Australian mining giant, Rio Tinto, conducted machine inspections on their fleet of bulk ore handling machines using fixed schedules and with limited guidance. Although thorough, this method can be time consuming and therefore very costly.

AMOG was engaged to provide assistance in the development of a framework for moving from fixed schedule inspections to Risk-Based Inspection (RBI) and then, using this guidance:

• Calculate inspection cycles, based on predicted failure points and fracture mechanics
• Interrogate FEA analysis to determine areas outside code compliance
• Migrate a rail mounted machine (REC3P) onto an RBI cycle
• Conduct a functional safety program on REC3P in parallel (including SIL verification)
• Establish critical components and identify current integrity and therefore risks associated with the Brochman 2 Crusher
• Develop the RBI program of the EII Car Dumper

AMOG's RBI strategy for Rio Tinto's rail mounted machines is estimated to have saved in the order of 50% of the direct costs of inspections, per machine, per year.