At the time of engagement, AMOG's client, the operator, conducted machine inspections on their fleet of bulk ore handling machines using fixed schedules, regardless of machine age or utilisation.

AMOG were engaged to conduct a program to redefine the fixed schedule inspection strategy to a Risk Based Inspection (RBI) strategy.

This was base on the criticality of structural regions and systems with potential to cause major damage (e.g. machine collapse), significant loss of production, or impact safety systems.

The RBI program was tailored to complement existing processes for:

  • Asset management
  • Functional safety management of C&I safety systems

The RBI program included machines of all ages, significantly different utilisation, 9 different OEMs, and designed to different industry codes.

Existing processes were also reviewed and updated to incorporate lessons learned from the RBI program. This included learning for procurement of new machines.

Risk Management Program (RMP) redesign to improve the management of critical rail-mounted machine assets:

  • Definition of legislative obligations for machine inspection
  • Development of procedures and templates for redesigned RMP program
  • FMECA – to define critical structural, mechanical and E&CI systems to prevent machine collapse

Structural analysis:

  • Redefine machine utilisation based upon actual operational profile (not assumed loads and combinations from AS4324)
  • Report detailed utilisation for strength, fatigue and buckling for entire structure (not just 20 worst locations, as per design assessments)

Define Risk Based Inspection (RBI) specification:

  • Derive RBI intervals of where, how and when to inspect to keep risk of failure 
  • Define reporting requirements and tolerable thresholds for damage on the machine

Inspection findings (no detected defects) are used to focus future inspections and extend future inspection intervals by providing feedback on uncertainties in fatigue damage predictions.

Key outcomes

Understanding of key degradation mechanisms and credible failure modes (trial inspections identified damage to machines in previously un-inspected regions)

Cost benefit comparison of inspection techniques and strategies related directly to risk profile and machine integrity

Understanding key degradation driver in machine settings and operation, based on regional breakdown of the structure

Reduced machine downtime for maintenance and reduced cost of inspection program

Further Outcomes

Identification of critical controls for managing machine integrity

Improved management of machine use, damage, operation to end of design life, and enhanced ability for life extension

Extrapolation of RBI specification to fleet of similar machines, tailored to machine utilisation