged to conduct an asset management audit.
The intent of the audit was to review existing maintenance systems, processes and practices, identify gaps against established industry benchmarks and ascertain improvement opportunities.
As a result of this audit, we implemented a revised labour model, supply agreements and maintenance regime through which we helped IPCM attain an increased return on capital expended by achieving over 24% reduction in Operations and Maintenance services cost per tonne, with no negative impact on plant performance.
The audit focused on three key areas, Maintenance Strategy, Work Management System, including planning and scheduling, and Cost Management, with the resulting improvements outlined below.
Work Management System (WMS), including planning and scheduling
Continued optimisation of the maintenance strategy in the Rylson8* software has resulted in the maintenance cost reductions for budgeted maintenance activities.