1. PORT KEMBLA COAL TEMINAL
Priority Structural Repairs
Chris Hadenham and Joe Jones

2. Background
30 year old machines approaching the end of their design life.
Extremely corrosive environment due to proximity to surf.
Poor condition of rails.
Significant safety and operational risk to posed by poor overall condition of machines.
Largely unknown level of risk exposure due to lack of regular inspection regime.
PKCT – Priority Structural Repairs

3. Assessment Process AUSTECH Structural Inspection Report
Annual machine inspections.
Itemised list of structural defects across the machines.
ASPEC Risk Assessment
High level risk assessment of all items raised by AUSTECH.
Prioritisation of repairs based on risk.
Scoping of repair works.
On-Site Repair Execution
Project / construction management by PPM.
Detailed engineering support by ASPEC (site instructions, FEA, etc.).
Further information from inspections and NDT.
PKCT – Priority Structural Repairs

4. RISK ASSESSMENT MATRIX
Yard Machines – Risk Profile
RISK ASSESSMENT MATRIX
Consequence 1 2 3 4 5
Likelihood
Low
Moderate
High
Extreme
PKCT – Priority Structural Repairs

5. Notable Cracks Identified
RC1
Pantograph bracing.
Anti-skew bracket.
BW boom hinge.
ST1
Gantry equaliser.
Gantry leg
ST2
Gantry leg
ST4
SL2
Landside equaliser
SL1
SL2
RC2
RC1
ST1
ST2
ST4
PKCT – Priority Structural Repairs

6. RC1 Pantograph Bracing
Analysis identified high likelihood of fatigue cracking in a number of areas leading to site investigation and NDT.
Cracking found in two locations on RC1.
3 day shutdown required to replace gussets.
Shutdown also on RC2 to perform inspection.
200mm Crack on one side
Crack initiating on the other side
PKCT – Priority Structural Repairs

7. RC1 Front Portal Leg Anti-Skew Bracket Cracks
Issue identified in by AUSTECH during inspection.
Cracking confirmed by NDT.
Cracks ‘gouged’ and repaired.
Poor condition of rails considered likely cause of cracking in anti-skew bracket.
PKCT – Priority Structural Repairs

8. RC1 Bucket Wheel Boom Hinge Cracked Weld
Heavy corrosion identified in end of equaliser by AUSTECH during inspection.
Area was cleaned and NDT requested due to identification of possible cracks.
Extent of cracking confirmed with NDT.
Cracks ‘gouged’ and repaired.
Poor execution of weld considered likely cause of cracking.
PKCT – Priority Structural Repairs

9. ST1 Main Gantry Equaliser Cracks
Cracks identified in end of equaliser by AUSTECH during annual inspection.
Additional NDT located fatigue cracking in bottom flange in two locations.
Cracks ‘gouged’ and repaired as temporary measure to return machine to service.
Equaliser replaced as a priority.
ST2 and ST4 inspected for similar damage.
Poor condition of rails and pins considered likely cause of fatigue in bottom flange.
PKCT – Priority Structural Repairs

10. ST1 Main Gantry Equaliser Cracks
PKCT – Priority Structural Repairs

11. ST1, ST2 and ST4 Gantry Leg Cracks
Cracks identified in ST4 Main Gantry leg by AUSTECH during annual inspection.
Additional NDT located fatigue cracking on ST2 and ST4 main gantry legs.
Weld detail: ‘CFW all-round’ not ‘FPBW’.
Cracks ‘gouged’ and repaired.
Portal accessed to review condition of weld from inside.
Poor weld detail and condition of rails considered likely cause of fatigue cracks.
PKCT – Priority Structural Repairs

12. SL2 Landside Equaliser Cracks
Cracks identified in SL2 Landside equaliser diaphragm by AUSTECH during annual inspection.
Design documentation has 5mm gap between diaphragm and bottom flange.
Weld of diaphragm to bottom flange appears to have occurred after construction.
Repair and investigation ongoing.
PKCT – Priority Structural Repairs