14
DAY TURNAROUND
20
METRE CYLINDER
0
INCIDENTS
THE CHALLENGE
Our client operates as fleet of five Cat 7495 HydraCrowd electric rope shovel excavators on mine sites within the Bowen Basin.
The average utilisation of this machine is 85% which is higher than most other electric mining shovels, with an average of 1,254,640 BCM (bank cubic metres) every month.
Any breakdown through hydraulic cylinder failure on this machine would cause enormous productivity loss for the operation.
To minimise loss, the client keeps two back-up HydraCrowd hydraulic cylinders on site for emergency replacement.
Every 10,000 working hours, the operating cylinders require a complete service.
They are removed and replaced with the standby cylinders and sent away for servicing.
THERE ARE ONLY 2 BACK-UP CYLINDERS FOR 5 MACHINES…
…so it is essential that the servicing and any necessary repair works are carried out with maximum precision and all stages are documented as per OEM requirements.
Furthermore, the cylinders must be thoroughly tested prior to dispatch to minimise the risk of an onsite failure and preventing loss of productivity and significant financial impacts to the project.
THE SOLUTION
Austchrome are the only company on the east coast of Australia that have the workshop scale and technical capacity to provide a servicing solution for the Cat 7495 HydraCrowd cylinder.
Scope of work completed:
• Cylinder received at repair workshop and craned onto specialised workbenches.
• Austchrome’s experienced mechanical fitters disassembled and inspected the cylinder, providing a detailed strip report to the client.
• Client approval obtained for the scope of work, and service commenced.
• Replacement parts ordered, ensuring all were new for maximum cylinder life.
• Old and deteriorated parts removed, including seals, bolts, washers, bearings, manifold, transfer pipes, and banding.
• Barrel transferred to Austchrome’s blast and paint facility for removal of old paint and application of a fresh coat.
• New components checked for defects before fitting.
• Cylinder reassembled with the help of 20-tonne gantry cranes in Austchrome’s assembly area.
• Thorough testing conducted, following OEM specifications for maximum operating life.
• After successful assembly and testing, manifold and orcott bearing wrapped in anti-corrosive material to protect against harsh conditions.
• Transportation arranged using a custom-made, certified transport stand designed in consultation with the OEM for protection during transit.