coal sampling seminar - mt arthur cpp audit€¦ · –learning: ensure all samplers are aware of...

Coal Sampling Seminar - Mt Arthur CPP AuditRyan Seears

Overview•Full Plant Audit conducted of CPP in August 2018.

•Part of Identification Phase Study of CHPP requirements to meet Mt Arthur’s 5YP,purpose was validating previous Processing Capacity Assessment’s. This Study isbeing run by BHP Coal Projects (Brisbane Based).

•This presentation will cover aspects of the Preparation and Execution of this Auditwith Learnings shared.

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Coal Sampling Seminar - Mt Arthur PlantAudit25 October 2018

CPP Feed Sample – Automatic Sampler•Our automatic Sampler is on our Raw Coal stream,prior to the CPP Feed stockpile (CircularStacker/Reclaimer).

•This sampler has a Physical cutter, allowing anuncrushed sample to be taken in Auto by PLC.Changed Sampler PLC parameters to ensure sufficientsample taken to cover the ‘Audit’ feed material plussome material either side to allow for blendingcharacteristic of Circular Stockpile.– important to ensure blend was consistent for entire

shift (no coal type changes)– complexity of having 2 Raw streams of different

throughputs feeding the CPP

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CPP Feed Sample – Automatic Sampler

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• Initial plan was to feed an individual working section (some direct from pit, somerehandle from ROM) to allow for a comparison of some historical Borecore results–didn’t want 100% pit feed, as this may result in a coarser PSD than ‘typical’– in practice, not able to be achieved due to Production constraints

CPP Feed Sample – Stopped Belt

•Also took 2 stopped belt CPP Feed samples (post CPP Feed Stockpile)– One done at start of Audit, one done at end of Audit– will allow for a comparison of Raw Stream Automatic sampler and CPP feed

sizings, estimate comminution due to Stacking/Reclaimer

•Location Considerations:• flat spot close to discharge point of vibrating feeder after conveyor•access for 200L drums nearby (forklift) – chose Eastern side•Roof, guarding, safe access and egress

• Isolation competencies (only authorised Level 2 isolators for Group isolation)

•Tools used: 20L ‘transfer’ buckets, short handled shovel, dustpan and brush

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CPP Feed Sample – Stopped Belt

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CPP Feed Sample – Stopped Belt Sample

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•Used a Corflute sign. Cut to beltprofile prior to sample day.

•To minimise downtime and due tominimal space in which samplecould be taken, we took one largeincrement from the belt (~3m for~600L).

CPP Samples - AuditPreparation•Samples and Sample Analysis requirements formulated by Project team withconsultation with site– Learning: ask for advice and be specific regarding sample analysis

methodology, i.e. changed ours to minimise lab subsampling requirements

•Reviewed previous ‘ad-hoc’ sample analysis results to help estimate requiredsample masses for analysis requirements

•People (Samplers)–Decided to do all 3 modules at once over ~4 hours. Required 10 people.–Each sampler not required to go up/down floors, all samples on same floor–Distributed so each sampler took same sample in each of the 3 modules

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CPP Samples - Audit

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•Sample matrix in Excel used to accumulate relevant information in one spot

CPP Samples – Sample Locations•Some samples locations required pre-work.

–Spiral reject poly pipe cut - allow sample to be taken before mixed with TBS reject– Scaffolding setup on top of cyclone overflow, allow samples to be safely taken

from launders of overflow distributors with hatch up.

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CPP Samples – Sample Scoops•Some samples scoops needed to be fabricated and purchased

– Cyclone overflow sample scoops of sufficient length and width to fitinto overflow distributor between overflow pipes•Learning: small scoop opening size and the large sample volumerequired (~200L) for the cyclone overflow samples meant this sampletook a long time to collect (3 cyclone banks per module, 3 modules)

– Coarse sample scoops•Had some already, 250x250 to ensure 3 x largest particle. In practice,too heavy to safely use. Used some smaller ones from lab company.

•Borrowed some collapsible scoops from Bruce Atkinson, yet due todischarge chute grizzly’s, would not fit under discharge lip

•Learning: ‘try before you buy’ or take accurate measurements toensure sample scoops will be fit for purpose

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CPP Samples – Sample Scoops– Had to put 200L coarse sample drums on Northern side of plant as this is where

overhead crane can access. Hence required transferring of sample from a 20L‘transfer’ bucket to the 200L drum.

–Had an extra person purely allocated to this, the coarse samplers swappedaround for fatigue.

–Used same scoop for the same sample in each module, reduce overall # ofscoops required• i.e spiral reject scoop used for just spiral reject sample in all 3 modules•Placed buckets of water to clean scoops between modules•Ensured no potential cross contamination between samples or modules

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CPP Samples – Sample Scoops

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CPP Samples – Safety Considerations•Job Hazard Analysis risk assessment started with workgroup on themorning of the Audit and completed in field. Individual risk assessmentsalso performed by each sampler.– interaction with moving machinery (forklift)– work area cleanliness: slip/trip hazards when constantly walking from

one sample location to another– Strains/Manual handling: one bucket at a time, utilise gantry crane to

bring buckets out of plant, job rotation if necessary and sufficient breaks– Suspended loads: crane operator trained and authorised and procedure

followed– Pinch points – sampling tools– Safety steps required to safely collect some samples

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CPP Samples – Audit Execution•CPP stopped belt samples went very well, total feed off time only 30min

•Feed on and off CPP multiple times throughout audit day due to somereclaimer issues. Waited around 15min after each delay which extendedoverall time.–Learning: didn’t have enough radio’s for all Samplers, so it was

difficult/time consuming for co-ordinator to communicate that feed wasoff to everyone

•Module 1 had an Electrical issue ~1hr in to audit, was off for most ofshift. Got going towards end and seeing had resources necessary,discarded previous material and did ‘1hr of power’ with only it running –snapshot of CPP performance–Learning: plan audit with sufficient time to allow for things to go wrong

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CPP Samples - Audit•Due to finishing sampling later than planned, unable to getsample buckets out of plant on same day or even all labelled,hence kept all buckets in relevant locations so would not getmixed up.

•Labelling (stickers provided by lab company) then performednext day. Due to extended period (~4 days) before the samplescould be brought out of plant due to personnel cranecompetencies, many of the buckets (and hence labels) gotquite wet when pre-cleaning for upcoming shutdown occurred.–Learning: ensure have labels for lids and buckets–Learning/tip: check buckets and lids that fit! Had various

different brands of buckets with specific lids, so had tosegregate the types

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CPP Samples - Audit

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• Interaction with shutdown day 2 dayslater, only a limited # of ‘laydown’ areasfor overhead gantry crane on each floorin the CPP that were taken up bysamples–Learning: make relevant plans for

samples to be removed from plant assoon as practical after the Audit

CPP Samples - Audit•One of the samplers had to leave about 4 hours early due to somecommunications shortfalls, hence the co-ordinator had to take some samples–Learning: ensure all samplers are aware of time requirement–Learning: ensuring you have a co-ordinator is very important

•Historian was used to review relevant CPP parameters post audit (CorrectMedium SG’s, cyclone pressures etc)

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coal sampling seminar - mt arthur cpp audit€¦ · –learning: ensure all samplers are aware of...

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