To allay the customer’s concerns and ensure the lowest possible risk of overrunning on plant shutdown, FLSmidth engineers took a proactive approach – to complete as much work as possible in advance of the shutdown and to perform visual inspections of all components, non-destructive testing of critical components, preassembly of components and measurement of the bucket wheel run out all at the Perth Supercenter.
“The key to reducing risk in any plant shutdown, is to complete as much as possible in advance, in a controlled workshop environment”
In meeting the customer requirements, FLSmidth’s ability to complete inhouse engineering work to design and assess a support structure for the assembly of the components was a big advantage. All work was completed inhouse by FLSmidth apart from the fabrication of the frame, outsourced to MPI Engineering and specialist assembly work on the bearings which was completed by SKF on our behalf. In this way, we ensured that a high-quality solution could be delivered.
After we proposed the full solution and the industry norms for assessment of the bucket wheel, everything was managed and delivered locally. The delivery included: mechanical design, structural assessment and certification, fabrication (outsourced), visual inspection, non-destructive testing, weld repair and painting, assembly, measurement and analysis, disassembly and package for return delivery. Assembly to the reclaimer on the customer site has now been successfully completed.
Regular communication between the customer and FLSmidth and tight collaboration between product line management, regional engineering, site services, the workshop team and sub suppliers resulted in the entire process taking approximately 16 weeks from the customer agreement date.