5. Kestrel longwall equipment
Shearer 1 x Bucyrus EL3000 with 375kw ranging arms
Roof supports 146 x 860 ton capacity supports each kit withPM4
control system
AFC 1 x 855kw CST P drive at Maingate
1 x 855kw CST KP drive at Tailgate
Pump stations 1 x SES pump station 900 litres/min capacity and 1 x
Kamat (Longwall Hydraulics) pump station 900 litres/min
capacity (shared over 2 systems)
1x High set system
Crusher 250 Kw drive unit
BSL 400 kw drive unit
Monorail Macquarie system
Nameplate capacity 2500 tonnes per hour
2 sets of longwall equipment each containing -
8. Industry safety benchmarking
2 July 2016 8
Source: Queensland Mines and Quarries, Safety Performance and Health Report 2008-09
9. Comparison - Lost Time Injury Frequency
Rate
Comparison of Lost Time Injury Frequency Rate Performance
Rio Tinto BU's v RTCA Operational Results June 10 YTD
0.0
0.4
0.8
1.2
1.6
Argyle-U/GDevelopmentProject
Bengalla
ChapudiCoalProject
CopperProjectsOffice
DampierSaltLimited
DiamondMarketingandSales
DiavikDiamondMines
Exploration
Kelian
KennecottEagleMineralsCompany
KennecottLandCompany
MTW
MurowaDiamonds
ResolutionCopperCompany
RioTintoAlcanCorporate
RioTintoColowyoMine
RioTintoJapan
RioTintoMineraPeru
RTCorporateOffices
RTGroupProcurement
RTIO-Other
TechnologyandInnovation
QMM
RichardsBay
CoalandAllied
BauxiteandAluminaAtlantic
HailCreek
RioTintoMinerals
Simandou
ERA
Argyle
BusinessDevelopment
IOCC
KennecottUtahCopperCorp
RTIOExpansionProjects
RTSharedServices
RTCABusinessUnit
Palabora
ClermontRegion
HVO
RTCA(QLDonly)
PrimaryMetalAsiaPacific
PilbaraMiningOperations
BauxiteandAluminaPacific
Rossing
RTMarine
RobeRiverandPilbaraInfrastructure
PrimaryMetalNorthAmerica
PrimaryMetalEurope,Middle-Eastand
Northparkes
KestrelMineExtension
Kestrel
Business Groups
LTIFR
10. Structure and organisation
• Start finish times
• Support and maintenance crews
• Single maintenance stoppage
• Rebuild – overhaul rather than fix
11. The maintenance management process
Operations
Plan
Work Management
Identify Work Plan Work
Schedule
Work
Analyse
Work
Complete
Work
Execute
Work
P
DC
A
Short-term
P
DC
A
Long-term
Business
Improvement
Programme
Execute
Action Plan
Root Cause
Identification
Incident
Defect
Elimination
Loss
Analysis
Reliability
Modelling
FMECA
Analysis
Criticality
Analysis
Define
Tactics
Whole of Life
Plan
Review
Tactics
Tactics
Implementation
(Mtce plan)
Spares
Optimisation
Tactic
Definition
Figure 1 – Business Process Relationships
12. Six Steps of Work Management
Identify
work
Plan
work
Schedule
work
Analyse
work
Complete
work
Execute
work
15. 2 July 2016 15
Kestrel Longwall start of block
• 4
Time to cut first 100m of block
0
5
10
15
20
25
30
LW301
LW302
LW303
LW304
LW305
LW306
LW307
LW308
days
16. Floods 2008
• Access to site
• IMT process for recovery
• Water quality
• Emulsion plant outcome
17. GFC 2009
• Reduced coking coal demand
• Alternate cutting shifts
• Allocation of labour from face
18. Where are we now
• 93 cut hours per week
• 5.9 million ROM tonnes forecast – 10%
• Saleable tonnes 18% increased on
previous year, 15% increase on previous
best year
19. 2 July 2016 19
Kestrel Longwall average weekly op time
• 1
average weekly operating time
0
10
20
30
40
50
60
70
80
90
100
LW301
LW302
LW303
LW304
LW305
LW306
LW307
LW308
hoursperweek
20. 2 July 2016 20
Kestrel 300 series ROM tonnes
with 2010 actual YTD & forecast
• 4
ROM Production
0
1
2
3
4
5
6
2004
2005
2006
2007
2008
2009
2010
milliontonnes
21. 2 July 2016 21
Kestrel 300 series saleable tonnes
with 2010 actual YTD & forecast
• 4
Saleable Production
0
1
2
3
4
5
6
2004
2005
2006
2007
2008
2009
2010
milliontonnes
300 series mining
22. 2 July 2016 22
Kestrel 300 series Longwall retreat
with 2010 actual YTD & forecast
• 4
Longwall retreat metres
0
1000
2000
3000
4000
5000
6000
2004
2005
2006
2007
2008
2009
2010
milliontonnes
23. 2 July 2016 23
Kestrel historical saleable tonnes
with 2010 actual YTD & forecast
• 4
Saleable Production
0
1
2
3
4
5
6
7
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
milliontonnes
