CHARL EKSTEEN

LEADING HAND BOILERMAKER

PERSONAL ACHIEVEMENTS

BOKONI PLATINUM MINES

SURFACE ORE STORAGE FACILITY

ORE HANDLING SYSTEM UPGRADE DECEMBER 2015

After being addressed by the SHE department and management to improve the current ore

handling system, with reference to previous success on all my projects, I accepted the challenge

and proceeded with a positive and safe mind set due to the fact that I enjoy challenges. During

this period I was acting as senior foreman/general engineering supervisor and I could utilize this

opportunity to proceed with the planning and presentation, until I were back on the floor.

SCOPE OF WORK

Planning, upgrading of current system, estimating, technical details and drafting of new

drawings, ordering of material from selected suppliers, fabricating, oversee installing

phase and commissioning of the new system. This includes refurbishing of the 6 mᶾ two

stage feeder pan. This were done as per MHSA and company procedure consisting of:

Investigating of the area together with the chief safety officer to identify all

hazards and risks

Drafting of an issue based risk assessment whereby all hazards and risks were

identified and control measures were put in place to eliminate or minimize the

concern

Ongoing hazard identification and risk assessments were done and controlled. This

data were captured and sent to the safety department on a daily basis

The feeder pan had to be disassembled and dye penetrant tested for cracks. Fortunately it

passed the test and we proceeded with the assembling as follows:

Replacement of all fasteners with electro galvanised swage fast high grip bolts.

Where it was impossible to insert the swage dolly we used electro galvanised GR

8.8 bolts complete with “sham lock” washers and “Cleve lock” nuts.

Replacement of all hard wearing body plates (liners) with 16 thick VRN 500 hard

wearing plates as per OEM specification, complete with electro galvanised, de-

embrittled Allen cap bolts, “sham lock” washers and “Cleve lock” nuts. The liner

plates were cut and countersunk drilled to reference drawings drafted by myself.

RESOURCES

No reference drawings were available. The new design were drafted by me, designed and

drawn, thereafter scrutinised and reviewed by a professional team consisting of:

Engineering manager

Structural engineer

Project and designing engineering consultant

Civil engineer

Engineering specialist

Section engineer

After revising the design only two amendments were done on the civil section

REPORTING STRUCTURE

Production manager

Engineering manager

Section engineer

Foreman

Constant liaising with the planned maintenance officer, estimator and senior

accountant to stay within financial margins and creating of planned maintenance

orders for future reference

AIM

To implement a cost saving initiative by inviting different suppliers to tender on this

project in order to compare costs

Utilizing existing resources and employees, also provide on the job training

Ensuring constant communication and strategic planning

Ensure to stay one step ahead, this will be positive towards the deadline

Allow enough window period for the commissioning phase, not to affect the concentrator

production schedule

Fabrication to be done neat, accurate, ergonomic and above average quality

FINANCIAL FACTORS (estimated to nearest value)

Allocated – R 1 600 000.00

Tender A – R 900 000.00 excluding installation

Tender B – R 820 000.00 excluding installation

Tender C – R 1 450 000.00 including installation, rigging to be done by the

company

Total estimation from myself – R 900 000.00 completing the whole project

Sub factors leading to such a huge saving

Utilised material that were already on site – minimum material were

obtained

Negotiating a good hourly rate with the mobile hydraulic crane supplier.

As it were December I suggest we hire the crane at a descent rate which

will generate income for his company, or he could let the crane stand in his

crane yard without generating income. As one of our sites also required a

mobile crane this period, the costs were split up between the two cost

centres

Body liner plates were cut and drilled to size which were a huge time and

cost saving as no extra labour or oxy-acetylene equipment were necessary

All consumables such as MIG wire, oxygen, acetylene, high tensile

fasteners and lock nuts and correct primer and final painting were

obtained from the company’s stock ledger or existing on site.

No unnecessary labour were utilized and overtime were kept to a

minimum through proper planning

Learner platers were given the opportunity to gain priceless experience

As mentioned earlier I allowed enough time to stay within the allowable

margin given by the company

The final bottom line added up to just over R 1 000 000.00, which still gave us a saving of R

600 000.00. However I were not awarded any kind of prize, the satisfaction that the project were

successful with no injury or time lost, made it priceless.

PREVIOUS MAJOR PROJECTS OR PROCEDURES MANAGED BY ME OR BEING INVOLVED

April 2007 - ore loading station facility underground to surface on the east compartment.

Managed, fabricate and install a new complete measuring flask

December 2007 - ore loading station facility underground to surface on the west

compartment. Managed, fabricate and install a new complete measuring flask

April 2008 - ore loading station facility underground to surface on the east compartment.

Managed, fabricate and install a new complete control chute

September 2008 - ore loading station facility underground to surface on the west

compartment. Managed, fabricate and install a new complete control chute

December 2008 - rock winder replacement of the gearbox. I assisted in the planning and

installation and the consulting were done by Coilmech which is part of ABB nowadays

January 2009 - rock winder replacement of drum bushes, I assisted with installation

April 2009 – man winder replacement of drum bushes, I assisted with installation and the

consulting were done by Coilmech which is part of ABB nowadays

September 2009 – headgear feeder pan. Planned, managed and installed a new feeder

supplied by Vipro. All existing support steel work were replaced

February 2010 – waste ore storage silo. Managed, fabricate and install a new complete

emergency side chute

October 2011 – run-off-mine (ROM) conveyer system. Managed, fabricate and install a

new complete ore handling system

December 2012 – water handling main pump station underground. I assisted in the

planning and installation of a new pump system. This project included designing of new

pump and motor support structures

April 2013 – rock winder. I assisted in the planning and installation of new groove plates

(wrapper plates) on the drum shell. This significantly increased the life span of the winder

steel rope after experiencing a lot of bad coiling. The consulting was done by ABB

February 2014 – compressed air plant. I assisted with the planning, installation and

commissioning on a water treatment system on both the open and closed circuit systems.

The purification system were designed and supplied by WESU eco-friendly treatment

August 2014 - ore loading station facility underground to surface on the east

compartment. Managed, fabricate and install a new complete control chute after

experiencing a massive mud rush and damaged by blasting. This were done in a record

time

December 2014 - man winder. I assisted in the planning and installation of new groove

plates (wrapper plates) on the drum shell. This significantly increased the life span of the

winder steel rope after experiencing a lot of bad coiling. The consulting was done by ABB

February 2015 - ore loading station facility underground to surface on the west

compartment. Managed, fabricate and install a new complete measuring flask, upgraded

landing facility to ensure better access for safe maintenance purposes

July 2015 - ore loading station facility underground to surface on the east compartment.

Managed, fabricate and install a new complete measuring flask, upgraded landing facility

to ensure better access for safe maintenance purposes

I was also involved with huge breakdowns on the compressors. This happened on various

occasions and every breakdown had to be rectified in a record time not to interfere with

production. Breakdowns normally resulted due to bad water causing damage to the

intercoolers, as we do struggle with very low quality of water. We are currently preparing a

presentation which involved various water engineers. The current purification system works

well on the open circuit but we still experience challenges on the closed circuit even by using

chemicals.

Kindly view pictures below as I proceeded with the 510 silo project.