Inspection Report Partially Dismantled Stacker · PDF fileInspection Report Partially Dismantled Stacker Reclaimers ... The two stacker reclaimer machines were ... (Note on stacker

Inspection Report Partially Dismantled Stacker Reclaimers

Port of Iskenderun, Republic of Turkey

Tony Meadows

12‐14 March 2008

Inspection Report for the two ‘partly’ dismantled Stevens Adamson Stacker / Reclaimers at the Port of Iskenderun in the Republic of Turkey.

Site Inspection conducted 12‐13 March 2008.

Port of Iskenderun Inspection Report Page 1 Conducted by Tony Meadows Dated: 12-13 March 2008

Table of Contents

Introduction Scope and Purpose ................................................................................... 1 Inspection Team ........................................................................................ 1 History of the Machines ............................................................................. 2 Executive Summary ................................................................................... 2 Section 1 Completeness of the Machines and the State of Disassembly The Trailing Tripper Assembly ................................................................... 3 Central Chute Work, Bypass Conveyors & Impact Tables......................... 7 Base Frame & Slew Deck .......................................................................... 8 Slew Deck Mast ....................................................................................... 10 Stacking & Reclaiming Boom ................................................................... 13 Counter Weight Frame & Counter Weights ............................................. 18 Documentation ......................................................................................... 22 Miscellaneous Components ..................................................................... 22 Conclusions ............................................................................................. 22 Section 2 Reassembly and Recommissioning, Time & Costs Assumptions ............................................................................................ 23 Time and Cost Estimate Details ............................................................... 23 Section 3 Expected Remaining Service Life of Machines & Ongoing Maintenance Costs Remaining Service Life ............................................................................ 25 On going Maintenance Costs ................................................................... 25


INSPECTION REPORT

PARTIALLY DISMANTLED STACKER RECLAIMERS

REPORT BY TONY MEADOWS 12-14 MARCH 2008

Introduction

Scope and Purpose Laing O’Rourke was commissioned by TOHECO to carry out an inspection and provide a report on two partially dismantled stacker reclaimer machines currently in storage at the Port of Iskenderun. The scope and purpose of the site visit and inspection report is limited to the following. 1. Undertake visual survey to determine the completeness of the stacker reclaimer

machines and the state of disassembly. 2. Provide a budget estimate as to the time and cost to reassemble and

recommission the machines. 3. Provide a view as to the expected life of the machines after recommissioning,

plus an estimate of the ongoing maintenance costs.

Inspection Team Inspection of the machines was carried out at the Port of Iskenderun, Turkey on the 12th & 14th March 2008. The inspection was carried out by Tony Meadows of Laing O'Rourke Australia, . Assisting on the inspection were Mr Faruk Kaya, Area Manager for the Iskenderun Region for TOHECO .


History of the Machines The two stacker reclaimer machines were originally supplied new by Stephens Adamson in 1988 as part of the National Coal Supply Corporation a as CoalHandling Facility. A previous report, which was carried out in 2004 prior to disassembly, suggests that the machines worked continuously up until 2001 at which point the coal handling plant began to be progressively closed down with final closure in March 2002. The previous report also suggests that the machines were extremely under utilised during their time in operation, with annual operational hours per machine of: Stacking: 700 hours Reclaiming: 1200 hours The machines were dismantled thru August/September 2006 and subsequently shipped to the Port of Iskenderun in the Republic of Turkey, where they are currently in storage.

Executive Summary The two machines have been partially disassembled into “as large as possible” sub assemblies. The machines appear to be substantially complete with all parts being salvaged. It appears that all operation and maintenance manuals along with all drawings have also been acquired and are stored in the shipping containers at the port of Iskendarun. The condition of the machines is as described in the inspection report carried out (by others) in October 2004. The cost to reassemble and recommission in East Kalimantan Indonesia would be in the order of USD $1.5million per machine. The reassembly & recommissioning of each machine would take around four months. Once recommissioned, and subject to regular maintenance, the machines would have a remaining service life of 20 - 25 years. Ongoing regular Maintenance costs per machine would range from USD $140k-310K/year depending on location.


Section 1: Completeness of the Machines and the State

of Disassembly This section of the report shall discuss each major sub assembly and comment on the state of completeness of the sub assemblies. As both machines are essentially identical and both machines have been broken down identically, my comments will be generic across the two machines.

The Trailing Tripper Assembly Photo (1) shows the tripper assembly of Stacker Reclaimer 210, prior to removal from machine and further dismantling.

Photo 1 (Tripper assembly prior to removal & dismantling)

The tripper assembly was removed and broken down, for transport purposes, into one major assembly / structure and around five smaller assemblies / structures.


Tripper Major Assembly / Structure : This consists of the basic tripper structure base frame /chassis the lower half of the rising conveyor including idlers, the two power & control cable reelers (including cables), the on board switch room and the on board transformers. Refer Photo (2) Note the PLC equipment has been removed from the switch room and is stored in one of the shipping containers. Upper Tripper Sub Assembly / Structure: This section has been removed by flame cutting from the main tripper structure, and consists of the upper half of the rising conveyor including the head chute. Refer Photo (3) Tripper Tail Sub Assembly / Structure: This section has been removed by flame cutting from the rear of the main tripper structure, and consists of the rear trailing section of the rising conveyor, walkway, stringers, and. Refer Photo (4) Tripper Bogies: Each tripper has four (4) bogie assemblies; all have been removed from the tripper structure and strapped to the walkway on the tripper base frames. Refer Photo (2) Tripper Toe hitch: each tripper has a toe hitch frame which connects the tripper to the travelling base frame assembly via a pinned joint with a spherical bearing, the toe hitches have been removed from the tripper structure by flame cutting and disconnected from the travelling base frame by removing the shaft from the pin joint. Refer Photo (5) (Note on stacker 310 it appears that the shaft could not be removed so the to hitch has been flame cut approximately 600 mm back from the Pin joint. This will require additional cost when reassembling this machine shaft may have to be destroyed and certainly a new spherical bearing should be installed and the toe hitch frame will have to be re-welded). Misc Tripper Walkways: to reduce transport volume a walkway has been removed from the side of the main tripper structure along the side of the onboard switch room. A stair and landing which allows access from the tripper main frame level to the upper slew deck level has also been removed from the toe hitch frame. Both of these walkways have been removed by flame cutting and will require re-welding during reassembly.


Photo 2 (Tripper major assembly/structure)

Photo 3 (Tripper upper sub assembly/structure)


Photo 4 (Tripper tail sub assembly/structure)

Photo 5 (Tripper toe hitches” the triangular frames”)


Central Chute Work, Bypass Conveyors & Impact Tables All of the chute work and bypass components between the tripper head chute and the stacker/reclaim boom have been removed as large subcomponents. Also the bypass conveyor and chute work to the reclaim impact table have been removed as large sub assemblies. Refer Photos (5 & 6) Some of the chute work stainless steel liner plates are very badly worn with damage thru to the chute body these chutes will have to be rebuilt and new liner plates installed.

Photo 6 (Central chute work)


Base Frame & Slew Deck Base Frame: the base frame and slew deck have been removed as one assembly ie: the slew bearing has not been disassembled. The base frame has had the travelling bogies removed by flame cutting the connection bolts at the interface flanges.

Photo 7 (Base frame & slew deck)

Base Frame Long Travel Bogies: each base frame has three (3) travelling bogie assemblies, there is one (1) large 10 wheel bogie assembly & two (2) smaller 8 wheel bogies. The bogie assemblies as described above have been removed as complete assemblies and have not been broken down any further Refer Photos (8 & 9)


Photo 8 (10 Wheel long travel bogies)

Photo 9 (8 Wheel long travel bogies)


Slew Deck Mast The slew deck mast which includes the hydraulic motor/pump house and the large hydraulic luffing cylinder, has been removed from the upper slew deck by flame cutting the mast legs immediately above the attachment flange plate for the stacker / reclaim boom. Refer Photo (10). The female top clevis of the hydraulic cylinder has been flame cut from the counter balance frame and is still attached to the cylinder clevis. Refer Photo (11). Part of the access platform and stairs to the upper section of the mast has also been removed for transport purposes. The accurate reattachment of the mast will be a critical element in the site reassembly of the machine, to ensure the correct alignment of the counter weight frame & the hydraulic luffing cylinder. The re-welding / testing and alignment of the mast should be planned and supervised by expert expatriate personnel. A large man hole was cut in the side flange of the mast leg as part of the disassembly operation; this manhole has been reinstalled and re-welded. Refer Photo (13) The welding of the man hole should be NDE tested to determine the quality of the welding Misc Access Stairs & Platforms: various access stairs & platforms have been removed from the mast structure during the disassembly process, these access stairs & platforms have been saved and are in storage with the other components.

Photo 10 (Slew deck mast being removed)


Photo 11 (Slew deck mast showing cylinder female clevis cut from counterweight frame)

Photo 12 (Slew deck mast in Iskenderun)


Photo 13 (Slew deck mast lower legs flame cuts & inspection man hole)


Stacking & Reclaiming Boom The stacking & reclaim boom Refer Photo (14) has been removed from the upper slew deck at the attachment flange on the mast legs. It appears that the only things removed have been the operator control cabin, the stockpile anti-collision cables & brackets and the conveyor belting.

Photo 14 (Stacker reclaim boom on Machine 210 prior to removal)


Boom Luffing Ropes & Jackstay Frame: The boom luffing ropes and jack stay frame are still attached to the boom. Refer Photo (15) Boom Conveyor Take up: the boom conveyor take up and pulleys are still attached to the boom assembly. Refer Photo (15) Boom Bucket Wheel: the boom bucket wheels are still attached to the boom assembly. Some of the buckets show sign of damage and cracking and, along with some bucket teeth, will have to be repaired or replaced. . Refer Photo (16) Boom Bucket Wheel Chute: It was not possible to “Safely” inspect the bucket wheel discharge chute work however a previous inspection carried out on site (by Others) in October 2004 prior to the machines being dismantled, had identified that the liner plates and chute work proper are worn through and will need refurbishing before the machine can be put back into service. Refer Photo (17) Operator control Cabin: The operator control cabins will need careful cleaning & refurbishing, there has been a fair amount of coal dust ingress into the cabin & electrical & control systems cabinets inside the cabins. It is recommended that the air-conditioning and Cabin pressurisation systems be replaced and up dated. The operator seats will have to be refurbished or replaced The operator control displays will also have to have all labelling replaced with the in country language. Refer Photos (19, 20 & 21)

Photo 15 (Stacker reclaimer boom assemblies at Iskenderun)


Photo 16 (Bucket wheel & bucket wheel drives)

Photo 17 (Bucket wheel chute)


Photo 18 (Boom operator control cabin removed from S/R 310)

Photo 19 (Boom operator cabin electrical and control cabinet showing Coal dust ingress)


Photo 20 (Boom operator cabin showing Operator display panel labels)


Counter Weight Frame & Counter Weights The counter weight frame Refer Photo (21) is a triangulated structure which is hinged at one end to the top of the slew deck mast structure and at the outer end carries the concrete counter weight plates. The frame connects to the stacker reclaim boom Jack stay via a double flat plate link the counter weight frame is luffed via the hydraulic cylinder attached to the mast structure. The luffing motion is transferred to the stacker reclaim boom via the flatbar link.

Photo 21 (Counter weight frame prior to removal from machine)


Counter Weight Frames: The counter weight frames Refer Photo (22 have been removed as complete units from the machines at the joint flange between the frame and the slew deck mast and apart from the removal of some access stairs and walkways they are complete.

Photo 22 (Counter weight frame)


Flatbar Links: the double flat bar links which connect the counter weight frame to the Jack stay frame on the stacker reclaim boom have been removed from the frame during the disassembly process, these flat bar links are lying inside the counter weight frames.

Photo 23 (Flat bar link inside counter weight frame)


Concrete Counter Weights: the concrete counter weights have been removed from the frame during the disassembly process, these concrete weights have been saved and are in storage with the other components.

Photo 23 (Concrete counter weights in foreground)

Misc Access Stairs & Platforms: various access stairs & platforms have been removed from the counter weight frame structure during the disassembly process; these access stairs and platforms have been saved and are in storage with the other components.


Documentation Operation & Maintenance Manuals: a full set of operation & maintenance manuals have been obtained from the original owners, these are in storage in a container at the port along with the stacker reclaimer components. Drawings: a full set of drawings have been obtained from the original owners, these are in storage in a container at the port along with the stacker reclaimer components. It also appears that the drawings for the whole plant including stock yard conveyors transfer towers etc have also been obtained and are with the stacker reclaimer drawings.

Miscellaneous Components Although it was not possible to open all containers it was confirmed during the visit

that any small components removed during dismantling process had been packed into shipping containers, these containers are currently in storage with the other major components at the port of Iskenderun. Conveyor belt from the stacker reclaimer booms have been rolled up and are also at the port.

Conclusions It appears that all larger parts have been disassembled and salvaged and that all components are in (following some refurbishment) are in serviceable condition. All small components removed from the larger assemblies have apparently been stored in containers. It appears that all documentation (Drawings & manuals) associated with machines have been obtained and therefore any components which have to be replaced or refurbished, could be remanufactured using the original drawings.


Section 2: Reassembly and Recommissioning,

Time & Costs

Assumptions

The reassembly location will be assumed to be in coastal east Kalimantan and will use approximate rates extracted from our current experience on the Bontang Upgrade Project.

The estimate will be in US dollars.

All components for the machines have been delivered to the erection site and

unloaded by others to a suitable location within erection crane radius of where they are to be erected (by others - the cost for this is not part of the estimated costs below).

All components for the machines which have been delivered in containers have

been sorted and separated from other stockyard components and identified by others and delivered to a location 200metres if the erection site of the machines (by others - the cost for this is not part of the estimated costs below).

The machines are to be reassembled and recommissioned in their current state,

that is with the existing electrical and control technology.

Sufficient rail and sleepers have been installed on which to reassemble the machines (by others - the cost for this is not part of the estimated costs below).

All Power & control cables have been installed in the stockyard to the Mid point

disconnection Box. (by others - the cost for this is not part of the estimated costs below).

The estimate will be for one machine - we will advise a factor to apply for

efficiency gains and costs sharing if a second machine is built with say a 2 month lag time between start dates.

Time and Cost Estimate Details It is estimated that each machine could be refurbished reassembled and recommissioned over a period of approximately Four (4) months subject to the above assumptions.


It is estimated that the cost to refurbish, reassemble & recommission each machine will be in the order of US$1.5 million. A cost reduction of approximately 10% on the second machine would be expected due to lessons learnt and sharing of some overhead costs if reassembly of the second machine was commenced say 2 months after the first machine.


Section 3: Expected Remaining Service Life of Machines

and Ongoing Maintenance Costs

Remaining Service Life It is not unreasonable to expect that a “well maintained” machine would have a service life of not less than 30 years. At some coal export terminals in Australia machines installed in the early 1970’s are still operating some 37 years later. It must be noted that it is likely/common for a machine of that age to have had “several” upgrades during its life, and the upgrades would usually involve increasing the stacking / reclaiming capacity of the machines and at the same time upgrading the control systems to the current technology. From the information available from a previous report (by others) which was carried out

in 2004, it appears that the dismantled machines inspected in Turkey had been in service for approximately 12 years, with the plant operating at approximately 40% of their design capacity of the machines. Therefore at worst from an operational hours perspective, the machines would be considered to have done only say 6 years work. We could safely assume that if the machines are reassembled, recommissioned and then “properly maintained”, they could operate at their current design capacity for at least another 20 -25 years. (It would not be unreasonable to assume that even if the machines under went a capacity upgrade some time in the future, that the 20- 25 year remaining life would still be achievable).

On going Maintenance Costs It is hard to estimate the ongoing maintenance costs of a particular machine, however some broad brush information obtained from terminal operators in Australia suggests that the amortised yearly costs of maintaining a machine (converted into the Indonesian labour cost context) are as follows:

For a machine operating in an inland environment: US$140K-190K /year

For a machine operating in a coastal environment: US$ 230K-310K /year The additional cost for a coastal location is due to the increased cost of more regular corrosion control work.

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Inspection Report Partially Dismantled Stacker · PDF fileInspection Report Partially Dismantled Stacker Reclaimers ... The two stacker reclaimer machines were ... (Note on stacker