Agenda Item 9.3 Report No 171/17ts TO: TECHNICAL SERVICES COMMITTEE - MONDAY 13 NOVEMBER 2017 SUBJECT: PURCHASE OF LANDFILL COMPACTOR AUTHOR: REGIONAL WASTE MANAGEMENT FACILITY MANAGER - REINIER LANN EXECUTIVE SUMMARY This report is to provide Council with information regarding the Landfill Compactor RECOMMENDATION That it be a recommended to Council: That Council approves the purchase of a Landfill Compactor 826 K from RWMF Plant Replacement Reserve 1. BACKGROUND During 2012 the Council bought a landfill compactor 816 IIF for compacting the waste at the landfill. The compactor is now due for replacement as it has reached it operational lifespan of 8,000+ hours. If a new compactor is not bought, Council’s expenses for maintenance of the old compactor will decrease significantly. Expected outcomes • To compact waste at the Regional Waste Management Facility (RWMF) • To increase machine and staff operating efficiency • To demonstrate an increased compaction rate • To increase the lifespan of the landfill Council currently owns a Caterpillar 816 F (24 tonnes) landfill compactor, which is now 5.25 years old and is due for replacement (Table 1 & Attachment A). The original lifespan was budgeted for under a 5 year replacement schedule. 1.1. VEHICLE DETAILS The purpose of the compactor is to compact waste at the landfill. The size of the current CAT 816 II F compactor is the smallest in the CAT’s compactor range. The Cat 816 II F (24 tonnes), due to its operational weight, would compact the least amount of waste in comparison with the CAT 826 K (40 tonnes).
Transcript
Agenda Item 9.3
Report No 171/17ts
TO: TECHNICAL SERVICES COMMITTEE - MONDAY 13 NOVEMBER 2017
This report is to provide Council with information regarding the Landfill Compactor
RECOMMENDATIONThat it be a recommended to Council:
That Council approves the purchase of a Landfill Compactor 826 K from RWMF Plant Replacement Reserve
1. BACKGROUND
During 2012 the Council bought a landfill compactor 816 IIF for compacting the waste at the landfill.The compactor is now due for replacement as it has reached it operational lifespan of 8,000+ hours. If a new compactor is not bought, Council’s expenses for maintenance of the old compactor will decrease significantly.
Expected outcomes• To compact waste at the Regional Waste Management Facility (RWMF)• To increase machine and staff operating efficiency• To demonstrate an increased compaction rate• To increase the lifespan of the landfill
Council currently owns a Caterpillar 816 F (24 tonnes) landfill compactor, which is now 5.25 years old and is due for replacement (Table 1 & Attachment A). The original lifespan was budgeted for under a 5 year replacement schedule.
1.1. VEHICLE DETAILS
The purpose of the compactor is to compact waste at the landfill. The size of the current CAT 816 II F compactor is the smallest in the CAT’s compactor range. The Cat 816 II F (24 tonnes), due to its operational weight, would compact the least amount of waste in comparison with the CAT 826 K (40 tonnes).
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Table 1: Vehicle Details
Vehicle Description CATERPILLAR 816F COMPACTOR
Asset Number 52970
Registration Number N/A
Purchase Date 29/06/2012
Proposed Change Over Date 2017/18
Council Department Technical Services Department
Section Regional Waste Management Facility
Hour Reading 8,023 Hours (31 October 2017)
1.2 LIFESPAN & REPLACEMENT
The Compactor has reached it optimal working lifespan at 8,000 hours (See Table 2).It operates daily in a harsh working environment, comparable to a mine site.Table 2: Comparison of Compactor lifespan with National Benchmark.
National Bench MarkReplacement
Type Year HoursCompactor - Landfill 8 8,000 hrASTC Compactor #52970 5,5 8,000 hr
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1.3. ASTC SENIOR MECHANIC SUMMARY REPORT
This compactor plant works under severe working conditions. Operators can feel that the machine is losing power during operation. This type of strong built plant does not get major structural damages easily, but loses its power and ability to work with full efficiency. Time taken to complete a given task in a given time extends with this sort of power loss.
As mentioned before, these machines rarely get any structural damages but oil test report and CAT recommendation highlights on the fact that machine needs immediate attention in terms of overhauling of major aggregates like engine, transmission and differential units. These overhauling costs are too high to maintain this piece of plant equipment next year.
A Technical Inspection Report (TA1) of the 816 II F on the 19 September 2017 by CAT, shows defects that requires monitoring at every 250 hour service (Attachment B). Due to the age of the compactor, oil samples are taken at every major service to determine the condition of the machine.
1.4. MAINTENANCE REPAIR COST
The current maintenance and repair cost total $153,770 over 5.25 years of it lifespan (Table 3 & Figure 1). Mayor upgrade of the wheel tips occurred in 2015/2016, which would recur in 2.5 years. The wheel tips aid the shredding and compaction of waste.
Future life cycle cost excluding maintenance cost is estimated at $248,564.00 (excluding GST) to take the landfill compactor beyond 8000 operating hours (Table 4).
Table 4: Future Running Cost
Plant Damage CostLoss of Power UnknownEngine reconditioning recommended at the end of the year $44,000.00Transmission reconditioning recommended at 10,000 hours $25,000.00Front differential reconditioning recommended at 10,000 hours $19,000.00Rear differential reconditioning recommended at 10,000 hours $20,564.00Wheel tip replacement at 10,000 hours $70,000.00Wheel tip replacement at 15,000 hours $70,000.00Total $248,564.00
Source: CAT Hastings Deering
The upgrading of the Landfill’s compactor would require that another machine need to be hired from Hastings Deering (CAT) from a branch outside Alice Springs. The cost for renting a compactor is $62,869.00 plus the $231,564.00 (life cycle cost) amount to $294,433.00 excluding GST (Table 5). This is more than the trade in value of the current compactor, which is $240,000.00.
Total Compactor Repair and Hire costRepair Compactor Sub- Total $231,564.00Rent Compactor Sub-Total $62,869.00Total $294,433.00Trade value $240,000.00
Source CAT: Hastings Deering
1.6. SUMMARY OF COSTINGS
The trade in value for the 816 I IF is $240,000.00; therefore the cost for the upgrade from 24 tonnes to a 40 tonnes compactor will be $900,000.00 (new cost) minus $240,000.00 (trade value) amounts to $660,000.00 excluding GST (Table 6).
Table 6: Costing Summary
Estimated Replacement Cost: $900,000.00
Estimated Trade value: $240,000.00
Estimated Change Over Price minus trade value: $660,000.00
Cost Spent to Date on Maintenance: $154,000.00
Estimated Repairs Cost Plus Rent of Machine $294,433.00
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1.7. COMPACTION
All compactors are not equal and the more the compactor weights the more waste it can compact in a cubic meter. Other factors influencing the compaction rate are the design of each company’s compactor and incorporating technology. The current compactor weighs 24 tonnes and an upgrade would be in the 40 tonnes range.
In 2012 few compactors had position technology available to improve efficiency but since then technology applications to landfills have increasingly developed. The advantages of incorporating this technology are that it reduces wear and tear, fuel, oil, enforce a compaction bench mark standard for operators and reduce staff costs. Other advantages are that waste would be compacted to the maximum and the computer data can be can be used to train staff and improve compaction KPI. The positioning technology used for compactors is similar to the commercially available technology for road graders etc.
The estimate is that a heavier upgraded compactor (tonnes) will increase compaction by 20% above the current density rate. The machine (40 tonnes) will save one year of landfill space for every 5 years due to the increased compaction rate (Table 7).
Table: 7: Compaction Data
CAT 816 F Compactor UpgradedOperating weight 24 tonnes 40 to 52 tonnesCompaction rate 500 to 700 kg/m3 850 to 950 kg/m3Increase compaction rate 0% 20% to 25%Averge m3/day landfilled 100 cubic meters 80 cubic meters
2. DISCUSSION
The 816 II F CAT compactor had reached it budgeted lifespan as a compactor, passing 8,000.00 hours. As the compactor machine hours increases there is a higher risk of breakdowns (Attachment B). The cost of extending the life of the current compactor by reconditioning the machine and renting another waste compactor for a month totals $294,433.00 (Table 5). The estimated trade value from CAT is $240,000.00 and will contribute to buying a new compactor (Table 6).
The upgrade of the current compactor (24 tonnes) to a 40 tonnes type of compactor is proposed to increase the lifespan of the landfill. Calculation indicate that if the compaction rate is increase from the current rate between 500-700 cubic meters to 850-900 cubic meters, including the incoporation of positionong technology, 20- 25% more space will be saved (Table 7). Compaction rate is affected by compactor design, landfill filling management techniques and the incorporation of technology.
The increased compaction rate will increase the lifespan of the Alice Springs Landfill by 20- 25% or ratio 5:1 years. Therefore, a tender should be called for a new landfill compactor with a operating weight of approxemitely 40 tonnes including positioning technology costing at least $660,000.00 (Table 6).
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3. POLICY IMPACS
The issues addressed in this Report are in accordance with the following Goals/Strategies of the Alice Springs Town Council Strategic Plan (2013-2017):
Goal 3: A town at the forefront of sustainable management & protection of its natural & built environment.• Effective waste management program encompassing waste reduction, reuse and
recycling
4. FINANCIAL IMPACTS
The machine will be purchased from the RWMF Plant Replacement Reserve and trade in value is returned to RWMF Plant Replacement Reserve.
5. SOCIAL IMPACTS
The extra weight from the compactor will increase compaction rates and subsequently extend the life of the landfill
6. ENVIRONMENTAL IMPACTS
Increased lifespan of RWMF through higher compaction rate.
7. PUBLIC RELATIONS
Increased lifespan for RWMF and reduction of money into an old machine
Landfill Compactor TAIInspection Number: 477285 Equipment Family: LANDFILL COMPACTOR Inspector: Paul RobisonCompleted On: 09/19/2017 07:1038 AMLocation: Asp tip face
