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REFERENCE MANUAL

JULY 1999
REV1

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COMPUTERISED MAINTENANCE MANAGEMENT
INFORMATION SYSTEM/RISK MANAGEMENT

REFERENCE MANUAL
RISK MANAGEMENT IN THE MAINTENANCE DOMAIN.
METHODOLOGIES, TECHNIQUES AND PROCESSES FOR ANGLOGOLD ENGINEERING TO
DETERMINE AND IDENTIFY RISKS, AND MAINTENANCE STRATEGIES FROM A SYSTEMS
PERSPECTIVE.

CONTENT
1. INTRODUCTION - PAGE 3
2. MAINTENANCE DEFINITION - PAGE 5
3. POLICIES - PAGE 5
4. RISK MANAGEMENT - PAGE 7
5. OBJECTIVES OF RISK MANAGEMENT & COMPUTERISED MAINTENANCE
MANAGEMENT INFORMATION SYSTEM INTEGRATION - PAGE 9
6. MAINTENANCE MANAGEMENT SYSTEM (CYCLE) - PAGE 10
7. MAINTENANCE PROCESS (OPERATIONAL SYSTEM) - PAGE 10
8. WORKORDER STRUCTURE - PAGE 11
9. WORKORDER FLOW - PAGE 11
10. MAINTENANCE MANAGEMENT INFORMATION SYSTEM
ACTIVITIES/FUNCTIONS - PAGE 12
11. TYPE OF JOB/WORK ORDER CARDS TO BE GENERATED - PAGE 12
12. JOB CARDS - PAGE 13
13. RISK ASSESSMENT TECHNIQUES - PAGE 14
14. BASE LINE RISK ASSESSMENT PROCESS - PAGE 15
15. MAINTENANCE STRATEGIES PROCESS - PAGE 15
16. ISSUE BASED RISK ASSESSMENT EQUIPMENT PROCESS - PAGE 16
17. ISSUE BASED RISK ASSESSMENT TASK PROCESS - PAGE 17
18. CMMIS/RISK MANAGEMENT IMPLEMENTATION PROCESS - PAGE 18
REFERENCES (BIOGRAPHY) - PAGE 32

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ANNEXURES
1 QUESTIONNAIRE: BASE LINE RISK ASSESSMENT - PAGE 34
2 QUESTIONNAIRE: ISSUE BASED RISK ASSESSMENT EQUIPMENT AND
MAINTENANCE STRATEGY DECISION DIAGRAM AND MAINTENANCE STRATEGY
TREE - PAGE 38
3 QUESTIONNAIRE: ISSUE BASED RISK ASSESSMENT TASKS, INCIDENTS,
ACCIDENTS - PAGE 45
4 BASELINE RISK ASSESSMENT FORM &VULNERABILITY FORM - PAGE 49
5 ISSUE BASED RISK ASSESSMENT EQUIPMENT FORM - PAGE 54
6 ISSUE BASED RISK ASSESSMENT TASKS, INCIDENTS, ACCIDENTS, PROCESSES,
NEW EQUIPMENT AND MODIFICATION FORMS - PAGE 57
7 MAINTENANCE STRAT. SERVICE ORDERS/JOB CARDS AND SHEETS - PAGE 61
7.1 SCHEDULED RESTORATION TASK – S/O CARD - PAGE 61
7.2 SCHEDULED DISCARD TASK – S/O CARD - PAGE 63
7.3 SCHEDULED ROUTINE SERVICE TASK – S/O CARD - PAGE 65
7.4 CONDITION MONITORING – SERVICE SHEET - PAGE 67
7.5 SCHEDULED ROUTINE SERVICE TASK – SERVICE SHEET - PAGE 68
7.6 ON-CONDITION TASK – SERVICE SHEET - PAGE 69
7.7 PREVENTIVE MAINTENANCE DAILY JOB REPORT CARD – SERVICE SHEET
- PAGE 70
7.8 AFTER HOURS BREAKDOWN CARD/SHEET - PAGE 72
8. EXAMPLE HIDDEN PROCESS AREA FORM AND P.A. WITH EQUIPMENT
LOCATIONS - PAGE 75
9. EXAMPLE OF P.A.’S AND EQUIPMENT LOCATIONS WITH CODES TO LOAD ON
CMMIS - PAGE 86
10. EXAMPLE OF FORM TO CATEGORISE EQUIPMENT WITH RISK ASSESSMENT OLD
MAINTENANCE STRATEGIES VS NEW MAINTENANCE STRATEGIES -PAGE 93
11. EXAMPLES OF PROCESS / LOCATION IDENTIFICATION, EQUIPMENT & NUMBER
IDENTIFICATION SYSTEM. - PAGE 95
12. EXAMPLES OF RISK ASSESSMENTS, EQUIPMENT & TASKS.- PAGE 108
13. ANGLOGOLD RISK MATRIXES, 1 & 2. - PAGE 135
14 CMMIS KPA's & KPI's - PAGE 138
15 RECOMMENDED CMMIS STRUCTURE (LABOUR) - PAGE 141

COMPILED BY: JAKKIE CLAASSENS - ENGINEER CMMIS/RISK MANAGEMENT - FEBRUARY 1999.
EDITED BY: HANS BROKKE - MANAGER ENGINEERING SYSTEMS - JULY 1999.

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This system/process is a framework to address the development and implementation of a maintenance plan. etc. production loss. essential for safety and health and production to know what maintenance strategies and techniques would be required for equipment and when it should be performed. high technology and sophisticated. 3 . It is. The equipment used for production is extremely costly. The Mine Health and Safety Act (Promulgated on the 15th of January 1997). These technical systems need to be operated safely and economically. The main objectives of the Act are to promote the Health and Safety of all persons employed or working at mines by:  Establishing a healthy and safe working environment and conditions. Risk Management in the Maintenance Domain is a management process. supervision and the employees. Failures of such systems have an impact and consequences on people's safety and health. minimizing and control of risks to health and safety by: identifying and recording hazards. which establishes new management strategies by transforming the present strategies. and requires the elimination. The processes by which failure occurs and the means to manage these failures are becoming high priorities in the mining industry and many other industries. equipment loss and environmental in certain areas. determination and implementation of protective measures and controls. risk management system and assessment techniques for continued improvement in systems and equipment reliability. INTRODUCTION From a systems perspective. Optimal maintenance strategies depend on the integrative functioning of management. therefore. A high degree of synergistic functioning of them is a prerequisite for Entrepreneurship.1.

risk. are:  Commitment from management. Individuals begin to base their decisions on either objective (clear) or subjective probabilities (intuition and judgment). and the possible results of each solution are clear. According to Hellriegel Slocum "Management" (seventh edition: 240) we can broadly classify the conditions under which decisions are made as certainty. then implementation of system. the decision makers may be able to make only a reasonable guess rather than an informed decision. and uncertainty. Certainty is the condition under which individuals are fully informed about a problem.  Introduce system to workforce  Commitment and participation from all levels.  Development of a comprehensive plan. the condition of risk enters into decision-making. identify alternative solutions. alternative solutions are obvious. The objective of the reference manual is to provide the necessary theoretical background of Risk Management methodologies and techniques integrated into a "Computerised Maintenance Management Information System" (CMMIS). will provide a sound basis in setting proper equipment maintenance strategies and tasks. and state the probability of each solution leading to the desired results. As information dwindles and becomes ambiguous. specify the probability of certain events. The process to get the people involved. When individuals can identify developments and events and their potential impact with great confidence. 4 . they make decisions under the condition of certainty. Risk Management methodologies and techniques integrated into a Maintenance Management Information System. Probability: The percentage of times that a specific outcome would occur if an individual were to make a particular decision. The condition of uncertainty occurs when individuals have little or no information about developments and events on which to base a decision. Management. Because of that uncertainty. Risk is the condition under which individuals can define a problem. It also provides a sound basis of the implementation of such integrated systems and techniques in setting proper equipment maintenance strategies and tasks. a large number of times. supervisors and employees will be part of a team doing assessments on equipment and tasks.

Maximum use will be made of cost effective computerised systems to support management decisions and control. 5 . Critical systems and processes will be evaluated by risk assessment to ensure continuity and optimisation. product output and quality. within the accepted AngloGold Maintenance Standard for longevity and safety at optimum resource cost. which will guide all future actions towards achieving the maintenance function/risk management objectives. 3. by applying Issue Based Risk Assessment Equipment (based on RCM/FMECA techniques). formalised and reviewed on a regular basis. a conscious decision will be made to select a maintenance strategy. POLICIES 3. All statutory requirements including those negotiated with the authorities will be fully complied with. All critical maintenance functions will be identified through risk assessments and suitable procedures and standards will be developed.1 Maintenance Policy The purpose of the Maintenance Management Information System/Risk Management is to ensure that maintenance activities are directed towards achievement of the objectives in a responsive and adaptive manner. MAINTENANCE DEFINITION To achieve the agreed Business Services and Mines operating process.2. For each equipment/item or system types. and units.

6 .HEAD OF ENGINEERING ANGLOGOLD.MENZIES . 3.2 Management Policy We are committed to:  Safe personnel and working environment  Available and reliable equipment  High technical skills and competency  High quality performance  Training and development of personnel  Measurement and communication  Compliance to statutory requirements  Cost effectiveness and productivity.D. I.

explosives. That is achieved through good planning and operational procedures and a proper Maintenance Management Information System. some of these are also applicable to surface operations. An effective safety management /risk management system is where management begins to plan for safety and maintenance by identifying and correcting hazardous situations before they cause accidents and address failure causes with the correct maintenance strategies. The major hazards are the high consequence/severity hazards. some more hazardous than others. Occupational accident hazards are the hazards associated with everyday work activities. falls of ground. current trends are for a "safety case" to be prepared. In the mining and process plants. as a means of justification the operation has been planned to a high degree of safety by looking at the safety management system of the operation and the identification and control of major and occupational hazards. it can answer the following questions: 7 . heat. such as. materials handling.4. In other words. It is the systematic examination of an operation. fires. etc. The risks to personnel arise from a variety of sources. Risk Assessment is the major prerequisite for the development of an effective safety management and maintenance management system. such as operations and maintenance of equipment. failures and their causes. it does not itself make an operation any more safe or efficient. in-rushes. noise and hazardous chemicals. dust. haulage and transport systems. safety is managed in a pro-active manner rather than reactive as in the past. radiation. Although Risk Assessment can play an important role in providing advice on safety. Risks in mining can be categorised as: major hazards and occupational accident hazards. RISK MANAGEMENT Risk assessment techniques can be used at the planning stage by identifying potential hazards and the factors contributing to them so that they can be eliminated or effectively controlled before the operations get underway. Here. and maintenance strategy. the purpose of which is to identify the potential for hazards. This would include stumbling and falling and contact with machinery.

or  Reduce the severity of the consequences by appropriate measures As risk is a function of consequence (severity) and probability. accidents.  Identification of risk reducing.  Quantitative Risk assessment is common in the high technology operations. There is no universal formula for rating risk in relative importance but a number of techniques have been developed to assess decision-making.  What can go wrong?  What are the effects and consequences?  How often will it happen?  Is there a need to reduce the risks and how can this be done? Despite the number of both complex and simple assessment techniques. new equipment. it is common practice to rate the probabilities using a subjective or simple numerical scale.  Estimation of probabilities/frequencies. which requires a complex mathematical approach using credible values of readily available component reliability data.  Estimation of causes. the underlying methodology is universal for tasks. We are using a matrix to rank risks. process. measures are taken to:  Reduce the probability/frequency of the event. The level of risk is then calculated by combining these two values according to "Risk = 8 . incidents. etc and consist of the following process:  Hazard identification. To reduce the risk.  In qualitative (subjective) risk assessments. termination or transfer measures. a degree or index of risk (see matrix on Page 136 & 137 ) can be calculated using estimates of these two properties. This approach is needed to determine the correct maintenance strategies if data is available and reliable.  Estimation of consequences/severities.  Evaluation and identification of unacceptable risks. Such estimates can be quantitative depending on the nature of the study.

Probability x Consequence" or using a matrix. Such methods are more than adequate in most low technology operations as long as the assessment has been 9 .

54 & 57). These requirements have necessitated a three tier strategy. namely: Baseline Risk Assessment.  Put various maintenance strategies into perspective  Maintain availability and reliability  Put a maintenance plan in place  Combine various maintenance strategies into logical scheduled work packets. Issue based Risk Assessments and continuous Workplace Risk Assessments which in each case will satisfy the needs of the SIMRAC proposals and those generated by the applicable legislation contained in the Mine Health and Safety Act (Act 29 of 1996). Modern approach  Be International Industry compliant  Be able to select accepted techniques  Be able to define opportunities and respond to threats  Determine risks to production. miners and artisans are comfortable with the scale used (matrix). Health and Safety and Environment  Be cost effective and more efficient. 5. (See Risk Assessment sheets/methodologies of AngloGold. 5 and 6 Pages 49.  Be legally compliant.  carried out with sufficient experience and knowledge and the management. 10 . OBJECTIVES OF RISK MANAGEMENT & CMMIS INTEGRATION The key objective of a Maintenance Management Information System and Risk Management System is to support the Maintenance function and to:  Be globally competitive. maintenance. operators. Annexure 4.

Inspections Scheduled: Restoration (Safety) & Discard Maint Admin.6. Maint Quality Management Task FMECA / RCM. System. history. Maint Man Reports. Opportunistic Task Planning. Preventive Predictive) Maint. Management Planning. MAINTENANCE MANAGEMENT SYSTEM (CYCLE) Maintenance. Preventive: (Use based. On Condition & Procurement Condition Monitoring Task Execution & Strategy List Results Management. MAINTENANCE PROCESS (OPERATIONAL SYSTEM) Maintenance Strategies. Cost Feedback Task detail & Data Analysis results Inspection Reports 11 . Performance Performance Management Risk assess. Standards 7. Maint Performance. results. Organisation. Shutdowns. Financing System compliance. Manpower. Routine Service Scheduling. Resources. Objectives. Maintenance Planning. Maintenance Plans Design Maintenance Audit. Optimisation. Policy.

WORK ORDER STRUCTURE Equipment Ad hoc Work Planned Maint Equipment request Requirements Breakdowns Planned Maint Tasks Planned Maint Task Frequencies Spares needed Work packages. Task Tools and definitions and schedules equipment Artisans Task Execution Plan Time 3. WORK ORDER FLOW (DOCUMENTATION FLOW SYSTEM) Spares Procurement Work Packages MMIS Task to F/M Scheduling (Schedules) Prioritise Tasks F/M verify & Artisan Complete Job Task Executed sign Card CMMIS receive Data into CMMIS Gen Man data (Job card) on Reports completed tasks Analyse Data 12 .8.

TYPE OF JOB/WORK ORDER CARDS TO BE GENERATED 11. to be flagged based on high-risk priority and legal requirement tasks. n) Contractor work and costs. critical areas. o) Total management module for projects. Policy. Financing 13 System compliance. i.1 Scheduled restoration task  Generated service order card 11.e.4. (w/shops or contractors). Maint Man Reports. Plant Shutdowns. Resources. Standards . j) Do loadings according to available persons on shop floor per process area. Organisation. g) Spares/Components needed for every restoration or discard task. 5. Maintenance Plans Design 11. i) Condition monitoring (trends.3 Routine service card/sheet  Generated sheet for normal services and service order cards for legal's 11. Objectives. d) Risk Assessment to be loaded on system.2 Scheduled discard task Maintenance. c) Schedules/frequencies based on risk priority. k) Movement of equipment/units to date (asset register up to date!) l) Asset register listed according to risk assessment. MAINTENANCE MANAGEMENT INFORMATION SYSTEM ACTIVITIES/FUNCTIONS a) Determine high cost areas and equipment. f) Service orders outstanding. e) Work loadings (work packages) per artisan group/per process area per risk assessment (matrix) priority. h) Re-order spares used after every restoration or discard task or on condition tasks. etc) and generate a work card when needed. Generated service order card System. Maint Performance. b) Flag system for repetitive failures. Management Planning. critical equipment and critical components. Manpower. m) Keep record of equipment sent for off-site repairs.4 On-condition Maintenancetask sheet Audit.

 On-condition generate sheet and responsibility daily/weekl 14 .

15 . h) Maintenance task procedure (steps to carry out work) i) Quantity of components used. e) Maintenance strategy codes. 12. b) Foreman name and code. KPA. process area. c) Type of maintenance strategy/task.5 Condition monitoring card/sheets  Daily/weekly sheets/card  Service order card if limits are reached/parameters (See Annexure 7 on Page 61 . c) Opportunist Maintenance: same as scheduled tasks d) On-condition tasks: daily job report card to be completed and sent back (work requirement sheet generated by system) e) Condition monitoring: report back on standard applicable sheet and Service order card when generated by system f) Breakdowns: report back on daily job report card g) After hour breakdowns: report back on after hour breakdown form h) Design-out and modifications: daily job report card i) Good housekeeping and safety & health tasks: daily job report card j) Construction work. f) Failure mode (causes) and codes. 11. equipment description.2 DATA NEEDED ON A JOB CARD/SERVICE ORDER a) Date. 6.e. artisans name and code. equipment location. new installation or process changes: use daily job report card. i.1 WHEN TO USE WHAT TYPE OF JOB CARD/SHEETS AND FEEDBACK a) Scheduled restoration and discard and legal routine service (to be send back once completed) (Service order generated by system) b) Routine services: generated service order (legal) to be completed and send back also the Work requirement sheet generated by the system. g) Maintenance schedules (time based/used based) Ref No.for job/work order cards and sheets). d) Component lists (Bill of materials). JOB CARDS 12.

completed. Task observations by the supervisor. at the planning stage of a project by identifying potential hazards so that they can be eliminated or controlled before the operation gets under way. Accidents and processes.  Continuous Risk Assessment. RISK ASSESSMENT TECHNIQUES  Base line Risk Assessment (Identification of Critical Process Areas and equipment. n) Equipment number. draw up maintenance schedules and controls to control the hazards). m) Date planned. (To draw up proper task procedures to address root causes of hazards. which should take place continually.  Issue Based Risk Assessment Equipment (to determine maintenance strategies based on the root causes and tasks). This is the most important form of risk assessment. 7. This approach determines sub-standard conditions and acts at the source. This is a line driven approach and comprises of On-Condition tasks/inspections (planned general inspections and critical part/component inspections). j) Component stock code or workshop order number. status. From the issue based risk assessment checklists are being drawn up to control or eliminate hazards associated with equipment and tasks. l) Responsible signatures. etc. unit number. Incidents. 16 . k) Hours worked. (Pro-active).  Issue Based Risk Assessment Tasks. and Routine service tasks. as an integral part of day-to-day management. These checklists are used in On-Condition tasks. activity code. etc.

BASE LINE RISK ASSESSMENT PROCESS (See Annexure 1 & 4 Pages 34 and 49 for questionnaire and format). frequency costs. MAINTENANCE STRATEGIES PROCESS Issue Based Risk Assessment Equipment Step 1 [FMECA/RCM format] Determine Maintenance Strategies/Tasks Step 2 [Using Maintenance Strategy Diagram] New equipment Conduct Issue Based Risk Assessment on New projects Step 3 Tasks Change process Modifications Repetitive failures Step 4 Write Maintenance Task Procedures Draw up Maintenance Step 5 Schedules/checklist 17 . etc. Identify causes of hazards New Project New Equipment Consequences/effects Probability/frequency Process change of hazards Estimation Structure change Determine Risk Conduct Issue Based Risk Assessment on high-risk equipment and tasks Recommend controls 9. Conduct Base Line Identify Major Hazards Risk Assessment (Impact on Business) Gather facts. incidents.8.

for Questionnaire and format) Conduct Issue Based Gather facts. costs. Risk Assessment on incidents.10. ISSUE BASED RISK ASSESSMENT EQUIPMENT PROCESS (See Annexure 2 & 5 Pages 38 and 54. process change and repetitive failures 18 . Critical Equipment etc. frequencies. Describe function of Determine Functional Identify Failure Mode equipment Failures [Causes] Determine Risk Failure effect/ Determine Probability consequences of Frequency [Causes Functional failures result into Functional Failures Existing Maintenance Recommend new Load onto OMM/ strategies and tasks strategies and tasks CMMIS program for [RCM] scheduling New: Equipment. modification.

ISSUE BASED RISK ASSESSMENT TASKS. Critical Tasks accidents etc. Identify hazards Identify Root Causes Consequences (severity) of Hazards Existing Determine Risk Determine Probability Tasks/Standards and and Frequency Controls (Causes could result into hazards) Recommend new Rewrite Task Approve Task controls/standards Procedure Procedure New: Equipment. Implement Task Modifications. Conduct Issue Based Gather facts. ETC (See Annexure 3 & 6 Pages 45 and 57 for Questionnaire and format). Project. PROCESSES. frequencies. ACCIDENTS. Risk Assessment on incidents. INCIDENTS.11. costs. Process Change Procedure 19 .

break down the mine. business unit. COMPUTERISED MAINTENANCE MANAGEMENT INFORMATION SYSTEM/RISK MANAGEMENT IMPLEMENTATION PROCESS Phase 1 List Assets (Inventory) Phase 2 Base Line Risk Assessment Phase 3 Maintenance Strategies/Plan New equipment New projects Phase 4 Work Management Process change New Systems Maintenance Performance (Measurement. Phase 6 CMMIS.1 PHASE 1: LIST ASSETS (INVENTORY) The first step before all assets are listed. Phase 5 Reports. etc) 18. Safety.12. CMMIS REGISTRATION: STRUCTURE (PLANT) KPA 9 GP PA Mill 1 Mill 2 Mill 3 [Equipm Loc] Pumping Conveying Lubricating System/activity Equip/Unit Motor Pump Fluid Coupling Components Rotor Bearing Shaft 20 . or plant into workable process areas and responsibility structures. Audits) Training and Development (Risk Man.

CMMIS REGISTRATION: STRUCTURE (MINE) SHAFT KPA SO9 PA Rock 1 Rock 2 Rock 3 [Equipm Drive Braking Hydraulic Loc] System Equip/Unit Motor Gearbox Coupling Components Rotor Bearing Shaft PRODUCTION KPA SO9 PA Levels [Equipment Locos Transfer Loc] System Equip/Unit Motor Gearbox Axle Components Rotor Bearing 21 .

etc.1.1.1.7 Process specifications. Equipment vulnerability 12. Major equipment . (See above structure) 12.2 PHASE 2: BASE LINE RISK ASSESSMENT 12. (See Annexure 2 & 5 Pages 38 and 54 for Questionnaire and format).1.10 Loading numbers into CMMIS System.1.breakdown into process areas. for questionnaire and format) 12.1. 12. 12. 12. (See Annexure 11 Page 96 for examples). 12. 12.9 Physical numbering of equipment locations and equipment. Process areas .6 Technical specifications of equipment.8 Equipment number identification and equipment location number identification.2. (List of all equipment per process area) 12.1 Conduct base line risk assessment.1.1 Asset inventory (all assets including buildings. special tools. special equipment.1.2.1.3 PHASE 3: MAINTENANCE STRATEGY This Phase is in five steps: Step 1 Conduct Issue Based Risk Assessment on equipment (Based on RCM/ FMECA) to identify failure modes.1. (See annexure 1& 5 Pages 34 and 54.5 Component Inventory.3 Responsibility structure . 22 . 12.2 Identify criticalities . 12.who is responsible for what process areas and equipment. (Bill of material) 12.4 Equipment inventory. consequences and frequencies/ Probabilities of failures. 12.2 Business unit/services .

Execution/implementation of new strategies.4.4. balancing 18. Pages 45 and 57).1 Planning and control of maintenance activities: . stating the hazard for each step that has to be followed/executed and why it must be done. (See Annexure 3 Page 45). (See Annexure 10 Page 94). Step 5 From that task procedure draw up a short schedule/procedure or checklist for the job card to prompt the person performing the maintenance task what to do and what to check/inspect to be able to execute the task successfully. in other words the consequence of the hazard and the risks which people are exposed to when performing the maintenance task. draw up maintenance strategies improvement plan. (See Annexure 3 & 6. Compare with existing (add or delete) 23 . 18. by updating of schedules and standards. (RCM diagram). Task scheduling . Quality data (data selection) . Next.4 PHASE 4: WORK MANAGEMENT 18. Step 2 Determine maintenance strategies/tasks using the maintenance strategy diagram. Step 4 Write Maintenance Task procedures. for the new maintenance requirements (schedules/frequencies). Workload. Step 3 Conduct Issue Based Risk Assessment on tasks identified in step 2.2 Data capturing .

.1 Management Report  Labour (Manpower)  Spares (Stores)  Costs (Finances)  Maintenance Information (OMM)  Training 24 .2. .5. .1 Performance Measurement . Benchmarking standards. . Overall equipment effectiveness). . (See Annexure 7 Page 61 for cards and sheets). 18. 18. Job cards. Performance measurement implementation. Set performance criteria (KPA's. Service order cards. Maintenance system performance using "Pareto Chart" or "Pragma" audit system. KPI's. Loading of schedules and maintenance strategies/tasks can now be loaded into the CMMIS System.3 Control documents and information . Work order/Service order structure.5. (See Annexure 14 Page 139 for KPA’s).5 PHASE 5: MAINTENANCE PERFORMANCE 18.4. Feedback information must be correct to do proper analysis.2 Maintenance Management Reports 18. Documentation flow system. .5. work sheets and checklists. Implement new performance measurement system. 18.

4 Training Reports 18.2. Artisan  Stores  Costs  Maintenance (OMM) .  System High Costs  Equipment High Costs  Labour  Contractor  Modifications  Projects 18.2.5. Complement/strength .2 Working Reports Foreman As per Management Report for his section. Call outs .3 Financial Report  Plant cost/tons treated  Section P. 18.5. Safety tasks 18. Breakdowns .2. Manpower requirements (loading) 25 .5.A.5 Management Reports Labour (Manpower) .5. Backlog .2.

Total workload 26 . Strategic spares in use . Total Rand/ton . Stores control (inventories): Working report for the Foremen .Hours . Strategic spares in for repair .. outstanding workload (includes Planned. Budget vs. actual  Total plant budget vs. Manpower available . Strategic spares consumed . Total value of spares on shelve .YTD/Month Maintenance Information . Total available month vs. total expenditure: R/ton . Items outstanding: Working report for the Foremen . Finance . unplanned work and overtime) . Planned work issued . Emergency orders processed.YTD/Month  Eng plant budget vs. Outstanding Service Orders . Overtime worked . R/Ton/Employee costed . Materials Management . Ad-hoc Reports (leave rosters). Eng Plant Actual: R/ton . Turn-around: Working report for the Foremen . Total available man-hours vs.

HCL . Collector . Chemical consumption . Manganese .m3/tons treated . actual) .m3/tons treated .R/Ton milled . Frotter .2. Compressed air/tons broken or processed .m3/tons treated . 18. kWh /gold recovered (target vs.m3/tons treated .5 Standard Report Data Production .5. actual) . actual) .m3/tons treated . River water . actual) . River water consumption . Pyrite . kWh/tons milled (target vs.m3/tons treated . utilisation) .m3/tons treated .m3/tons treated . Milling (availability vs. kWh /tons treated (target vs. Tons milling (target vs. Uranium recovered/tons treated .m3/tons treated . River water .R/Ton treated 27 . Cyanide .m3/tons treated . Gold recovered/tons treated . Potable water consumption . Ad-hoc reports .m3/tons treated . Ammonia . Coal . actual) . Flocculants . Calcine . Tons treated (target vs. Sulphuric .

Manpower Reports
- Manpower requirements (Loading sheet)
- Total complements (Per Patterson Grading):
Progressive graphs (years)
- Manpower availability: Progressive graphs
(analysis)
- Tons milled/Eng. employee: Progressive graphs
- Kg gold recovered/Eng employee: Progressive
graphs
- Equity of employment
- Manpower structure/individual Met. Works
- Leave Rosters
- Ad-hoc Reports

Manpower Reports
- Preventive maintenance completed (Hours)
- Routine maintenance completed (Hours)
- % Service orders completed (Actual target)
- Summary of miss services (Backlog)
- Total number of call outs/breakdowns
- Call-out analysis
- Breakdown analysis
- Breakdowns/call-outs/Engineering employee
- Call-outs/Engineering employee
- Repetitive maintenance analysis
(incidents/accidents)
- Equipment failure analysis
- Component failure analysis/equipment type
- Component consumptions/type
- Equipment/component life cycles (rightsizing)
- Equipment comparisons complex (life cycles)
- Spares and material availability
- Equipment replacement
- Maintenance scheduling

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- Equipment history (data capturing)
- Material consumption
- Reconditioned unit analysis
- Condition monitoring i.e. vibration/oil analysis
- Work category analysis
- Outstanding workload analysis
- Maintainable equipment inventories
- Component inventories
- Total asset inventory
- Maintenance schedules (Routine/preventive,
registers)
- Maintenance frequency control
- Unit movement report (motors/gearboxes)
- Job card reports (formats)
- Maintenance type analysis (run to
failure/prevention/condition, etc)
- Component/material stock level and
consumption
- Legal logbook inventory
- Vehicle inventories
- Critical component inventory
- Critical equipment inventory
- Planned task observations (Standard work
procedure)
- Planned partial observations (Critical task
procedure)
- Task procedure scheduling
- Equipment inventory updating (new/redundant)
- Unique number identifications
- Nuclear sources inventories
- Nuclear sources inspection schedules
- Accidental damage analysis
- Equipment/component/material on test analysis
- Ad-hoc reports

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Maintenance Cost Analysis
- Total maintenance cost (present versus previous
year)
- Maintenance cost/tons processed (Rand/tons)
- Maintenance cost/eng employee
- Maintenance cost/kg of gold recovered
(Rand/kg)
- Overtime worked (actual versus target)
- Equipment failure cost analysis
- Component failure cost analysis
- Maintenance cost analysis/process area
- Maintenance cost analysis/equipment type
- Production downtime cost analysis
- Equipment/component/material consumption
cost/store stock
- Labour cost analysis (standard rates)
- Vehicle maintenance cost analysis
- Rand/kw/tons processed
- Compressed air m3/ton cost
- Mine air used cost analysis
- Chemical cost analyses
- Accident/incident/property damage cost analysis
- Maintenance contract cost analysis
- Labour hire cost analysis
- Abnormal repair cost analysis
- Capital replacement cost analysis
- Workshop cost analysis
- Equipment hire cost analysis
- Standard stock price report
- Equipment on test cost report
- Identification of high cost equipment/component/
waters processed areas analysis
- Maintenance shutdown cost analysis

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Training courses cost analysis .S. Modules 31 . Metallurgy bonus cost analysis . Training effectiveness monitoring (productivity) . Ad-hoc reports Training and Development . Equipment replacement cost analysis . Breakdown cost analysis . Major repair cost analysis . Reconditioned equipment cost analysis . Call-out cost analysis . Inventory of Engineering employees .A. Repetitive maintenance cost analysis . Token travelling cost analysis . . Training progress reporting system . Maintenance cost per process area .M. Development plan for each Engineering employee . Plant improvement cost analysis (modifications) . Occasional travelling cost analysis . Training progress monitoring system . Scheduling of training courses per Engineering employee . Scrap material/equipment analysis . Additional bonus cost analysis . Redundant equipment resale analysis . New installation cost analysis . Personal protective equipment cost analysis . Property damage cost report . S. Ad-hoc reports .

6 Set benchmarking standards to measure your business strategies and maintenance strategies. The training must enable them to do the risk assessments required by the Mine Health and Safety Act.3.7 Set KPA's and KPI's for above mentioned audit contents. 18. 18.5.2 Maintenance System Performance (@PRAGMA) 18.1 Risk Management Training to be given to all employees in Risk Assessment techniques and methodologies related to their level of work standard. production people to be inducted.6. the work order structure and work packages and their prioritising what it means.5.3.3. 18.6 PHASE 6 : TRAINING 18.4 Task Personnel to be trained on all the tasks he will be exposed to in the working place/area.3. and the documentation flow.1 Maintenance System Compliance (Technical strategies) 18. 6 monthly) 18.3. job card flow systems.5. Training to Artisans i.5. and all related maintenance on the equipment.5.e.e. 18. 32 .5.3 Maintenance Management Audits 18.5 Establish frequencies of audits (i.3.3. 18. Foremen and artisans on how the maintenance system works and what reports it can generate. etc. 18.5.2 CMMIS Training to be given to Engineers.6.6. what information is needed back and why.3 Technical Training to be selective to the technology and equipment standard used.6. The task must address the hazard and risks associated with the equipment and the consequences if he does not comply with the standards.4 Identification/execution of maintenance improvement plans 18.3 Maintenance Cost efficiencies 18.5.

6. CONCLUSION The challenge facing maintenance and risk management can be met by implementing the methodologies and techniques as set out in this document.Brokke – Manager Engineering Systems 33 . knowledge. reliability and safety  Longer equipment life (cost saving)  Improve Team Work. 13. COMPUTERISED MAINTENANCE MANAGEMENT INFORMATION SYSTEM/RISK BENEFITS  Globally competitive  Corporate data base and legal compliance  Put Maintenance strategies into perspective  Understanding of how assets/equipment works and can fail (Business Efficiency)  Higher plant availability. 18.J. I. motivate and empower.D.5 Safety & Hazards Personnel to be inducted and trained in safety and health measures and the programme in use at that particular Mine or Business Services.Menzies – Head of Engineering A.

REFERENCES (Biography) 1. 2. Robert W Vivigan and Gawie S du Toit.Centered Maintenance. John Moubray. Techniques and Insets) 3. 1995 34 . Hellriegel Slocum. 7th Edition. Anthony C Valsamakis. RCMII Reliability . Project Risk Management on (Processes. Management. Jasper L Coetzee Maintenance. The theory and principle of Risk Management 4. Chris Chapman and Stephen Ward. Maintenance Publisher 1997 5.

ANNEXURE 1 35 .

e. exposure to. material and environment? 36 . environment and material (costs of process loss)?  What controls must be put in place to control or eliminate hazards i. QUESTIONS (MAJOR SYSTEMS: TASK RELATED)  What causes the equipment to become a hazard? (i. physical condition to the equipment when doing maintenance or operating it. material (Process loss) and environment (i. equipment. when people operate or do maintenance on the units of the major equipment (system). safety. material (process loss) and environment?  What will the severity of that hazard be on people (injury). (Code of Practices and emergency procedures and hazard elimination)? Major equipment/systems is a hazard. when operating or maintaining it)?  What will the severity be on people.e.  What causes the hazard?  What will the impact/effect/consequences of the hazard be on people. physical contact. the units are the causes)  What will the impact/effect/consequences of that hazard be on people. equipment (costs). ANNEXURE 1 QUESTIONNAIRE: BASE LINE RISK ASSESSMENT QUESTIONS  Identify all the major hazards that effect the Mine or Business Service.e.

37 . the following process/questions are to be followed/asked: * List all the equipment/units and spares. COP's and standards. MAJOR HAZARDS * Fire * Power failure * Flammable gas explosion * Hazardous chemicals * Flooding * Dust * Noise * Radiation * Major Equipment (Systems) * Tramming * Transporting * Explosives * F.O. QUESTIONS ON EQUIPMENT/UNITS TO DETERMINE THE VULNERABILITY To identify the vulnerability/criticality of the equipment/units.  List the significance of risks. * What causes the equipment/units to fail? (Any failure causes the equipment to be a hazard).G.)  What is the probability/frequency of the event occurring?  Controls to be put in place i. ANNEXURE 1 – (Contd.e.

38 .)  What causes the spare equipment (e. production (material/process loss) and the environment?  What is the probability/frequency of the event occurring?  What controls/actions are to be in place to control or eliminate the failures/loss? (Hazards) Controls: * Procedures * Maintenance strategies * C. ANNEXURE 1 – (Contd.P’s * Standards. the equipment itself. the equipment itself.g. production (material/process loss) and the environment?  What is the impact/effect/consequences for not having a spare (winder rope) on people safety.O. winder ropes) to be a hazard?  What is the impact/effect/consequences of that failure (winder rope) on people safety.

ANNEXURE 2 39 .

40 . the inability of an asset to meet the desired standard of performance (unsatisfactory condition)?  Total loss of function: item stops working. (At this level. output.  Partial loss of function: fails to meet specific performance standard. material. These effects/consequences determine what preventative maintenance (if any) is needed. ANNEXURE 2 BASIC QUESTIONS ON THE EQUIPMENT TO DETERMINE MAINTENANCE STRATEGIES/TASKS  FUNCTION: Performance standard. we manage failures by applying maintenance strategies/tasks). operating costs and safety. QUESTION: In what ways does it fail to fulfil its functions?  FAILURE MODES (CAUSE): Are reasonably likely to cause each loss of function (failure).e?  Downtime (production loss/process)  Effect on equipment (damage)  Effect/consequence on people (safety and health)  Effect/consequence on environment. equipment and the environment). i. QUESTION: What are the functions and associated performance standards of the asset in its present operating context?  FUNCTIONAL FAILURES: Is. environmental issues. product quality. QUESTION: What causes each functional failure?  FAILURE EFFECTS (CONSEQUENCES): What would happen if the item fails to fulfil its function. QUESTION: What happens when failure occurs? (The impact on people.

e. or equipment/item (functional) failure occur? QUESTION: What is the frequency of failures or (if no data) what is the probability that the cause could result in a functional failure?  SEVERITY: Severity is the effect/consequences of the functional failure on people.  CURRENT MAINTENANCE STRATEGIES: List all present maintenance strategies (preventive) and tasks related to the Failure Modes (Causes). component or block). Overhauling an assembly.e. incident.e. regardless of its condition at the time. QUESTION: In what way does each failure matter? (Cost and injuries i. ANNEXURE 2 – (Contd. vibration. and failure effect/consequences (severity) and frequency/probability determine what preventive maintenance is needed. at or before a specified age limit.  Scheduled discard Tasks (Use Based Maintenance): Discarding an item at or before a specified life limit.  Scheduled restoration (Use Based Maintenance): Re-manufacturing a component. Condition Monitoring is monitoring the condition i. etc. regardless of its condition at the time (scheduled replacement i. (Using RCM decision diagram. days lost). measure it and draw trends.  PREVENTIVE MAINTENANCE (TASKS):  (On-Condition Tasks/Condition Monitoring) (Predictive Maintenance): Most failures give some warnings that they are about to occur (potential failures) which are identifiable as physical conditions. when risk is high in that impact areas.e. i.). feel listen and repair if faulty. QUESTION: What can be done to prevent each failure?  RECOMMENDED MAINTENANCE STRATEGIES/TASKS: The failure modes (causes).e. oil analysis.)  PROBABILITY/FREQUENCY: Is the rate at which the events (causes) that create an accident. also construction repairs. material. On condition task is look. Who must do it and how frequent. 41 . equipment and environment (i. cost implication and injuries).

If the risk is high on the following impact areas. weekly. regardless of its condition at the time and replace with new design.e. testing brakes.e. or modified equipment to prevent risks to safety of people and environmental impact.)  Routine Service Tasks: Routine Service Tasks is do it. ANNEXURE 2 – (Contd. to determine if there are any functional failures. Note: If task cannot reduce the risk the item must be redesigned or the process must be changed. i.PLC's. which has safety and health or environmental consequences.e. etc. also production and equipment. performing restoration or discard tasks on equipment that failed. then a scheduled failure finding task is to be performed (routine service) i. people safety. go down the tree as described here under. Health and Environmental: (When Risk is high on people or safety. is worth doing if it reduces the risk of that failure on its own to a reasonably practicable low level or eliminates it (causes). etc. Most of these failures are associated with protective devices. redesign. pre-use inspections.  (People) Safety. equipment. monthly etc. change oil.  Opportunistic Maintenance Tasks: When the opportunity is there to apply either restoration or discard tasks. Also doing legal requirement tasks.  Redesign/Design out Maintenance: When preventative maintenance tasks could not be found to prevent a failure or it affects safety or the environment. electrical.  DECISION DIAGRAM (MAINTENANCE STRATEGIES/TASKS) IMPACT AREAS: On the evaluation sheet (Risk Assessment) the risks are identified and quantified. material (production loss). set v-belts. change filters. go down the tree) A proactive task to prevent the failure. if no suitable routine service task. 42 . environment. test equipment. etc). i.e. testing safety equipment and devices. etc. If the risk is not reduced/prevented. depending on risk. Discarding an item at or before a specified life limit. Plant shutdowns. which are not fail safe .  Corrective Maintenance Tasks: After hour breakdowns (call-outs) and during working hours breakdowns. at a frequency.. then to determine the maintenance tasks/strategy from the diagram.  Hidden Failure (Equipment): (When Risk is high on equipment go down the tree) A task to prevent the failure of a "hidden function/proactive task" is worth doing if it reduces the risk of the multiple failures associated with that function to a reasonably practicable low level. i.

discard and predictive maintenance tasks. then redesign or modify. Pro-active maintenance is to be applied if the risks are high (i. go down the tree) If a failure has non-operational (production loss) consequences. then no scheduled maintenance and if the repair cost is to high. redesign is an option. Cost of Repair = Labour cost per year on that item/unit plus spares cost (the number of times the item has been repaired). If not.equipment. Cost of task (breakdown) = Labour cost + spares cost + production loss. ANNEXURE 2 – (Contd. production and environment. a preventive/proactive task is worth doing if the cost of the task over a period of time is less than the cost of repair over the same period. go down the tree) If the failure has operational (production) consequences. a preventive/proactive task is only worth doing if the total cost of doing it over a period of time is less than the cost of the operational (production loss) consequences and the cost of repair over the same period. consequence/severity and frequency/probability of failure) on the impact areas . Proactive tasks are scheduled restoration.)  (Material loss) Operational consequences: (When Risks is high on material production loss. Cost of Repair = Labour cost + spares cost. Note: Cost of task = Labour cost per year on that item/unit plus spares when it fails plus production loss. safety. If it is not justified. 43 .e. hours standing due to the breakdown/failure. i. Labour cost + spares cost x number of times repairing item < (less than) production loss + labour cost + spares cost.  Non-Operational (Equipment): (When Risk is high on equipment and no hidden failure.e.

I. TEMPERATURE. OIL ANALYSIS.) MAINTENANCE STRATEGY STRUCTURE DESIGN OUT PREVENTIVE CORRECTIVE MAINTENANCE MAINTENANCE MAINTENANCE USE BASE/TIME BASE PREDICTIVE MAINTENANCE MAINTENANCE SCHEDULED SCHEDULED ROUTINE (SERVICE) OPPORTUNISTIC ON CONDITION CONDITION RESTORATION TASK REPLACEMENT TASKS MAINTENANCE/TASKS MAINTENANCE MONITORING (OVERHAUL) (DISCARD TASKS) INSPECTIONS THE UNIT IS OPENED COMPONENT WHEN CHANGING OIL ACID PLANT WHEN GOING TO A UNIT DOING: VIBRATION AND INSPECTED AT A REPLACEMENT OR CHANGE FILTER. SPECIFIC TIME. BLOCK REPLACEMENT. TESTING. REPAIRING HANDRAILS. 42 . LISTEN AND (RECORD). TIME REPLACED/DISCARD WALKWAYS WHEN RELATED. CARRIED OUT WHEN PARTICULAR FAILURE OCCURS. CHECK (RECORD).E. DO IT.E. I. YOU REPLACED WHICH ARE NO MATTER THE LEGAL REQUIREMENT PRESSURE. DAILY. INSPECT THE PHYSICAL TESTS. I.E. SEE. ETC. ETC.42 ANNEXURE 2 (Contd. 6 MONTHLY & YEARLY. WEEKLY. REPAIR GET A TREND ON A RESTORE AS NEW.E. SMELL. CORRODED. MAINTENANCE. FEEL. ASK CONDITION OF IT. CHANGED WITH SAFETY UNIT/ITEM ALSO GRAPH TO DETERMINE NEW/OVERHAULED DEVICES/EQUIPMENT.). NOT OPERATE TO DESIGN STANDARD. I. TASKS I. ETC. THIS TASKS ARE ETC. ETC. FLOW AND COMPONENTS REPLACED/DISCARDED MONTHLY. (RECORD). I. ETC. TEMPERATURE 3 OR 6 MONTHLY THE ITEMS OR TIME INTERVALS. WEEKLY.E. CONDITION. PRESSURE MAINTENANCE.E. COMPONENT. MONTHLY. SET SHUTDOWN. WHEN: FAULTY. WHEN TO DO ONES OR STRUCTURES. TENSION. HAVE TO RECORD TO WORN OR DAMAGED. WHEN FAULTY. COMPONENTS ARE (DAILY. FLOW.

) MAINTENANCE STRATEGY DECISION DIAGRAM Hidden Failure Safety Consequence Environmental Consequence Operational Consequence H S Environmental E Consequence O Will the loss of function caused by Does the failure mode Does the failure mode cause a Does the failure mode have a direct this failure mode on its own become cause a loss of function loss of function or other adverse effect on operational capability evident to the operating crew under Yes Yes or other damage which No N damage which could breach No (output. ANNEXURE 2 (Contd.g. customer service or No normal circumstances? could hurt or kill any known environmental operating costs in addition to the direct someone? standard or regulation? cost of repair)? o No Yes No Yes H1 N1 Is a task to detect whether the S1 O1 Is a task to detect whether the Is a task to detect whether the Is a task to detect whether the failure is occurring or about to failure is occurring or about to failure is occurring or about to failure is occurring or about to occur technically feasible and worth occur technically feasible and worth occur technically feasible and worth occur technically feasible and worth doing? No doing? doing? doing? Yes No Yes No Yes No Yes No Scheduled Scheduled Scheduled Scheduled On-condition task On-condition task H2On-condition On-condition task Is a scheduled restoration task to O2 N2 task reduce the failure rate technically feasible and worth doing? S2 Is a scheduled restoration task to avoid failures technically feasible Is a scheduled restoration task to reduce the failure rate technically Is a scheduled restoration task to reduce the failure rate technically No and worth doing? feasible and worth doing? feasible and worth doing? Yes No Yes No Yes No Yes No Scheduled Scheduled Restoration task Restoration task Scheduled Scheduled H3 S3 Restoration task Restoration task Is a scheduled discard task to O3 N3 feasible and worth doing? No reduce the failure rate technically Is a scheduled discard task to avoid failures technically feasible and Is a scheduled discard task to reduce the failure rate technically feasible Is a scheduled discard task to reduce the failure rate technically feasible and worth doing? and worth doing? worth doing? Yes No Yes No Scheduled Scheduled Yes No Yes No Discard task Discard task H4 S4 Is a failure-finding task to detect Is a combination of tasks to avoid No scheduled Scheduled No scheduled Scheduled failures technically feasible and Maintenance the failure technically feasible Discard Task Maintenance Discard Task worth doing? and worth doing? e. Yes Routine Service Notasks No Yes Redesign may Redesign may Be desirable Scheduled failure. quality. Be desirable H5 Combination of Redesign is finding task Could the compulsory tasks multiple failure affect safety or the environment Note: No Scheduled Maintenance means Run to Failure Redesign is Yes No No scheduled Redesign may be compulsory maintenance desirable 43 .

ANNEXURE 3 44 .

g. operating or maintaining that machine or equipment .falling/stumbling . This process is as follows:  All the causes that are task related and resulted in the hazard in the Base Line Risk Assessment (e. ANNEXURE 3 ISSUE BASED OPERATIONS (Tasks. (Everyday work activity .  What can go wrong? (What if?) . material (Process loss). BASIC QUESTIONS ON ISSUE BASED RISK ASSESSMENT ON TASKS. (e. An issue Based Risk Assessment is to be conducted on these tasks if it has a significant impact on people safety and/or process losses and/or equipment damage and/or an environmental impact. power failure. legal. (e. Evaluate step by step. as per the CMMIS Risk Management Reference Manual. come in contact . (tasks). list all the steps that have to be followed to perform/execute a task (operation and maintenance).e.g. For each step ask the following questions:  With what can the person. etc). and environment?  What is the probability/frequency of the causes that resulted in the hazard? (How often)  What is the probability/frequency that the cause in relation to the severity of the 45 . equipment.g. Risk Index 28-48)  An Issue Based Risk Assessment needs to be conducted on all the causes that are related and resulted in the hazard identified in the Base Line Risk Assessment.e.materials handling . new equipment) From Base Line Major Hazards.contact with machinery etc).  What is the physical condition of the machine/equipment and area? There are further questions to be asked on all the possible hazards (Hazard criteria from Risk Management Reference Manual) to which that person is exposed. as per the CMMIS Risk Management Reference Manual and the emergency procedure which controls the Hazard. emergency &task procedures must be compiled/written and reviewed. process. tools. activities. MODIFICATIONS. the unwanted event is a situation with the potential to cause harm. using the two different Issue Based techniques. using hazard criteria for Issue Based Assessments. to the person operating or performing a maintenance task on the machine.  What causes the hazard?  What will the impact/effect/consequences of that hazard be on people safety. other people in same area. i. incidents. Fire)  Assess/Evaluate the causes that are task related on the major equipment/systems. that could cause harm? (Physical contact with. accidents. Fire). damage or injury in the domain of safety.Equipment (material errors i. Significance A.e. PROCESS or TASKS) Note: Before assessing a task. flooding. external – rocks). equipment. etc.External (i. INCIDENTS AND ACCIDENTS  HAZARD DEFINITION A source of danger that may cause loss. Fire. malfunctions) .People (Human errors) . QUESTIONS: (NEW EQUIPMENT. equipment.

area. environmental.)  What are the existing controls. accident could happen on people and result in the hazard? ANNEXURE 3 – (Contd. other people in same working area. eliminate or transfer the risk? QUESTIONS: (INCIDENTS AND ACCIDENTS)  This Issue Based Risk Assessment concentrates on unsafe acts and unsafe conditions  With what did the person came in contact with? While he was performing his duties. i. Fall of ground .  What was the physical condition of the machine/equipment. Ionising radiation Inrushes Ventilation 46 . legal.e. OTHER HAZARDS FOR ISSUE BASED RISK ASSESSMENT WHICH PEOPLE ARE EXPOSED TOO (TO BE EVALUATED AS WELL)  Hazardous substances  Radiation  Superfluous material  Vibration  Flammable substances  Temperature  Electricity  Illumination  Water  Pressure  Ergonomics  Noise  Dust Also the following hazards could be used to prompt the team for underground hazard: Strata Control/Rock Mechanics . tools. operating equipment or maintaining equipment or travelling to or from his workplace. etc)  Unsafe acts and conditions. standards and procedures to control. etc?  What went wrong?  People (Human errors)  Equipment/machine (Material errors and malfunction)  External (Activities. standards and procedures?  What are the recommended controls.

EQUIPMENT ISSUE BASED . Machines . falling. Stumbling. FACILITATOR . Explosives . Contact with electricity . Locomotives . Lifting . Entrapment . 47 . Spontaneous combustion Transport Systems . Trackless equipment .Respirable dust ANNEXURE 3 (Contd. Temperature . Noise . Flammable dust . Shafts Occupational Hazards . Conveyors .) Fires and explosives . Fire .. Sources of ignition .TASK . etc RESOURCES TO CONDUCT AN ASSESSMENT (THE TEAM) ISSUE BASED . Irreparable atmosphere . Explosive atmosphere .FACILITATOR GES/Engineering Supervisor Safety Officer/Foreman * Engineering Supervisor * Operations Supervisor * Operations Supervisor * Engineering Supervisor * Artisan * Operator * Operator * Artisan * Specialist * Specialist * Safety Officer * Training Officer * Training Officer * Scribe * Scribe The team members will be used as and when they are required to specific/appropriate equipment/tasks related issues.

ANNEXURE 4 48 .

49 .

) RISK ASSESSMENT INPUT WORKSHEET Type of Reference Revision Revision Mine / Plant Process Area Activity / System Page number Assessment (Master Reference) Date Number Base-line FSG 1/04/8 14 Jan 1998 000 FSGno3Plant Milling Conveying _1_ of _29__ Consequence Effect on People. Significance Ref No Hazard Cause Equipment. ANNEXURE 4 (Contd. Environment Occupation S Fr R (ABC) For last Page see Page 50 50 . Production.

51

ANNEXURE 4 (Contd.)

Last Page of Risk Assessment Input Worksheet as shown on Page 49
No.Hazard

Action Required By Whom By When Sign Off
after completion

ANNEXURE 4 (Contd.)

EQUIPMENT/ UNITS VULNERABILITY ( RISK ASSESSMENT )
LEGEND
PR = PROBABILITY (QUALITATIVE DATA)
FR = FREQUENCY (QUANTITATIVE DATA)
S = SEVERITY
R = RISK
* NOTE: Using AngloGold Risk Matrixes
P = People Eq = Equipment Env.= Environment Mat = Material (Process Loss )

BUS.UNIT: SECTION: EQUIP. /UNIT:
DATE: ________________________________________________________________

HAZARD CAUSE * EFFECT / CONSEQUENCE PR PROBABILITY / S PR R EXISTING RECOMMENDED COSTS S P R
( EQ./UNIT or FREQUENCY THAT THE or CONTROLS CONTROLS or
FAILURE OR FR CAUSE COULD RESULT FR R
NO SPARE) INTO A HAZARD

COMMENTS:

52

53

ANNEXURE 4 (Contd.)

HAZARD CAUSE * EFFECT / CONSEQUENCE PR PROBABILITY / S PR R EXISTING RECOMMENDED COSTS S P R
or FREQUENCY THAT THE or CONTROLS CONTROLS or
FR CAUSE COULD RESULT FR R
INTO A HAZARD

COMMENTS:

ANNEXURE 5 54 .

) EQUIPMENT ISSUE BASED RISK ASSESSMENT/EVALUATION ON FAILURE MODE/EFFECT AND CRITICALITY ANALYSIS KPA (Bus./ Failure Unit/Equipment no: ***** Failure: Component Code: Function: . ANNEXURE 5 (Contd.Unit) : PROCESS AREA (Section) : DATE : LEGEND Pr = Probability(Qualitative) EQUIPMENT/LOCATION Fr = Frequency ( Quantitative) SYSTEM : Nº S = Severity UNIT/EQUIPMENT : Nº R = Risk CONSEQEUNCE/EFFECT * PEOPLE * EQ = EQUIPMENT *MAT = MATERIAL * ENV = ENVIRONMENT (PROCESS LOSS) Unit/ Functional Failure Cause of Failure * Failure Effect/ PR Probability/ S PR R Current Maintenance Recommended Maintenance Components (Loss of Function) (Failure Mode) Consequence or Frequency that the or Strategies/ Tasks Strategies / Tasks Function (What Happens when it FR Cause Could Result FR Fails) (Severity) in Funct.

Unit/ Functional Cause of Failure * Failure Effect/ Consequence Pr/ Probability/ S PR R Current Maintenance Recommended Components Failure (Loss (Failure Mode) (What Happens when it Fails) Fr Frequency that the Or Strategies/ Tasks Maintenance Strategies / Function of Function) (Severity) Cause Could Result FR Tasks in function failure 57 .

ANNEXURE 6 58 .

ANNEXURE 6 (Contd.) Risk Assessment Work Sheet (Summary sheet!) ISSUE: Reference Revision Revision Type of Assessment Mine / Plant Process Area Activity / System Page number (Master Reference) Date Number Issue-based _1_ of _10__ Ex Base Line Issue New Equipment Post Incident New Facility Task Review Change in Process X No Hazard Significance of Risk: Score: 41 (A B C) Score: 40 (A B C) Score: 36 (A B C) Score: 35 (A B C) Score: (A B C) Score: (A B C) Score: (A B C) Score: (A B C) Score: (A B C) Score: (A B C) Score: (A B C) 59 .

and Mat. Existing Controls S FR R (Re-engineering of Process) S FR R (Production). Environment. B. the significant risks are carried over to the summary sheet shown on Page 57 Type of Reference Revision Revision Date Mine / Plant Process Area Activity / System Page number Assessment (Master Reference) Number Issue- Based FSG 3/41/8 14 Jan 1998 002 FSGno1 Shaft Sinking _2_ of _10__ Hazard No: Hazard: Significance of Risk: (A.) Hazard Analysis sheet. Equipment.60 ANNEXURE 6 (Contd. (Re-organization of work) . there could be many of them. C) Consequence Effect on People Recommended Controls Cause Safety.

) Last Page of Analysis Sheets as shown on Page 58 NoHazard Action Required By Whom By When Sign Off after completion 61 . ANNEXURE 6 (Contd.

ANNEXURE 7 62 .

) 63 .P. 1 SERVICE ORDER : PREVENTIVE MAINTENANCE Task Description: SCHEDULED RESTORATION TASK JOB Nº: Description and function: Work type: K. ANNEXURE 7 (Contd.: EQUIP. LOC.A. Nº: (Activity version) Foreman's Name: Foreman’s code: Artisan’s Name: Artisan’s Code: Planned date: Date completed: Job status: Closed Normal time: H Continued Overtime: H Task: Engineering Delay time due to the following: Operational Travelling Time: H Operation time: H Engineering: H Spares: H TOTAL JOB DURATION: H ARTISAN'S SIGNATURE FOREMAN'S SIGNATURE ANNEXURE 7 (Contd.) SRT.: P.A.: Equipment Nº: Unit Nº: Schedule Ref.

17 CONTAMINATED GLAND SERVICE 27 MISALIGNMENT ETC) 08 POOR QUALITY COMPONENT 18 SLIME SPILLAGE 28 EXCESSIVE LUBRICATION 09 POOR QUALITY MATERIAL 19 ACID SPILLAGE 29 POWER SURGE FAILURE 10 POOR CONDUCTIVITY 20 EXCESSIVE DUST 30 DONE COMPONENTS / BILL OF MATERIAL WORK SCHEDULE/TASKS STEPS DESCRIPTION Y N CODE FAILURE COMPONENT STOCK CODE DESCRIPTION CODE ANNEXURE 7 (Contd. 1 64 . 2 COMPONENT FAILURE MODES (CAUSES) AND CODES CODE DESCRIPTION CODE DESCRIPTION CODE DESCRIPTION 01 MOISTURE 11 END OF LIFESPAN 21 ENVIRONMENTAL CONDITION 02 VIBRATION 12 INCORRECT LUBRICANT 22 POOR WORKMANSHIP 03 STUCK / BLOCKED 13 CONTAMINATED LUBRICANT 23 INADEQUATE VENTILATION 04 SURGE / CAVITATION 14 SABOTAGE 24 CORROSION 05 INADEQUATE LUBRICATION 15 INCORRECT COMPONENT / 25 INCORRECT DESIGN (REDESIGN) MATERIAL 06 INADEQUATE GLANDSERVICE 16 MALICIOUS DAMAGE 26 INCORRECT COMPONENT FITTED 07 BURNT (V-BELTS. SRT.) SDT. MOTORS.

: P. SERVICE ORDER : PREVENTIVE MAINTENANCE Task Description: SCHEDULED DISCARD TASK JOB Nº: Description and function: Work type: K.A.) SDT. 2 65 .A.: EQUIP. Nº: (Activity version) Foreman's Name: Foreman’s code: Artisan’s Name: Artisan’s Code: Planned date: Date completed: Job status: Closed Normal time: H Continued Overtime: H Task: Engineering Delay time due to the following: Operational Travelling Time: H Operation time: H Engineering: H Spares: H TOTAL JOB DURATION: H TASK DESCRIPTION: ARTISAN'S SIGNATURE FOREMAN'S SIGNATURE ANNEXURE 7 (Contd. LOC.: Equipment Nº: Unit Nº: Schedule Ref.P.

2. ARRANGE TO HAVE PUMP STOPPED AND ISOLATED. INSTALL NEW PUMP. ANNEXURE 7 (Contd. 1 SERVICE ORDER : PREVENTIVE MAINTENANCE 66 . MOTORS. COMPONENT FAILURE MODES (CAUSES) AND CODES CODE DESCRIPTION CODE DESCRIPTION CODE DESCRIPTION 01 MOISTURE 11 END OF LIFESPAN 21 ENVIRONMENTAL CONDITION 02 VIBRATION 12 INCORRECT LUBRICANT 22 POOR WORKMANSHIP 03 STUCK / BLOCKED 13 CONTAMINATED LUBRICANT 23 INADEQUATE VENTILATION 04 SURGE / CAVITATION 14 SABOTAGE 24 CORROSION 05 INADEQUATE LUBRICATION 15 INCORRECT COMPONENT / 25 INCORRECT DESIGN (REDESIGN) MATERIAL 06 INADEQUATE GLANDSERVICE 16 MALICIOUS DAMAGE 26 INCORRECT COMPONENT FITTED 07 BURNT (V-BELTS. 17 CONTAMINATED GLAND SERVICE 27 MISALIGNMENT ETC) 08 POOR QUALITY COMPONENT 18 SLIME SPILLAGE 28 EXCESSIVE LUBRICATION 09 POOR QUALITY MATERIAL 19 ACID SPILLAGE 29 POWER SURGE FAILURE 10 POOR CONDUCTIVITY 20 EXCESSIVE DUST 30 DONE COMPONENTS / BILL OF MATERIAL WORK SCHEDULE/TASKS STEPS DESCRIPTION Y N CODE FAILURE COMPONENT STOCK CODE CODE DESCRIPTION 1. REMOVE PUMP FROM SUMP. 3.) RST.

LOC.: Equipment Nº: Unit Nº: Schedule Ref.A.) RST.P.: EQUIP.A. 2 COMPONENT FAILURE MODES (CAUSES) AND CODES CODE DESCRIPTION CODE DESCRIPTION CODE DESCRIPTION 67 .: P. Nº: (Activity version) Foreman's Name: Foreman’s code: Artisan’s Name: Artisan’s Code: Planned date: Date completed: Job status: Closed Normal time: H Continued Overtime: H Task: Engineering Delay time due to the following: Operational Travelling Time: H Operation time: H Engineering: H Spares: H TOTAL JOB DURATION: H TASK DESCRIPTION:LEGAL INSPECTION/TEST ARTISAN'S SIGNATURE FOREMAN'S SIGNATURE ANNEXURE 7 (Contd. Task Description: SCHEDULED ROUTINE SERVICE TASK JOB Nº: Description and function: Work type: K.

17 CONTAMINATED GLAND SERVICE 27 MISALIGNMENT ETC) 08 POOR QUALITY COMPONENT 18 SLIME SPILLAGE 28 EXCESSIVE LUBRICATION 09 POOR QUALITY MATERIAL 19 ACID SPILLAGE 29 POWER SURGE FAILURE 10 POOR CONDUCTIVITY 20 EXCESSIVE DUST 30 FAULTS IDENTIFIED AND ACTIONS TAKEN FAULTS IDENTIFIED (FUNCTIONAL FAILURES) CAUSE (CODE) ACTION DONE COMPONENTS / BILL OF MATERIAL WORK SCHEDULE/TASKS STEPS DESCRIPTION Y N CODE FAILURE COMPONENT STOCK CODE CODE DESCRIPTION 68 .01 MOISTURE 11 END OF LIFESPAN 21 ENVIRONMENTAL CONDITION 02 VIBRATION 12 INCORRECT LUBRICANT 22 POOR WORKMANSHIP 03 STUCK / BLOCKED 13 CONTAMINATED LUBRICANT 23 INADEQUATE VENTILATION 04 SURGE / CAVITATION 14 SABOTAGE 24 CORROSION 05 INADEQUATE LUBRICATION 15 INCORRECT COMPONENT / 25 INCORRECT DESIGN (REDESIGN) MATERIAL 06 INADEQUATE GLANDSERVICE 16 MALICIOUS DAMAGE 26 INCORRECT COMPONENT FITTED 07 BURNT (V-BELTS. MOTORS.

A. ANNEXURE 7 (Contd. EQUIPMENT LOCATION: FOREMAN'S NAME: FOREMAN’S CODE: ARTISAN’S NAME: ARTISAN’S CODE: MONTH: WEEK END DATE: JOB Nº EQUIP. P.) PREDICTIVE MAINTENANCE CONDITION MONITORING TASKS K. UNIT Nº TASK DESCRIPTION ACTIVITY ACTIVITY JOB TIME START DATE DATE Nº CODE VERSION STATUS COMPLETED C O HRS MIN 69 .A.P.

70 ANNEXURE 7 (Contd.A. P.P.A.) PREDICTIVE MAINTENANCE ROUTINE SERVICE TASKS K. UNIT Nº TASK DESCRIPTION ACTIVITY ACTIVITY JOB TIME START DATE DATE Nº CODE VERSION STATUS COMPLETED C O HRS MIN . EQUIPMENT LOCATION: FOREMAN'S NAME: FOREMAN’S CODE: ARTISAN’S NAME: ARTISAN’S CODE: MONTH: WEEK END DATE: JOB Nº EQUIP.

ANNEXURE 7 (Contd. P. EQUIPMENT LOCATION: FOREMAN'S NAME: FOREMAN’S CODE: ARTISAN’S NAME: ARTISAN’S CODE: MONTH: WEEK END DATE: JOB Nº EQUIP.A. UNIT Nº TASK DESCRIPTION ACTIVITY ACTIVITY JOB TIME START DATE DATE Nº CODE VERSION STATUS COMPLETED C O HRS MIN 71 .P.) PREDICTIVE MAINTENANCE ON CONDITION TASKS K.A.

RADIOS. WALKWAYS. UFS'S. SLEEVE. SHAFTS. ETC) HOURS WORKED (TRAVELLING TIME INCLUDED) JOB EQUIPMENT/ MAINTENANCE FAILURE MODE QTY COMPONENT/ FAILURE MODE COST NORMAL TRAVEL OVERTIME TOTAL No UNIT NO STRATEGY CODES (COMPONENT) STOCK CODES CAUSE (CODE) TIME OR S. HANDRAILS. VALVE. EARTH LEAKAGES.72 ANNEXURE 7 (Contd. STRUCTURES. CONTACTORS. LINER. IMPELLER. GATE. OVERLOADS.E. ETC) ARTISAN NAME: 09 ROUTINE SERVICES ARTISAN CODE: 10 SAFETY WORK (GOOD HOUSE KEEPING TASKS) FAILURE MODE (CAUSE) FAILURE MODE CAUSES ARE THE COMPONENTS OF THE UNIT/EQUIPMENT WHICH FAILED I. GEARS. W/O NO: DATE SEND: DATE RECEIVED: ASSISTANTS HOUR METER DOWN TIME LOSS PRODUCTION TIME NORMAL AFTER HOUR ARTISAN SIGNATURE FOREMAN SIGNATURE .R. DOCS. CIRCUIT BREAKERS.) PREVENTIVE MAINTENANCE (USE BASED AND PREDICTIVE) DAILY JOB REPORT (ARTISAN) CODES MAINTENANCE STRATEGY/CODES DATE WORKED: 02 UNPREDICTABLE KPA: 03 BREAKDOWN (RESTORATION OR DISCARD TASK) PROCESS AREA (PA): 04 AFTER HOUR BREAKDOWN (UNIQUE) SYSTEM (EQUIPMENT LOCATION): 05 CONSTRUCTION (NEW INSTALLATION OR PROCESS CHANGES) FOREMAN NAME: 06 SIGN OUT/MODIFICATION (EQUIPMENT CHANGE OR MODIFICATION) FOREMAN CODE: 08 ON CONDITION (ROUTINE INSPECTION AND REPAIR) I. NO DESCRIPTION OF MAINTENANCE STRATEGY: NOTE: ONLY BREAKDOWNS AND CALL-OUTS HAVE PRODUCTION/PROCESS LOSS CONSEQUENCE: EQUIPMENT SENT TO WORKSHOP. PLC'S. SEALS.E. (BEARINGS.

MOTORS. ANNEXURE 7 (Contd. ETC) 22 POOR WORKMANSHIP 08 POOR QUALITY COMPONENT 23 INADEQUATE VENTILATION 09 POOR QUALITY MATERIAL 24 CORROSION 10 POOR CONDUCTIVITY 25 INCORRECT DESIGN (REDESIGN) 11 END OF LIFESPAN (NOT PERFORMING TO DESIRED DESIGNED STANDARD) 26 INCORRECT COMPONENT FITTED 12 INCORRECT LUBRICANT 27 MISALIGNMENT 13 CONTAMINATED LUBRICANT 28 EXCESSIVE LUBRICATION 14 SABOTAGE 29 POWER SURGE FAILURE 15 INCORRECT COMPONENT/MATERIAL 73 .) FAILURE MODE CODES (CAUSE) 01 MOISTURE 16 MALICIOUS DAMAGE 02 VIBRATION 17 CONTAMINATED GLAND SERVICE 03 STUCK/BLOCKED 18 SLIME SPILLAGE 04 SURGE/CAVITATION 19 ACID SPILLAGE 05 INADEQUATE LUBRICATION/LACK OF LUBRICATION 20 EXCESSIVE DUST 06 INADEQUATE GLAND SERVICE/LACK OF GLAND SERVICE 21 ENVIRONMENTAL CONDITIONS (AND TIME. ETC) 07 BURNT (V-BELTS.

) AFTER HOUR BREAKDOWN DATE WORKED KPA PA TIME CALLED TIME ARRIVED TIME START TIME FINISHED ON SURFACE UNIT / EQUIPMENT N_ ARTISAN NAME ARTISAN CODE TRADE CALLED BY WHOM? DESIGNATION SHIFTFOREMAN’S INVESTIGATION: (PHYSICAL/ OPERATIONAL CONDITION) Why it Failed? ARTISAN REPORT: (PHYSICAL/ OPERATIONAL CONDITION) Why it failed? FUNCTIONALFAILURE TOTAL FAILURE PARTIAL FAILURE Standby Unit YES OR NO STOP/START YES OR NO COMPONENT QUANTITY FAILURE MODE/CAUSE CODE RESTORATION TASK DISCARD TASK Comments: …………………………………………………………………………………………………………………………………………………. Lime etc. ANNEXURE 7 (Contd..) 22 POOR WORKMANSHIP 08 POOR QUALITY COMPONENT 23 INADEQUATE VENTILATION 09 POOR QUALITY MATERIAL 24 CORROSION 10 POOR CONDUCTIVITY 25 INCORRECT DESIGN(Re-design) 11 END OF LIFESPAN(Not performing to desired designed standard) 26 INCORRECT COMPONENT FITTED 12 INCORRECT LUBRICANT 27 MISALIGNMENT 13 CONTAMINATED LUBRICANT 28 EXCESSIVE LUBRICATION 14 SABOTAGE 29 POWER SURGE/FAILURE 74 .) 07 BURNT (V-Belts. Motors etc. FAILURE MODE (CAUSE) 01 MOISTURE 16 MALICIOUS DAMAGE 02 VIBRATION 17 CONTAMINATED GLAND SERVICE 03 STUCK/BLOCKED 18 SLIME SPILLAGE 04 SURGE/CAVITATION 19 ACID SPILLAGE 05 INADEQUATE LUBRICATION / LACK OF LUBRICATION 20 EXCESSIVE DUST 06 INADEQUATE GLAND SERVICE / LACK OF GLAND SERVICE 21 ENVIRONMENTAL CONDITIONS (Acid.

) SHIFT FOREMAN AND ARTISAN’S REPORT BY COMPLETION OF BREAKDOWN EQUIPMENT TESTED YES NO UNIT FOUND IN ORDER YES NO SHIFT F/MAN SIGNATURE ARTISAN SIGNATURE THIS PART TO BE FILLED IN BY THE ENGINEERING FOREMAN LOSS PROCESS POTENTIAL R PEOPLE LABOUR R ACTUAL R MATERIAL SPARES R PROPERTY DAMAGE R TOTAL R ENGINEERING FOREMANS COMMENTS SIGNATURE: GES/ENG. DOMAIN MANAGER’S COMMENTS SIGNATURE: PPS/MET. 01 MOISTURE 16 MALICIOUS DAMAGE 02 VIBRATION 17 CONTAMINATED GLAND SERVICE 15 INCORRECT COMPONENT/MATERIAL ANNEXURE 7 (Contd. DOMAIN MANAGER’S COMMENTS or MINE OVERSEER / SHIFT BOSS SIGNATURE: MANAGERS COMMENTS: SIGNATURE: ENGINEERS COMMENTS: SIGNATURE: 75 .

ANNEXURE 8 76 .

77 .

L E. Ore Handling Ore Handling 1 Conveying Conv.L. 1A Idlers Frame Rollers Belt Clips Stringers Pulleys Conv.) Hidden Process Area Process Area Hidden E. 1A Idlers Frame Rollers Belt Clips Stringers Pulleys Drive Drive 1 Motor Shaft Bearing Rotor F/D Gearbox Drive 2 Motor Gearbox Aux Lubricating 78 . Unit Comp. ANNEXURE 8 (Contd.

4 Motor Pump Fluid drive .) Pumping Power Supply HT (MCC1) Breaker Feeder LT (MCC2 Breaker Feeder Leach Leach 1 Agitation Tank 1 .4 Motor Pump Fluid drive Leach 2 Agitation Tank 1 .8 Valves Spindle Diaphragm Body Pumping Pump1 .79 ANNEXURE 8 (Contd.8 Valves Spindle Diaphragm Body Pumping Pump1 .

1 .2 Lubricating Hyd Pump No.4 Lubricating 3 Lub No. 1 Lifting Detector No. 1 . ANNEXURE 8 (Contd. 1/Bin No. 1 .6 Sorting 2 Pumping Bridge 1 . 1 Lifting 6 Pump No. No. 2 Structures 9 Mill Silo No. 1 .5 Ore Hand 2 Pumping 2 Pump No. 1 . 1 . 1 Power Supply Magnet No.8 Drive Loop No.20 Sorting Sorting 1 Conveying Vibrator No. 1/LT Sub No. Loops Magnet Structures Met Detecting Milling Mill 1 Conveying Mill 2 Pumping Mill 3 Lubricating Mill 4 Drive Mill 5 Power Supply Mill 6 Lifting Mill 7 Storage Mill 8 Feeding Mill 9 Screening Mill 10 Weighing Mill 11 Hydraulics Mill 12 Inst. 1 . 1/Crane No.) Hidden PA PA Code Hidden Eq Loc Code Eq Loc. etc. 2 Feeding 8 Silo No.5 ore handling Drive 4 Drive No. Loops Mill 13 Barring Mill 14 Cooling Mill 15 Structures Mill 16 Cycloning Thickening Thick 1 Pumping Thick 2 Lubricating Thick 3 Drive 80 . 1 . 1/Silo No. Storage 7 Bin No. 1 Storage Feeding Vibrating Structures Weighing Crushing Crusher 1 Conveying Crusher 2 Pumping Crusher 3 Lubricating Crusher 4 Drive Crusher 5 Power Supply Lifting Storage Feeding Hydraulics Inst.6 10 Plough Feeder No.5 Power Supply 5 HT Sub No. 1 11 Brute Force Feeder No. Ore Handling Ore Hand 1 Conveying 1 Conv.

Loops CIL 6 Screening CIL 7 Cooling CIL 8 Structure Sampling Agitation CIP CIP 1 Lubricating CIP 2 Pumping Power Supply Storage Inst. Loops Screening Cooling Structure Sampling Agitation Elution Elution Pumping Power Supply Lifting Storage Inst. Loops Screening Heating Steam Gen Eluting Carbon Regen Kiln 1 Pumping Kiln 2 Drive Kiln 3 Power Supply Storage Feeding Inst. Loops Screening Cooling Structure 81 . Loops Cooling Structure Sampling Leaching Leach 1 Pumping Leach 2 Power Supply Lifting Storage Inst.) Thick 4 Power Supply Thick 5 Lifting Thick 6 Storage Feeding Inst. ANNEXURE 8 (Contd. Loops Screening Structure Cooling Sampling Lubricating Agitation CIL CIL 1 Pumping CIL 2 Power Supply CIL 3 Lifting CIL 4 Storage CIL 5 Inst.

ANNEXURE 8 (Contd.) Heating Elect Win Electro 1 Pumping Electro 2 Power Supply Electro 3 Lifting Electro 4 Cells Rectifying Storage Hydraulics Filter Press Inst. Loops Extraction Smelt House Smelt House Pumping Power Supply Lifting Storage Hydraulics Weighing Inst. Loops Structure Extraction Ovens Filter Press Acid Treat Residue Residue Pumping Residue 1 Drive Residue 2 Power Supply Residue 3 Lifting Residue 4 Storage Residue 5 Feeding Hydraulics Inst. Loops Screening Structure Sampling Agitation Services O Block Power Supply IMS M/W Shop C House E/W Shop PC Build I/W Shop W Shops R/W Shop P/W Shop Stores Calorifying Washing 82 .

Loops Structure Sampling Lime Slaking Lime Slake 1 Conveying Lime Slake 2 Pumping Lubricating Drive Power Supply Lifting Storage Feeding Inst. ANNEXURE 8 (Contd. Loops Structure 83 . Loops Structure Filtering Drying Flocculent Flocculent Pumping Floc 1 Lifting Floc 2 Storage Feeding Inst.) Compressors Compressors Pumping Compressor 1 Lubricating Compressor 2 Drive Compressor 3 Power Supply Compressor 4 Lifting Compressor 5 Cooling Compressor 6 Inst. Loops Structure Mixing Extraction Agitation Cyanide Cyanide Pumping Power Supply Lifting Storage Inst. Loops Power Supply Sampling Mixing Structure Water Treatment W Treatment Pumping Power Supply Lifting Feeding Inst. Loops Structure Heating Caustic Caustic Pumping Power Supply Lifting Storage Inst.

Loops Structure Pump Cells Pump Cells Conveying Pumping Drive Power Supply Lifting Storage Feeding Vibrating Inst. Loops Screening Structure Sampling Agitation 84 . Loops Screening Structure Sampling Agitation Filtering Mixing Flotation Float Pumping Float 1 Lubricating Float 2 Drive Float 3 Power Supply Float 4 Lifting Float 5 Storage Float 6 Inst. ANNEXURE 8 (Contd. Loops Structure Extraction Water Dams Water Dams Pumping Power Supply Lifting Inst. Loops Float 7 Structure Float 8 Sampling Agitation Ovens CCIX CCIX 1 Pumping CCIX 2 Power Supply CCIX 3 Lifting CCIX 4 Storage CCIX 5 Inst.) Heating Agitation HCL Storage HCL Storage Pumping Power Supply Lifting Storage Inst.

Loops SX 6 Structure Sampling Agitation ADU ADU Pumping Lubricating Drive Lifting Storage Structure Sampling Agitation Boilers Boilers 1 Conveying Boilers 2 Pumping Boilers 3 Drive Boilers 4 Power Supply Lifting Storage Feeding Weighing Inst. ANNEXURE 8 (Contd.) Solvent SX 1 Pumping Extraction SX 2 Power Supply SX 3 Lifting SX 4 Storage SX 5 Inst. Loops Drive Structure ESC Sub ESC Sub Power Supply Structure VR Sub VR Sub Power Supply Structure Filtration Filtration Pumping Conveying Drive Power Supply Feeding Inst. Loops Structure Sampling Extraction Water Plant Water Plant Pumping Power Supply Lifting Storage Inst. Loops Structure Filtering Sampling Agitation Lifting 85 .

Loops Structure Storage Carbon Columns Carbon Columns Pumping Power Supply Lifting Inst. ANNEXURE 8 (Contd. Loops Structure Screening Sampling Agitation Feeding Heating Conversion Converter Inst.) 86 . Loops Structure Agitation Roasting Roasting Pumping Power Supply Lifting Storage Inst.) Mixing Vacuum Neutralizing Neutralizing Pumping Power Supply Lifting Storage Inst. Loops Structure Screening Conditioning Conditioner Pumping Power Supply Lifting Storage Inst. Loops Drive Screening Structure ANNEXURE 8 (Contd. Loops Blower Power Supply Pumping Lubricating Drive Lifting Cooling Structure Sampling Acid Storage Acid Storage Pumping Power Supply Lifting Inst.

Loops Screening Cooling Structure Sampling Agitation Heating Rectifying Cells Extraction Ovens Filter press Separation Washing Filtering Mixing Vacuum Swing Mill Pulverizing 87 . Loops River Water Pumping Power Supply Lifting Storage Inst. Loops Screening Structure Laboratory Chem Lab 1 Pumping Chem Lab 2 Conveying Sample Prep Drive Power Supply Storage Feeding Vibrating Weighing Inst. Loops Structure Monitoring Monitoring Pumping West Paydam Drive Conveying Power Supply Lifting Storage Screening Structure Inst.Slimes Dams Grassdam Feeding Decanting Distribution Return Water Return Water Pumping Power Supply Lifting Inst.

ANNEXURE 9 ANNEXURE 9 (Contd.) 88 .

HIDDEN PROCESS AREAS METALLURGICAL PLANTS 8GP 9GP 1GP 2GP 8UP WMP WAP EAP EBP SBP MTS Ore Handling X X X Sorting X Crushing X Milling X X X X Thickening X X X X X X X X X X Leaching X X X X X X X X CIP (Adsorption) X X CIL X Elution X X X Carbon Regen X X X Electro winning X X X Smelthouse X Residue X X X Services X X X X X X X X X X X Compressors X X X X Floculant X X X X X X X X Water Treatment X X X X X X X X Lime Slaking X X Cyanide X X X X X Caustic X X X X HCL (Acid) storage X X X Dams (Water) X X X X X X X Pumpcells X Flotation X X X X X X CCIX X X Solvent Extraction X X ADU X X Boilers X X X Water Plant X X ESC SUB X X X X X X X X X X VR SUB X X X X X X X X X X Filtration X Neutralising X Roasting X X Conversion X X Acid Storage X X X Carbon Column X Conditioning Slimes Dams X Return Water X Monitoring X X Boreholes X River Water X Laboratory X X X X X X X X X X X ANNEXURE 9 (Contd.) 89 .

1/Silo No.6 Crusher 04 10 Drive 10 Plough Feeder No. 2 Crusher 02 8 Decanting 8 Silo No.5 Sorting Sorting 01 4 Cells 4 Drive No. 1 Mill 04 16 Filter Press 16 Detector No.20 Mill 06 18 Calorifying 18 Mill 07 19 Heating 19 Mill 08 20 Hydraulics 20 Mill 09 21 Instrumentation Workshop 21 Mill 10 22 Instrumentation Loops 22 Mill 11 23 Lifting 23 Mill 12 24 Lubricating 24 Mill 13 25 Mechanical Workshop 25 Mill 14 26 Magnet 26 Mill 15 27 Met Detecting 27 Mill 16 28 Milling 28 Milling 29 Mixing 29 Thickening Thick 01 30 Ovens 30 Thick 02 31 Paint Workshop 31 Thick 03 32 Power Supply 32 Thick 04 33 Pulverizing 33 Thick 05 34 Pumping 34 Thick 06 35 Rigger Workshop 35 Thickening 36 Rectifying 36 Leaching Leach 01 37 Sampling 37 Leach 02 38 Screening 38 Leaching 39 Separating 39 ANNEXURE 9 (Contd. 1 . 1 Mill 03 15 Feeding 15 Magnet No. 1 Crusher 05 11 Drying 11 Vibrator No.4 Ore Hand 3 Barring 3 Lub No. ANGLOGOLD BUSINESS SERVICES METALLURGICAL PLANTS PROCESS AREAS AND EQUIPMENT LOCATIONS Hidden PA PA Code Hidden Eq Loc Code Eq Loc Ore Handling Ore Hand 01 1 Acid Treat 1 Conv.5 Ore Hand 02 2 Agitating 2 Pump No. 1 Mill 05 17 Filtering 17 Brute Force Feeder No. No. 1/Crane No.8 Mill 02 14 Extracting 14 Loop No.) Carbon In Leach CIL 01 40 Steam Generating 40 CIL 02 41 Storage 41 CIL 03 42 Stores 42 90 . 1 . 2 Crusher 03 9 Distributing 9 Mill Silo No. 1 . 1 .2 Milling Mill 01 13 Eluting 13 Hyd Pump No. 1 . 1/Bin No. 1 . 1 . 1/LT Sub No.5 Sorting 02 5 Conveying 5 HT Sub No. 1 . Crushing Crusher 01 7 Cycloning 7 Bin No. 1 Sorting 6 Cooling 6 Pump No. etc.6 Crushing 12 Electrical Workshop 12 Bridge 1 .

) Lime Slaking Lime Slaking 89 Lime Slak01 90 Lime Slak02 91 Cyanide Cyanide 92 91 . CIL 04 43 Structure 43 CIL 05 44 Swing Mill 44 CIL 06 45 Vacuum 45 CIL 07 46 Vibrating 46 CIL 08 47 Washing 47 CIL 48 Weighing 48 Carbon In Pulp CIP 01 49 CIP 02 50 CIP 51 Elution Elution 52 Carbon Regen Kiln 01 53 Kiln 02 54 Kiln 03 55 Carbon Reg 56 Acid Treat 57 Electro Winning Electro 01 58 Electro 02 59 Electro 03 60 Electro 04 61 Electro 05 62 Electro 06 63 Elect Win 64 Smelt House S House 65 Residue Residue 66 Residue 01 67 Residue 02 68 Residue 03 69 Residue 04 70 Residue 05 71 Services O Block 72 IMS 73 C House 74 PC Build 75 Workshops 76 Services 77 Compressors Composer 78 Comp 01 79 Comp 02 80 Comp 03 81 Comp 04 82 Comp 05 83 Comp 06 84 Flocculent Flocculent 85 Floc 01 86 Floc 02 87 Water Treatment Water 88 Treatment ANNEXURE 9 (Contd.

) Slimes Dams Grassdam 136 Nº 1 Comp 137 Nº 2 Comp 138 A Gulley 139 W Ext Dam 140 SE Dam 141 92 .Caustic Caustic 93 Hydro Chloric Acid HCL Store 94 Storage Water Dams Water Dams 95 Pump Cells Pump Cells 96 Flotation Float 97 Float 01 98 Float 02 99 Float 03 100 Float 04 101 Float 05 102 Float 06 103 Float 07 104 Float 08 105 CCIX CCIX 106 CCIX 01 107 CCIX 02 108 CCIX 03 109 CCIX 04 110 CCIX 05 111 Solvent Extraction SX 112 SX 01 113 SX 02 114 SX 03 115 SX 04 116 SX 05 117 SX 06 118 ADU ADU 119 Boilers Boilers 120 Boilers 01 121 Boilers 02 122 Boilers 03 123 Boilers 04 124 Escom Sub Station ESC Sub 125 Vaal River Sub VR Sub 126 Filtration Filtration 127 Neutralizing Neutralize 128 Roasting Roasting 129 Conversion Conversion 130 Converter 131 Blower 132 Acid Storage Acid Store 133 Carbon Columns Carbon Col 134 Conditioning Condition 135 ANNEXURE 9 (Contd.

E Dam 142 S Dam 143 Mizpah Dam 144 Res System 145 Slimes Dams 146 Return Water Bokkamp 147 Queen Mary 148 E Return 149 S Return 150 Miz Return 151 8 Set Dam 152 Return Water 153 Transfer Water Crossroads 154 Center Spill 155 Mon Feed 156 9Bleed Dam 157 B Hole Res 158 Transfer Water 159 Monitoring Monitoring 160 W Monitors 161 W Paydam 162 River Water Pringle St 163 Ork Bridge 164 Nº 8 Bridge 165 River Water 166 Laboratory Chem Lab 1 167 Chem Lab 2 168 S Prep 169 Laboratory 170 Storm Water Stormwater 171 Eye Water Eye Water 172 Seepage Boat Club 173 Seep Drain 174 Seepage 175 Tips No1 GP Tip 176 No8 GP Tip 177 No9 GP Tip 178 Tips 179 ANNEXURE 9 (Contd.) Borehole B Hole 01 180 B Hole 02 181 B Hole 03 182 B Hole 04 183 B Hole 05 184 B Hole 06 185 B Hole 07 186 93 .

B Hole 08 187 B Hole 09 188 B Hole 10 189 B Hole 11 190 B Hole 12 191 B Hole 13 192 B Hole 14 193 B Hole 15 194 Borehole 195 94 .

ANNEXURE 10 95 .

CMT ORDER OF PRIORITY 1. OLD TASK FREQ. P = PEOPLE 2. NEW TASK FREQ. DESCRIPTION ABC No. ENV = ENVIRONMENT RISK UNIT RISK CLASS ASSESS. SCHED No. PR = PRODUCTION (MATERIAL) 4. ANNEXURE 10 (Contd. 96 . SCHED No.) SCHEDULE RESTORATION TASK – SRT RISK ASSESSMENT TASK IDENTIFICATION SCHEDULE DISCARD TASK – SDT ROUTINE SERVICE TASK – RST OPPORTUNISTIC MAINTENANCE TASK – OMT PROCESS AREA : ________________________________ ON CONDITION INSPECTION TASK – OCT CONDITION MONITORING . EQ = EQUIPMENT 3. UNIT No.

ANNEXURE 11 97 .

T.) ANGLOGOLD PLANTS STD ELECTRICAL UNIT IDENTIFICATION ESC SUB STATION CS UNINTERRUPTED POWER SUPPLY UPS GENERAL SUB STATION SS CALORIFIER CAL MOTOR CONTROL CENTRE MCC CAMERAS CCTV UNIT CONTROL PANEL INSIDE MC BATTERY CHARGER BCH MCC (CUBICLE) BATTERY B HIGH TENSION PANEL HT TRIPPING BATTERIES BTU HIGH TENSION ISOLATOR HTI MIST PRECIP RECTIFORMER MPZ CIRCUIT BREAKER CB THYRISTOR CONTROL CUBICLE TCC BULK OIL CIRCUIT BREAKER CCB RECTIFIER PANEL ZP MINIMUM OIL CIRCUIT BREAKER SOV RECTIFIER Z VACUUM CONTACTOR VC KILOWATT HOUR METRE kWh VACUUM BREAKER VB LIQUID STARTER LS POWER TRANSFORMER PTXR WELDING PLUG WP LIGHTING TRANSFORMER LTXR TELEPHONE EXCHANGE TX CONTROL TRANSFORMER CTXR ALTERNATOR ALT INSTRUMENT TRANSFORMER ITXR GENERATOR GEN POTENTIAL TRANSFORMER PT SF6 H. CONTACTOR SF6C POWER FACTOR CORRECTION PFC PLC CUBICLE PLC EARTH LEAKAGE EL FIELD MARSHALLING CUBICLE FMC LT CONTACTOR LTC JOINT BOX JB AC VARIABLE SPEED DRIVE VSD METRE PANEL MP VAPORMATIC STARTER VS AIR CONDITIONER ACO REMOTE STATION RS HOT PLATE HPL LIGHTING DISTRIBUTION LDB OVEN OV BOARD URN URN INSTRUMENT DISTRIBUTION IDB FAN HEATER FAH BOARD DRYING HEATER DH HIGH MAST LIGHTING HM WATER COOLER WC MICRO WAVE OVEN MVO VACUUM CLEANER VCL BAR HEATER BH STOVE STV MICRO FICH MCF 98 .T. ANNEXURE 11 (Contd. BREAKER SF6B CURRENT TRANSFORMER CT SF6 H.

Red Brown Brown No 1 North Standard WP . Green Blue Blue South Uranium Standard SP . Red Red Red Flame Proof WUP . Red Red Red Flame Proof WP . White White White Flame Proof EP X White Blue Blue Spark Proof EP Y White Brown Brown A. Cream Cream Cream Spark Proof SP SS Cream Brown Brown 9# Gold Standard 9-GP . ANNEXURE 11 (Contd. International Orange Orange Orange No 9 Uranium Standard WUP .STK021-8F-5.L. Standard AFL . fan cowls and terminal boxes are to be painted dark brown . Red Blue Blue Spark Proof WUP .) ANGLOGOLD PLANTS ELECTRIC MOTOR IDENTIFICATION AND COLOUR CODING LETTER IDENTI-FICATION COLOUR IDENTIFICATION BASIC FAN TERMINAL PLANT MOTOR TYPE PREFIX SUFFIX MOTOR COWL BOX No 2 North Standard EP . fan cowls and terminal boxes are to be painted aircraft blue .CKS279D38. Cream Red Cream 8# Gold Standard SP . Green Green Green Flame Proof SP .F. Red Blue Blue NOTE: Flameproof motors. 99 . Spark proof motors.

Timer/Solenoid.g.: Voltage to current converter: EX-001 E designates the measured variable and X the computed or read out. Flow Solenoid: FY-001. Machine: AI-001 Cycad: AI-002 Redox Transmitter: OT-001 100 . ANNEXURE 11 (Contd.g. Volume Booster: PB-001 Power supply: JX-001 Prog.g. PA-001. E.g. Log Controller: PLC-001 Speed Transmitter: ST-001 Weigher Transmitter: WT-001 Weigher Element: WE-001 Weigher Source: WRa-001 Density Element: DE-001 Density Source: DRa-001 Density Transmitter: DT-001 Poppet Sampler: KZ-001 Water Trap/Filter: MF-001 Flow hand Switch: FHS-001 Pressure hand switch: PHS-001 Level solenoid valve: LY-001 Lubricator: XN-001 Square Root Indicator: FI-001 Relay Electrical: EY-001 Relay Pneumatic: PY-001 Control valve: CV-001 On Off Valve: FZ-001 Positioner: ZC-001 Current to Pneumatic: IP-001 A. Timer: K-001.: To identify an alarm: XA-001 A specific alarm: Flow/Pressure/pH will thus be indicated as such: FA-001. Level Solenoid: LY-001.. Level Solenoid. Timer/Solenoid: KY-001. pH-001 E.) ANGLOGOLD PLANTS NOTE: A FEW EXAMPLES OF HOW TO APPLY THE NUMBER IDENTIFICATION SYSTEM E.: To number a Timer/Solenoid: Timer. then refer to it as: XHV-001 or if it is a flow hand valve then: FHV-001 Or if it is a pressure hand valve: PHV-001 E.A. Flow Solenoid. passive or output function. ALTHOUGH WE KNOW IT IS E/I.: If a hand valve stands separate from a loop.

COMPUTER. CONVERTER X RELAY. ANNEXURE 11 (Contd. ACTUATE.) ANGLOGOLD PLANTS NUMBER IDENTIFICATION SYSTEM PREFIX NO 1 PREFIX NO 2 A ANALYTICAL ALARM B BURNER FLAME BOOSTER C CONDUCTIVITY CONTROL D DENSITY DETECTOR/DIFFERENTIAL E VOLTAGE PRIMARY ELEMENT F FLOW FILTER/FRACTION G GAUGING (DIM) STEEL/GLASS H MANUAL HAND HIGH I CURRENT INDICATE J POWER SCAN K TIME CONTROL STATION L LEVEL LOW OR LIGHT PILOT M MOISTURE MIDDLE OR INTERMEDIATE N LUBRICATOR O OXIDATION (ORP) ORIFICE/RESTRICTION P PRESSURE POINT OR PNEUMATIC Q QUANTITY/EVENT INTEGRATE OR TOTALIZER R RATIO RECORD OR PRINTER Ra RADIO ACTIVITY S SPEED/FREQUENCY SWITCH OR SWITCH T TEMPERATURE TRANSMITTER U MULTI VARIABLE MULTIFUNCTION V VISCOSITY VALVE/LOUVRE/DAMPER WELL W WEIGHT/FORCE TRANSDUCER. UNCLASSIFIED Y Z POSITION OR STATUS pH HYDROGEN ION CONC 101 . SOLENOID DRIVE.

ANNEXURE 11 (Contd.)

ANGLOGOLD PLANTS
PROCESS/LOCATION IDENTIFICATIONS
ACID PLANT A PRECIP PLANT P

A.D.U. PLANT AD PRE LEACH PL

ASSAY DEPARTMENT AS PAINT SHOP PS

AUTO MILLS AM RECOVERY R

CARBON ACID TREATMENT AT RUBBER LINER SHOP RL

BOILER PLANT B RESIDUE DISPOSAL RD

CYANIDE PLANT C RAIL BIN RB

CALCINE SECTION CC MILL STORAGE MS

C.C.D. PLANT CD SLIMES PLANT S

CLARIFICATION CL SMELT HOUSE SH

COMPRESSOR PLANT CO STOCK PILE SP

CRUSHER PLANT CR SOLVENT EXTRACTION SX

C.C.I.X. PLANT CX BALL MILL BM

CAUSTIC STORAGE CA TUBE MILL TM

DEWATERING D VAAL RIVER V

ELECTROWINNING EW WATER PLANT W

ELUTION EL WORKSHOPS WH

FLOTATION PLANT F WASTE ROCK WR

GRINDING PLANT G WASHING & SORTING SCREENING WS

FLOC PLANT I WATER DAMS WD

LEACH PLANT L POTABLE WATER PW

LIME SLAKING LS ADSORPTION AP

MONITORS MT CHANGE HOUSE CH

MANGANESE STORAGE MA INTER MINE STORE IMS

NEUTRALISING N BACKFILL PLANT BF

OUTSIDE SECTION OS CARBON IN PULP CIP

ORE HANDLING OH CARBON IN LEACH CIL

WOODCHIP PLANT WCP FLASH FLOAT PLANT FF

LABORATORY LB TREATMENT TR

HYDROCHLORIC ACID STORAGE HA MILLING M

BUILDING BU THICKENING TH

CENTRAL SECTION CE

102

ANNEXURE 11 (Contd.)

ANGLOGOLD PLANTS

EQUIPMENT IDENTIFICATIONS

AGITATORS
A GUNS MONITOR G

FLOAT CELL FCM GRINDERS GR

AIR CYLINDER AC GOLD ANALYSER GA

ARC FURNACE AF HOISTS H

AMMONIA RECEIVER AMR HYDRAULIC CYLINDERS HC

DRYING TOWER DT LUBRICATORS L

ADSORPTION TOWER ABT LIQUID STARTER LQS

STRIPPING TOWER STR MILL 1-100 M

AUTO CLAVE ATC MAGNETS MA

BELT CONVEYORS B PLOUGH FEEDER PF

BARRING GEAR BG PUMPS P

BLOWER BL POWER SAW PS

BOILER BR PUNCH SHEARS PSH

CRUSHER C RETORT FURNACE RF

CENTRIFUGE CEN ROTO SCOOP RT

CALCINE FURNACE CF SLAKERS SL

CHAIN FEEDER CHF STOCK TANKS ST

COMPRESSOR CO SCREW CUTTING MACHINE SCM

COOLING TOWER CT THICKENERS T

CROSS FLOW TOWER CFT SAMPLERS S

DRILLING MACHINE DM RECTIFIER Z

DISC FILTERS DF LATHE LT

IND. DRYING MACHINE DR PINION GEAR PG

PACHUCA E GIRTH GEAR GG

103

ANNEXURE 11 (Contd.)

ANGLOGOLD PLANTS

EQUIPMENT IDENTIFICATIONS

EXTRACTOR EX BELT SANDER BSM

FILTERS F TROMMEL SCREEN TS

FANS FA BINS BN

FLUID DRIVE FD HOPPERS FH

TRIPPER BELTS TB CYCLONE CY

VIBRATORS V DROP BOX (ROCK) DB

VALVES VL CHUTES CH

WINCHES W LAUNDERS LD

IND. WASHING MACHINE WM SPLITTER BOXES SB

KILN K ADSORPTION COLUMN APC

LIFT/ELEVATOR LFT ELUSION COLUMN EC

FEED SCREW FS MEASURING CHAMBER MC

AIR RECEIVER AR RINSE CHAMBER RC

CELL MACHINE CM CRAWL BEAM CB

MIST PRECIPITATOR MP CARBON COLUMN CC

SPIN DRIER SD WATER SOFTENER SW

TUMBLE DRIER TD VANE FEEDER VF

OIL HEATERS OH VACUUM PUMP VP

LINEAR SCREEN LNR CRAWL BEAM TROLLEY CBT

HEAT EXCHANGER HE ROTARY VALVE RV

AIR DRYER AD DISCHARGE HOPPER DH

GENERATOR GEN UNDERFLOW BOX (SLIME) UB

POWER PACK PP PULVERIZER PV

POT SWINGLER PSW CASCADE SPLITTER CS

SULPHUR COMBUSTION FURNACE SCF HYDRAULIC PRESS HP

V BLENDER VB FRIDGE FR

INCENERATOR INC

104

H. ANNEXURE 11 (Contd. RECORDER IPR COMPRESSOR CONTROL UNIT CU I. CONVERTER IP CONDUCTIVITY ELEMENT CE POWER SUPPLY J CONDUCTIVITY TRANSMITTER CT LEVEL CONTROL LC CONDUCTIVITY CONTROLLER CC LEVEL CONTROL VALVE LCV CONDUCTIVITY RECORDER CR LEVEL ELEMENT LE CONDUCTIVITY METRE CM LEVEL TRANSMITTER LT DENSITY SOURCE DX LEVEL RECORDER LR DENSITY DETECTOR DD LEVEL SOLENOID LY DENSITY TRANSMITTER DT LEVEL INDICATOR LI DENSITY CONTROLLER DC LEVEL LOW ALARM LLA DENSITY RECORDER DR LEVEL HIGH ALARM LHA DENSITY CONTROL VALVE DCV AIR FILTER REGULATOR PFR FLOW ELEMENT FE PRESSURE INDICATOR CONTROL ARC FLOW TRANSMITTER FT PRESSURE CONTROL VALVE PCV FLOW TOTALISER FQ PRESSURE TRANSMITTER PT FLOW INDICATOR FI PRESSURE RECORDER PR FLOW METRE FM PRESSURE GAUGE PI FLOW CONTROL VALVE FCV PRESSURE SWITCH PS FLOW RECORDER CONTROLLER FRC PRESSURE ALARM LOW PAL MASS FLOW INDICATOR TOTAL FIQ PRESSURE CONTROLLER PC FLOW RECORDER FR PRESSURE RECORD/ CONTROLLER PRC MILL MONITORING SYSTEM MMS GROENEWALD PANEL GP1 TIMER UNIT TU ACTUATOR L2 WATER TRAP PF 105 .P. CONTROL VALVE ACV FLOW PRESSURE RECORDER FPR BLOW OFF UNIT BOU I.P. LOW ALARM ALA FLOW TOTALISER FQ P.H.H.) ANGLOGOLD PLANTS EQUIPMENT IDENTIFICATIONS: INSTRUMENTATION ANALYSER RECORDER AR FLOW INDICATOR CONTROLLER FIC CONDUCTIVITY CONTROLLER AC FLOW MULTIPLIER UNIT FU P. BENCH METRE AM FLOW INDICATOR RECORDER FIR SO2 ANALYSER AA FLOW INDICATOR TRANSMITTER FIT P.

ANNEXURE 11 (Contd.) ANGLOGOLD PLANTS EQUIPMENT IDENTIFICATIONS INSTRUMENTATION EXTRACTOR UNIT U ALARM AL VANE SWITCH S ACTUATOR AT TEMP CONTROL VALVE TCV ANALYSER AN TEMP INDICATOR CONTROL TIC AIR DRYER AD TEMPERATURE RECORDER TR BOOSTER BT TEMPERATURE ELEMENT TE BELT WEIGHER BW VACUUM RECORDER VR BARRIER SUPPLY BS BLOW OFF VALVE BOV CONTROLLER CL WEIGHT SOURCE WX COUNTER CT WEIGHT DETECTOR CT CONVERTER CV WEIGHT TOTALISER WQ DP CELL DP SOLENOID Y DIGITAL INPUT DI SOLENOID VALVE YV ELEMENT EL GAUGE GG ORE SORTER OS HEAD HD ORIFICE OF INDICATOR ID POSITIONER PS INTEGRATOR IG PARTICLE SIZE MONITOR PSM LEVEL CONTROLLER LC PROGRAMMABLE LOGIC FPR CONTROL MONITOR MN RECORDER R METRE MT REGULATOR RG SORTER ST RELAY OUTPUT RO SAMPLER SM SOLENOID SL SWITCH SW SENSOR SN TIMER TI TOTALIZER TT TACHO (GENERATOR) TO TRANSMITTER TR TRANSDUCER TD TUBE TB ULTRA SONIC US THERMO COUPLE TC VALVE VL MILL MONITORING 106 .

) ANGLOGOLD PLANTS EQUIPMENT IDENTIFICATIONS INSTRUMENTATION PHOTO STAT MACHINE PHM CYLE CY ULTRA SONIC BATH USB CARBOLITE FURNACE CAF HEATER BATH HB COMPUTER COM PRINTER PRT WATER PURIFICATOR WPF CHROMATO GRAPH CG MICRO BALANCER MB MICRO SCOPE MS SWINE MILL SPS SULPHUR DETERMINATOR SDT MAGNETIC MIXER XM SCALE SC SPECTROMETER SPM BULLION ROLLER BRL MAGNETIC SAMPLE SPLITTER XS CAROUSEL SPLITTER CRS 107 . ANNEXURE 11 (Contd.

) ANGLOGOLD PLANTS INSTRUMENTATION FUNCTION IDENTIFICATION ACID A NUCLEAR N BUBBLE B ORE O CONDUCTIVITY C POWER P DENSITY D PRESSURE PE E TORQUE Q FLOW F RATIO R GOLD G SPEED S HEIGHT H TEMPERATURE T DIP I VOLUME U J VACUUM VA K WATER W LEVEL L MAGNETIC X MASS M Y Z 108 . ANNEXURE 11 (Contd.

ANNEXURE 11 (Contd.) ANGLOGOLD PLANTS NEW EQUIPMENT IDENTIFICATION EQUIPMENT FEED BOX FB LOOP & 109 .

ANNEXURE 12 110 .

1. Wheels / Labour : 1 Art @ R45/hr x 4hrs = R 1.3 Bearing 1.1 Lack of 8 5 2 2. Hoist gearbox 1.111 ANNEXURE 12 (Contd. Pendant 1. 1 in 20 years 5 5 14 lubricate Fitter. Electrician. 6 Monthly service load test by Rigger and purposes. 1. safety circuits R 5 500. testing brakes & operation Function : 4.2 1 in 25 years construction 9. near miss. 2.2 Incorrectly 1. maintenance and 8.00 1.4 1 in 25 years 5 5 14 company. 50 ton. Electrician testing safety Lifting and lowering 5.3 1 in 20 years by outside safety tests by Fitter and to be repaired. The gearbox will have 5 5 14 4. Schedule Routine Service 2. Hoist motor 1. Weekly inspection 1. Long and P If or when gearboxes fails the Pr 1.5 1 in 25 years 5 5 14 11. Rope failure years operation and devices and pendent. Brakes 1. 3. By-yearly Routine sevice ie 1. Control – 1. Inspecting all Cross travel 1.1 1 in 20 years 8 5 2 Fitter. Monthly causes of the total failures. 1 in 20 years 8 5 2 1. Long travel cross travel consequence to people will be a 1.1 1 in 20 years 5 5 14 Electrician and 3 Monthly. Fitter and gearbox / gearboxes.5 Shaft failure will result in the long and cross 1. Schedule on condition task 9G1AMBUH1D 1.4 Gear failure Eq If and when the gearboxes fail it Pr 1.00 .4 1 in 25 years 8 5 2 Rigger./Failure F r r Unit/Equipment no: Total Failure: 1. Fitter lubrication. Electrician monthly: Rigger. Hoist drum assembled 1. 5 5 14 Safe working load supply and Equipment cost will be 1. mill building for 7. Fitter. 3 Monthly check etc.6 Loose or travel of the hoist becoming 5 5 14 Rigger.2 1 in 25 years 8 5 2 and Rigger. to take hook measurement.) VAAL RIVER METALLURGY METALLURGY EQUIPMENT ISSUE BASED EVALUATION ON FAILURE MODE/EFFECT AND CRITICALLY ANALYSIS KPA (Plant) : Nº 9 Gold Plant PROCESS AREA MILLING DATE : LEGEND (Section) : Pr = Probability (Qualitative Data) (EQUIPMENT/LOCATION) Fr = Frequency ( Quantitative Data) SYSTEM : LIFTING Nº S = Severity UNIT/EQUIPMENT : OVERHEAD R = Risk HOIST MILL BUILDING (50T) Nº 9G1AMBUH1D CONSEQEUNCE/EFFECT * PEOPLE * EQ = EQUIPMENT * MAT = MATERIAL * ENV = ENVIRONMENT (PROCESS LOSS) Unit/components Functional Failure Cause of Failure * Failure Effect/ Consequence P Probability/ S P R Current Maintenance Recommended Maintenance and Function (Loss of Function) ( Failure Mode) ( What Happens when it Fails) r Frequency that the r Strategies/ Tasks Strategies / Tasks (Severity) o Cause Could o r Result in r F Funct.3 1 in 20 years Component Code: gearbox lubrication 8 5 2 Electrician. Rigger of equipment in the 6.5 1 in 25 years 8 5 2 hook sizes. Hook 1.00 1 Assist @ R20/hr x 4hrs = R 80.. Electrician.6 1 in 25 years 5 5 14 structure 180. 10.00 Total = R 5 760. 3. Check task / i.e.6 1 in 25 8 5 2 3. Rope guides broken bolts stationary.

2 1 in 20 years 4 5 20 2.3 1 in 20 years 5 5 14 1.00 Mat If or when gearbox fails no Pr 2. ANNEXURE 12 (Contd.2 Lack of 2.3 1 in 20 years 8 5 2 1.5 1 in 25 years 8 5 2 1.) pins injury to people 6 – 59 shift lost. 1. 2.7 Loose or equipment = R 12 500.1 1 in 15 years 5 5 14 (See previous page 2. 1 in 20 years 5 5 14 loss will occur. Cost of 2.4 1 in 20 years 5 5 14 lubrication 2.7 1 in 25 years 5 5 14 2.5 Gear failure perform its duty the gearbox will 2.2 1 in 20 years 4 5 20 Total = R 13 020. The only cost 1.6 1 in 25 years 4 5 20 2 Assist @ R20/hr x 4hrs = R 2. 1 in 15 years 5 5 14 Maint strategies as per ones task.6 1 in 25 years 4 5 20 2.6 1 in 25 years 5 5 14 assembled 2. 1 in 20 years 8 5 2 consequence will be low.5 1 in 25 years 4 5 20 R 360.6 1 in 25 years 5 5 14 Env If or when the gearbox fails the Pr 1.4 1 in 20 years 4 5 20 broken bolts.1 Shearing people as load or hook can cause 2.4 Bearing Eq If and when gearbox fails it will Pr 2 1 in 5years 4 5 20 failure result in the crane not being able to 2.6 1 in 25 years 8 5 2 2.3 1 in 25 years 4 5 20 2.00 2.00 2.4 1 in 25 years 5 5 14 1. 2.5 1 in 25 years 5 5 14 2.1 1 in 20 years 8 5 2 enclosed area.1 1 in 20 years 5 5 14 would be that of the equipment.4 1 in 20 years 4 5 20 2.00 1.4 1 in 25 years 8 5 2 1.1 1 in 15 years 4 5 20 2.00 Total = 13 020.3 1 in 25 years 4 5 20 2.6 Shaft failure have to be overhauled. The 2.2 1 in 25 years 5 5 14 Total = R 5 500.7 1 in 25 years 4 5 20 112 .2 1 in 20 years 5 5 14 recommendations.2 1 in 25 years 8 5 2 1. Main hoist P If and when gearbox fails it could Pr 2. Totally 1.) Unit/components Functional Failure Cause of Failure * Failure Effect/ Consequence P Probability/ S P R Current Maintenance Recommended Maintenance and Function (Loss of Function) ( Failure Mode) ( What Happens when it Fails) r Frequency that the r Strategies/ Tasks Strategies / Tasks (Severity) o Cause Could o r Result in r F Funct. 1 in 15 years 4 5 20 production loss will occur.7 1 in 25 years 4 5 20 160.3 1 in 25 years 5 5 14 2. gearbox have serious consequences on 2.5 1 in 25 years 5 5 14 1./Failure F r r Mat If or when gearbox fail no material Pr 1.1 1 in 15 years 4 5 20 cost will be that of Equipment only. 1.3 Incorrectly 2.00 2.5 1 in 25 years 4 5 20 2. Labour 2 Art @ R45/hr x 4hrs = 2.

1 Loose on consequence will be low – Near 3.6 1 in 25 years 8 5 2 2.00 Mat If or when drum fails no production Pr 3 1 in 15 years 4 5 20 loss will occur.1 Incorrect serious injuries to people 60 – 599 4. The only cost will 3. Hoist drum P If or when drum fails the Pr 3 1 in 15 years 8 5 2 Maint strategies as per ones task.2 1 in 15 years 4 5 20 Total = R 21 720.2 1 in 20 years 8 5 2 2. 2.) Unit/components Functional Failure Cause of Failure * Failure Effect/ Consequence P Probability/ S P R Current Maintenance Recommended Maintenance and Function (Loss of Function) ( Failure Mode) ( What Happens when it Fails) r/ Frequency that the r Strategies/ Tasks Strategies / Tasks (Severity) F Cause Could o r Result in r Funct.2 1 in 15 years 4 5 20 recommendations.) 5. 3.113 ANNEXURE 12 (Contd.1 1 in 15 years 4 5 20 (See previous page operation days lost.4 1 in 20 years 8 5 2 2.2 Safety 4.3 1 in 25 years 4 5 20 catch / spring 4.1 1in 15 years 8 5 2 low.00 4.2 Bearings 3. 3./Failure F r Env If and when gearbox fails the Pr 2 1 in 15 years 8 5 2 consequence to the environment is 2.7 1 in 25 years 8 5 2 3. 4. 3. It will have to be 4.3 1 in 25 years 8 5 2 3.00 3.3 Distortion of hook 5.1 1 in 20 years 4 5 20 be that of the equipment.4 1 in 25 years 4 5 20 failure 5. 3.3 1 in 25 years 4 5 20 Labour: 3 Art @ R45/hr x 8hrs = R1080.) 3.3 Worn Eq If or when drum fails the hoist will Pr 3 1 in 15 years 4 5 20 (grooves) stop operating.00 4.1 1 in 20 years 8 5 2 area is totally enclosed. 5. Assist @ R20/hr x 8hrs = R 640.3 1 in 25 years 8 5 2 2.2 1 in 15 years 8 5 2 recommendations. Hook P If or when hook fails it could cause Pr 4 1 in 15 years 4 5 20 Maint strategies as per ones tasks.1 1 in 20 years 4 5 20 overhauled or repaired.5 1 in 25 years 8 5 2 2. as the 3.4 Sheaves .00 Total = R 21 720.2 1 in 15 years 8 5 2 3.1 1 in 20 years 8 5 2 (See previous page broken bolts miss.3 1 in 25 years 8 5 2 5. The cost 4.3 1 in 25 years 4 5 20 Env If or when the drum fails the Pr 3 1 in 15 years 8 5 2 consequence will be low.2 1 in 15 years 4 5 20 will be equipment = R 20 000.

6 1 in 15 years 4 5 20 installation Eq If or when rope fails the crane will Pr 5 1 in 15 years 4 5 20 5. The rope will have 5.2 1 in 15 years 4 5 20 5.00 Mat No material loss will occur if or Pr 5 1 in 15 years 4 5 20 when rope fails.3 1 in 15 years 4 5 20 operation 5.1 1 in 25 years 4 5 20 be that of equipment = R 11 040.5 Incorrect 5. The only cost will 5. 5. Equipment cost 5. Rope P If or when rope fails it could have Pr 5 1 in 15 years 4 5 20 Maint strategies as per ones task.3 1 in 15 years 8 5 2 5.3 1 in 15 years 4 5 20 5.6 1 in 15 years 4 5 20 R320. The only 4. 5.1 1 in 15 years 8 5 2 fails.6 1 in 15 years 8 5 2 114 .3 Incorrect 5.1 1 in 15 years 4 5 20 cost would be that on equipment = 4.00 Total = R 11 040.6 1 in 15 years 4 5 20 Env If or when the rope fails the Pr 5 1 in 15 years 8 5 2 consequence to the environment 5.6 Faulty unit stop operating.3 1 in 25 years 8 5 2 5.2 1 in 25 years 8 5 2 4.5 1 in 25 years 4 5 20 2 Assist @ R20/hr x 8hrs = 5. 4.5 1 in 25 years 4 5 20 5.2 1 in 15 years 4 5 20 recommendations.2 1 in 25 years 4 5 20 R 23 180. ANNEXURE 12 (Contd.2 Rope guides 599 days lost.3 1 in 25 years 4 5 20 Env The consequence will be low on the Pr 4 1 in 15 years 8 5 2 environment if and when hook 4.00 5.) nit/components and Functional Failure Cause of Failure * Failure Effect/ Consequence P Probability/ S P R Current Maintenance Recommended Maintenance Function (Loss of Function) ( Failure Mode) ( What Happens when it Fails) r/ Frequency that the r/ Strategies/ Tasks Strategies / Tasks (Severity) F Cause Could F r Result in r Funct.4 1 in 15 years 4 5 20 R720. Enclosed area./Failure Mat If and when the hook fails no Pr 4 1 in 15 years 4 5 20 material loss will occur.00 5.00 4.4 1 in 15 years 4 5 20 5.2 1 in 15 years 8 5 2 5.00 5.) 5.5 1 in 25 years 8 5 2 5.5 1 in 25 years 4 5 20 5.3 1 in 15 years 4 5 20 devices) Labour: 2 Art @ R45/hr x 8hrs = 5.4 Worn drum 5.1 1 in 25 years 8 5 2 will be low.2 1 in 15 years 4 5 20 (safety (rope) = R 10 000.1 Sheaves serious consequence on people 60 – 5.1 1 in 25 years 4 5 20 switches to be changed.1 1 in 25 years 4 5 20 (See previous page 5.4 1 in 15 years 4 5 20 5.4 1 in 15 years 8 5 2 5. 5.

5 1 in 15 years 8 5 2 7. The motor will have to 7.1 Rotor consequences will be a near miss.2 1 in 15 years 8 5 2 6. 7.4 1 in 10 years 8 5 2 6.5 Failure of Equipment cost = R 7 500. The brakes 6. 6.) worn) 6.00 6.1 Ingress of consequence could be serious 6 – 6.00 6.00 2 Assist @ R20/hr x 4hrs = R160.00 pendant Total = R 7 760.4 1 in 20 years 4 5 20 R360.5 1 in 15 years 4 5 20 Env If or when the brakes fail the Pr 6 1 in 10 years 8 5 2 consequences to the environment 6.2 1 in 15 years 4 5 20 setting replaced.5 1 in 15 years 5 5 14 6.3 1 in 20 years 5 5 14 6.00 7. 6. Brakes P If or when brake fails the Pr 6 1 in 10 years 5 5 14 Maint strategies as per ones tasks.2 Stator 7.1 1 in 15 years 4 5 20 be overhauled. Totally enclosed.2 1 in 15 years 4 5 20 R 17 000.4 1 in 20 years 8 5 2 Eq If or when motor fails the hoist will Pr 7 1 in 15 years 4 5 20 not operate.00 6. ANNEXURE 12 (Contd.00 Total = R 17 520. Equipment cost = 7.4 Shaft 7.00 Mat If or when brakes fail no material Pr 6 1 in 10 years 4 5 20 loss will occur.1 1 in 20 years 4 5 20 be equipment cost = R 7 760.2 1 in 15 years 8 5 2 7.3 1 in 20 years 4 5 20 6.1 1 in 20 years 8 5 2 till be low. The only cost will 6.3 1 in 15 years 4 5 20 Labour: 2 Art @ R45/hr x 4hrs = 7./Failure 6.3 1 in 20 years 8 5 2 6.3 1 in 20 years 4 5 20 6.00 115 .4 1 in 10 years 5 5 14 coil 6.5 1 in 15 years 4 5 20 control / 1 Assist @ R20/hr x 4hrs = R 80.1 1 in 20 years 4 5 20 6.3 Bearings 7.4 1 in 10 years 4 5 20 remote 1 Art @ R45/hr x 4hrs = R 180.4 1 in 10 years 4 5 20 6.2 1 in 15 years 4 5 20 6.4 Incorrect will have to be overhauled or 6.3 Incorrectly Eq If or when brakes fail the crane will Pr 6 1 in 10 years 4 5 20 installed become inoperative. 7. 6.3 1 in 15 years 8 5 2 7.2 1 in 15 years 5 5 14 recommendations. Hoist motor P If or when the motor fails the Pr 7 1 in 15 years 8 5 2 Routine service task by electrician 7. 6.2 Failure of 6.) Unit/components Functional Failure Cause of Failure * Failure Effect/ Consequence P Probability/ S P R Current Maintenance Recommended Maintenance and Function (Loss of Function) ( Failure Mode) ( What Happens when it Fails) r/ Frequency that the r/ Strategies/ Tasks Strategies / Tasks (Severity) F Cause Could F r Result in r Funct.1 1 in 20 years 5 5 14 (See previous page dirt (faces 59 shifts lost.1 1 in 15 years 8 5 2 3 monthly.

The pendant 8.1 1 in 5 years 5 4 19 3 monthly.00 8.2 1 in 15 years 8 5 2 7.3 1 in 5 years 5 4 19 3 500.1 1 in 15 years 8 5 2 will be low.00 7.2 1 in 10 years 5 4 14 8. Pendant / P If or when pendant fails it could Pr 8 1 in 5 years 5 4 19 Routine service task by electrician remote result in injuries to people (buttons 8.3 1 in 5 years 8 4 4 8.4 1 in 10 years 5 5 14 Labour: 1 Art @ R45/hr x 2hrs = R 90.1 Buttons 8.00 8. Totally enclosed. ANNEXURE 12 (Contd.1 1 in 15 years 4 5 20 be that of equipment only = 7. 7. The cost will be 8.3 Incorrect Eq If or when pendant fails the hoist Pr 8 1 in 5 years 5 4 19 operation will fail to operate.2 Cable failure 8.2 1 in 10 years 5 5 14 590.00 Total = R 3 590. 8.4 Moisture will have to be repaired or 8.4 1 in 10 years 5 4 14 8.3 1 in 15 years 4 5 20 7.3 1 in 15 years 8 5 2 7.3 1 in 5 years 5 4 19 8.2 1 in 10 years 5 5 14 replaced./Failure Mat If or when motor fails no material Pr 7 1 in 15 years 4 5 20 loss will occur and the cost would 7.2 1 in 10 years 8 5 2 8.1 1 in 5 years 8 4 4 area.4 1 in 20 years 8 5 2 8.4 1 in 10 years 8 5 2 116 . Cost will be equipment R 8.1 1 in 5 years 5 4 19 8.00 Mat If or when pendant fails no material Pr 8 1 in 5 years 5 4 19 loss will occur.) Unit/components Functional Failure Cause of Failure * Failure Effect/ Consequence P Probability/ S P R Current Maintenance Recommended Maintenance and Function (Loss of Function) ( Failure Mode) ( What Happens when it Fails) r/ Frequency that the r/ Strategies/ Tasks Strategies / Tasks (Severity) F Cause Could F r Result in r Funct. Enclosed 8.2 1 in 15 years 4 5 20 R 17 520.4 1 in 20 years 4 5 20 Env If or when motor fails the Pr 7 1 in 15 years 8 5 2 consequence to the environment 7. 8.1 1 in 5 years 5 4 19 that of equipment only = R 3 8.3 1 in 5 years 5 4 19 8.4 1 in 10 years 5 5 14 Env If or when the pendant fails the Pr 8 1 in 5 years 8 4 4 consequence will be low. control stuck) 6 – 59 days lost.

2 1 in 5 years 5 4 19 circuits 10.00 Labour: 1 Art @ R45/hr x 2hrs = R 90.3 1 in 20 years 5 5 14 Env If or when guides fail the Pr 9 1 in 15 years 8 5 2 consequence to the environment 9.3 1 in 5 years 5 4 19 10.2 1 in 15 years 5 5 14 equipment = 9.00 9./Failure 9. P If or when circuit fails the Pr 10 1 in 5 years 5 4 19 Routine service task testing safety supply and consequence to people could result 10. 9.3 1 in 20 years 8 5 2 10.2 Lack of near miss.1 1 in 15 years 8 5 2 will be low.3 Foreign Eq If or when guides fail it can Pr 9 1 in 15 years 5 5 14 objects (dirt.1 1 in 15 years 5 5 14 etc. Repairs 10.4 Over-wind Labour: 1 Art @ R45/hr x 4hrs = mechanical R 180. Control.3 1 in 5 years 5 4 19 leakage unit equipment will be = R 5 000.1 1 in 15 years 5 5 14 cost would be that of equipment 9. Cost of 9.2 1 in 15 years 8 5 2 failure one. 10.00 Mat If or when guides fails no Pr 9 1 in 15 years 5 5 14 production loss will occur. Enclosed area. safety in injuries 6 – 59 days lost.3 Earth will have to be done.00 10.117 ANNEXURE 12 (Contd.2 Contractors The hoist will not operate.2 1 in 15 years 5 5 14 only = R 3 830.1 1 in 10 years 5 5 14 10. The guides will 9. Cost of 10.00 1 Assist @ R20/hr x 2hrs = R 40.2 1 in 15 years 8 5 2 9.) Unit/components Functional Failure Cause of Failure * Failure Effect/ Consequence P Probability/ S P R Current Maintenance Recommended Maintenance and Function (Loss of Function) ( Failure Mode) ( What Happens when it Fails) r/ Frequency that the r/ Strategies/ Tasks Strategies / Tasks (Severity) F Cause Could F r Result in r Funct.3 1 in 20 years 8 5 2 9.3 1 in 20 years 5 5 14 R 3 700.00 switch Total = R 5 180.1 1 in 15 years 8 5 2 monthly and on. 9. lubrication 9. The 9.00 Total = R 3 830.) have to be replaced.00 .1 Rope failure consequence to people will be a 9. Rope guides P If or when guides fail the Pr 9 1 in 15 years 8 5 2 Routine service task by Rigger 3 9. damage the rope.2 1 in 5 years 5 4 19 10. 10.condition as per 9.1 1 in 10 years 5 4 14 devices 3 monthly.1 Limit Eq If or when circuits fail it could Pr 11 1 in 5 years 5 4 19 switches result in damage to rope and guide.

11.3 1 in 50 years 4 5 20 R 7 540.00 10. 10.00 P If or when wheels and structure Pr 11 1 in 50 years 4 5 20 fails no production loss will occur. 11.5 1 in 50 years 8 5 2 11.00 5 Assist @ R20/hr x 12 hrs = R 960.3 Poor quality fails the hoist will stop operating.3 1 in 50 years 4 5 20 be = R 5 500.) Unit/components Functional Failure Cause of Failure * Failure Effect/ Consequence P Probability/ S P R Current Maintenance Recommended Maintenance and Function (Loss of Function) ( Failure Mode) ( What Happens when it Fails) r/ Frequency that the r/ Strategies/ Tasks Strategies / Tasks (Severity) F Cause Could F r Result in r Funct. 11.1 1 in 10 years 5 5 14 that of equipment only = R 5 10.1 Corrosion 11.1 1 in 50 years 4 5 20 The cost will be that of equipment 11.1 1 in 10 years 8 5 2 when circuits fail.2 1 in 5 years 5 4 19 180.2 1 in 5 years 8 4 4 10.3 1 in 5 years 8 4 4 11 heels & P If or when wheels and structure Pr 11 1 in 50 years 8 5 2 Maint strategies as per ones tasks structure fails the consequence will be low./Failure Mat No material loss will occur if and Pr 10 1 in 5 years 5 4 19 when circuits fail the cost will be 10.2 1 in 50 years 4 5 20 = 11.00 Total = R 7 540.2 Incorrect 11.3 1 in 5 years 5 4 19 Env The consequence to the Pr 10 1 in 5 years 8 4 4 environment will be low if and 10.3 1 in 50 years 8 5 2 118 . ANNEXURE 12 (Contd. The equipment cost will 11.00 Eq If or when wheels and structure Pr 11 1 in 50 years 8 5 2 fails the consequence to the 11. 11.2 1 in 50 years 8 5 2 11.6 1 in 50 years 8 5 2 operation Eq If or when wheels and structure Pr 11 1 in 50 years 4 5 20 11.2 1 in 50 years 4 5 20 repaired.4 1 in 50 years 8 5 2 11.1 1 in 50 years 8 5 2 environment will be low.1 1 in 50 years 4 5 20 of material The equipment will have to be 11.00 Labour: 2 Art @ R45/hr x 12hrs = R 1 080.

) VAAL RIVER METALLURGY ISSUED BASED (PROCESS) RISK ASSESSMENT. Environment. No effect on equipment. fall to a lower level/ onto moving ISRS program. People Severity and Frequency is from matrix 1 (Days lost per event). Moving crane start and operate the accessories. No effect Pr 1 in 20 years 8 5 2 . Material and Security Consequential loss/Frequency are from matrix 2 (Rand lost per event). 119 ANNEXURE 12 (Contd. PR = PROBABILITY (QUALITATIVE DATA) FR = FREQUENCY (QUANTITATIVE DATA) S = SEVERITY R = RISK * NOTE: Severity/Frequency ranking from matrix P = People Eq. INCIDENTS AND ACCIDENTS. PLANT: 9GP SECTION: MILLING TASK: SCHEDULE RESTORATION TASK OVERHEAD (HOIST) CRANE INCIDENT: _____________________________________________________________ DATE: 15/07/1998 ACCIDENT _____________________________________________________________ PROCESS: ___________________________________________________ HAZARD CAUSE * EFFECT / CONSEQUENCE Pr PROBABILITY / S Pr R EXISTING CONTROLS RECOMMENDED S P R / FREQUENCY THAT THE / CONTROLS / Fr CAUSE COULD RESULT Fr r INTO A HAZARD Physical 1. 1. and into ropes and Minerals Act Reg. ( Equipment) crane. in task contact: people can actually equipment. Nº….. Pr 1 in 20 years 8 5 2 Mat. May cause a fatal because a person can Pr 1 in 20 years 1 5 38 Lock out procedure as per Enforce lock out 4 6 15 1. Eq. Equipment.1) Not locked out. procedure. Wear safety belt. (QUALITATIVE & QUANTITATIVE) LEGEND TASKS. No process loss or effect Pr 1 in 20 years 8 5 2 Env. = Equipment Sec = Security 1.. procedure and isolate.) Moving crane P. En = Environment Mat = Material (Process Loss ) 2.

3) Training on task 5 5 rails procedures. Mat.4. ANNEXURE 12 (Contd.4 Bump into 1. electric As existing 8 5 2 trips. Low consequence Pr 1 in 30 years 8 5 2 Stopper blocks.2 Ropes crane.2) Confined space. 1) Enforce lockout 5 5 141 long/cross traverse Can operate and start. Nº procedure and isolate.5) 1 in 15 years 3 5 26 correct PPE. 1.1) Not locked out P.2. Fr 1. In task 5 4 919 1.2.2.1) May fall to lower level . and body when caught Fr 1. drum. procedure.2. changing rope. Low consequence Pr 1 in 30 years 8 5 2 Env. limit switches.) HAZARD CAUSE * EFFECT / CONSEQUENCE Pr PPPROBABILITY / S Pr EXISTING CONTROLS RECOMMENDED S P R / FREQUENCY THAT THE / CONTROLS / Fr CAUSE COULD RESULT Fr r INTO A HAZARD Equipment: 1. 1. cause a fatal Pr 1.4) Removing Mat.2) 1 in 2 years 3 4 31 ISRS program. 1. P.) 1 in 20 years 3 5 26 Lock out procedure as per Enforce lock out 5 5 141 People can/may start arms. COMMENTS: For the ropes and the drum effects/ consequence on Equipment/ Material and Environment .4..3) 1 in 2 years 3 4 31 Minerals Act Reg.3) 1 in 20 years.2) 1 in 20 years 1 5 38 As per ISRS & regulation. procedure. Pr 1.3) Removing Eq.3) Tripped over crane training. guards. use 5 4 4 ropes/adjusting brakes (60 day T loss) Pr 1.4.2. 1 5 38 Lifting coarse.2.1) Not locked out.4.2. Low consequence 8 5 2 brake.1) 1 in 20 years 1 5 38 PTO. lockout procedure.2.4. 1.4. overhead 2) safety belt 5 5 14 1.Low consequence HAZARD CAUSE * EFFECT / CONSEQUENCE Pr PROBABILITY / S Pr EXISTING CONTROLS RECOMMENDED S P / FREQUENCY THAT THE / CONTROLS / Fr CAUSE COULD RESULT Fr r INTO A HAZARD 1.may Pr 1. between ropes & drum.5) Improper Env. May cause severe injuries to hands. Pr 1. Low consequence Pr 1 in 30 years 8 5 2 120 .4) 1 in 5 years 3 4 31 Wear safety belt.2. 5 4 191 Drum of hoist 1. leg.4. shoe’s etc.2. gloves when 5 5 remove motors. Eq. Low consequence 8 4 4 operation. 414 1.) When changing Fr 1. Low consequence 8 4 4 coupling pins.2.

5 5 141 1. Eq.5.1) Removing of P.6 Coupling 1.3) 1 in 20 years 1 5 38 PPE safety belts.6) 1 in 30 years 1 5 38 1 6 rails. 525 Volt may cause electric shock and Pr 1.) Broken pendant 1.7.5.7. leather gloves.2) trip and fall 1. 5 5 14 motor.7.6. safety belt.can PTO’s lockout procedure. Low consequence 8 5 2 8 5 2 COMMENTS: Redesign access gate to interlock electrical supply to isolate electricity when opening the gate.5 Electric 1.5) 1 in 30 years 1 5 38 the hazard.5. know the consequence of 1 6 333 grommets Pr 1. cause laceration of finger. Mat.4) Confined space 1.7.5) No safety belt 1. Low consequence 8 5 2 Restoration task.6) 1 in 20 years 1 5 38 5 5 1.6.5.6) Fail to lock out.7.121 ANNEXURE 12 (Contd. Low consequence (Unscreened) Env. May cause a fatal because a person can Pr 1.1) 1 in 12 years 5 5 14 PPE.5.7. between motor and steel structure.5.1) Open boxes P.4) 1 in 20 years 1 5 38 5 5 414 positioning 1.1) 1 in 30 years 1 5 38 Lock out procedure. Eq. heights. Low consequence Mat.5.5.4) 1 in 30 years 1 5 38 and tasks. and lockout procedures.1) 1 in 20 years 1 5 38 Lock out procedure. Pr 1. Enforce task procedures 1 6 333 equipment.2) 1 in 20 years 1 5 38 Access locked gates. Eq.7. Interlocked access gate.5. Which may lead to a fatal.6) Inadequate earthing /cable Mat. Minor injury. Low consequence 8 5 2 8 5 2 Env.1) Working on P. Enforce the wearing of a 5 5 414 1.7.4. 1 6 333 1. .2) 1 in 15 years 1 5 38 Screened cables.7.7 Fall to lower 1. Low consequence Env.7.3) Improper 1.3) Loose Pr 1. 1. 1 6 1.4) Power supply Pr 1.3) 1 in 15 years 1 5 38 On condition inspections On the job training to 1 6 333 connections .) HAZARD CAUSE * EFFECT / CONSEQUENCE Pr PROBABILITY / S Pr R EXISTING CONTROLS RECOMMENDED S P R / FREQUENCY THAT THE / CONTROLS / Fr CAUSE COULD RESULT Fr r INTO A HAZARD 1. Apply existing controls. On condition task and 8 5 2 scheduled. 5 5 141 level.5. open Pr 1. fall to a lower level from that height.5. Low consequence 1. Low consequence 1.7.5. .5) 1 in 20 years 1 5 38 5 5 1. hands may be caught Pr 1. Low consequence 1. 1.7.2) Damaged cable burns.

3) 1 in 10 years 4 4 25 PCR inspections and check competency tests. Low consequence Pr 2.1) 1 in 1 year 4 3 30 1. 1. Tools to be in a good tools.5) 1 in 15 years 4 5 20 PTO inspections.) Over inspection safety tools.1.4) 1 in 15 years 4 5 20 4 6 1.1.) PCR checklist Artisans to use correct 7 5 5 2. 1. 4 6 2.2) 1 in 2 years 8 5 2 8 5 2 Pr 2.1.2) 1 in 2 years 5 3 24 7 5 5 2.2) 1 in 10 years 4 4 25 Restoration task.2) Rope guide 1.) 1 in 5 years 4 4 25 4 6 151 walking surfaces.1.2) Hoist 1. 2.) PTO Supply correct tools. Tools improper tools tools incorrectly it may cause a serious Pr 2. When using incorrect tools.4) 1 in 15 years 4 5 20 lists.1) 1 in 2 years 8 3 7 8 5 2 Pr 2.1.1.) Ropes & P. Low consequence Pr 2.1) 1 in 2 year 5 3 24 7 5 5 equipment.3) 1 in 2 years 8 5 2 8 5 2 Physical condition: 1.4) Lack of Eq. maintenance Corrosion – 1.R16 000-00.1. 1. utilization 1. incompetent 1. May cause minor damage to the Fr 2. Refresher and training 4 6 151 wear/damage.5) 1 in 15 years 4 5 20 4 6 Mat.2) 1 in 2 years 8 3 7 8 5 2 Pr 2.5) Used by Cost of rope +/.3) Incorrect using of training and refresher. On the job training on the task.2) Defective tools injury to hands and the body.1.1. damaged 1. Damaged rope/hook and improper Pr 1. tasks.1) Structure.1.1.3) Incorrect 2.1. . Pr 2.2) 1 in 1 year 4 3 30 2.1.) Area 1.3) 1 in 10 years 4 4 25 4 6 515 people.1) Incorrect and P. 1.2) 1 in 10 years 4 4 25 4 6 151 surfaces. 7 5 5 2.) Equipment Hooks utilization may cause a serious injury to 1. condition.1) 1 in 5 years 4 4 25 schedules. Eq.1) Improper body and hands. 1. 7 5 5 2. Incorrect use and maintenance may Pr 1. training cause serious damage to equipment.3) 1 in 2 years 8 3 7 8 5 2 Env.1) 1 in 2 years 8 5 2 8 5 2 Pr 2.) 1 IN 5 years 4 4 25 On condition tasks and Proper on the job training 4 6 151 1.30 1 in 1 year 4 3 30 3. defective Pr 2.1) 1 in 5 years 4 4 25 4 6 515 Poles and concrete 1. Low consequence COMMENTS: 122 .) HAZARD CAUSE EFFECT / CONSEQUENCE Pr PROBABILITY / S Pr R EXISTING CONTROLS RECOMMENDED S P R * / FREQUENCY THAT THE / CONTROLS / Fr CAUSE COULD RESULT Fr r INTO A HAZARD Physical contact: 2. As above 4 6 wear/damage. 4 6 515 1. ANNEXURE 12 (Contd.1. Low consequence Env.3) 1 in 2 years 5 3 24 7 5 5 Mat. 4 6 515 rope/hook .1.

serious injury.3) 1 in 10 years 3 3 36 8 3 7 1.2.1) Improper 1. Corroded structure and concrete to be Pr 2. 1.4) 1 in 15 years 8 4 4 checklists. On condition tasks awareness. Low consequence – No effect on environment.3) 1 in 10 years 8 3 7 PCR inspections and other 8 3 7 Incorrect maintenance.) HAZARD CAUSE EFFECT / CONSEQUENCE Pr PROBABILITY / S Pr R EXISTING CONTROLS RECOMMENDED S P R / FREQUENCY THAT THE / CONTROLS / * Fr CAUSE COULD RESULT Fr r INTO A HAZARD 1. Walkways may cause a person to trip standards. Holes in concrete and corroded steel. May cause loss of hearing ( serious ) Pr 1 in 20 years 4 5 20 Noise surveys and ear Enforce wearing of ear 6 5 9 substances N/A protection.4) 1 in 15 years 3 4 31 8 4 4 Mat.2. Low consequence – No effect on process. 2.2. 8 3 7 utilization. 4 6 15 Area steel /concrete.1 Steel structure/ and fall.123 ANNEXURE 12 (Contd.2) 1 in 10 years 8 3 7 Scheduled restoration tasks. PCR (Corroded surfaces repaired +/. Env. Mat. N/A area Flammable N/A substances N/A Electricity N/A Water N/A.4) Used by incompetent persons. +/. Low consequence Pr 1. 1. 8 4 4 1. Can cause severe damage when used Pr 1.1) 1 in 15 years 5 5 14 On condition tasks and PCR On condition tasks . Hazardous N/A P. Low consequence _ No process loss.2. walkway corrosion. Pr 2.2.2.2) Hoist wear P. Existing controls and 8 3 7 damage 1. PTO inspections. Loss control Enforce existing controls. Holes in concrete. Eq.1) Normal wear of P.40 days off for a broken leg or arm.1) 1 in 5 years 3 3 36 8 3 7 improperly. Pressure Running machinery Noise N/A Dust N/A Radiation N/A Vibration N/A Temperature .1. inspections and training and handrails) in hazard awareness. 1.2) 1.2.2) 1 in 10 years 3 3 36 8 3 7 1.2. Env. training to be enforced.3) Lack of training. Eq.R5 000-00 inspections.2.1. Train people in hazard 2. Low consequence – No effect on environment / Therefore risks are acceptable.2.2.1) 1 in 15 years 4 4 25 Pcr checklists. 1.1) 1 in 5 years 8 3 7 On condition task.2. Physical Condition 2. protection in the Milling Superfluous material.

Enforce existing controls. may cause a serious injury. training.) HAZARD CAUSE EFFECT / CONSEQUENCE Pr PROBABILITY / S Pr R EXISTING CONTROLS RECOMMENDED S P R / FREQUENCY THAT THE / CONTROLS / * Fr CAUSE COULD RESULT Fr r INTO A HAZARD Ergonomics : P. Low consequence Pr 1 in 20 years 8 4 4 8 4 4 COMMENTS: ALL NOT APPICABLE AS PER SURVEY’S DONE. Low consequence Pr 1 in 20 years 8 4 4 8 4 4 Env. ANNEXURE 12 (Contd. Hazard awareness artificial light. Eq. 124 . which On condition tasks. 4 4 25 * Illumination Lack of natural or cause a person to trip and fall. Low consequence Pr 1 in 20 years 8 4 4 8 4 4 Mat. When not properly illuminated it can Pr 1 in 10 years 4 3 30 Light surveys.

Schedule a discard task – to AM-M1-P1 1.3 1 x suct.2) Pump surging.3) Metal volume.2) 1 in 1 year 8 4 4 failure and the average UFE of the 11 weeks. – glands.1) 4 in 1 year 8 3 7 2.) Currently the pumps are run to replace the wet end parts every Component Code: impeller and impellers.) Motor.) Damaged 1.2) 1 in 1 year 4 4 25 pump. l/sec at a 3 art. 1. impeller. . 1. Particles.) Daily routine inspection. D Frame Pump liners 1. etc. liner = R 2490 density from 1 x Insert = R 1127 the mill 1 x Eng. Eq. x 2hrs @R45= R270 22metre 1 x Impeller = R 4100 head @ 1. will not deliver the required ./Failure r Unit/Equipment no: Total Failure: 1. 1. If the wet end fails.) Vee-belts. Impeller diameter 775mm and pump speed 486RPM. and this will lead to 1.3) 4 in 1 year 4 3 30 Delivers 298 5. 1. Function: 2.) 4 in 1 year 8 3 7 1. 1.3) 4 in 1 year 8 3 7 wet-end is +/-10-12 weeks. material. the pump Pr 1. ) Damaged P. suction liner.) 4 in 1 year 4 3 30 3. Low consequence on people – Pr 1. Liner = R2501 discharge Total costs = R 10 488-00 sump to the cyclones.1) 4 in 1 year 4 3 30 Envirotech D Frame 4. Driven by 140Kw motor @ 1485Rpm by means of .1) Coarse 1.) KPA (Plant) : WGP PROCESS AREA Milling DATE : 1998/05/28 LEGEND (Section) : Pr = Probability (Qualitative Data) (EQUIPMENT/LOCATION) Fr = Frequency ( Quantitative Data) SYSTEM : Pump Systems Nº S = Severity UNIT/EQUIPMENT : D Frame Nº AM-M1-P1 R = Risk Pump CONSEQEUNCE/EFFECT * PEOPLE * EQ = EQUIPMENT * MAT = MATERIAL * ENV = ENVIRONMENT (PROCESS LOSS) Unit/components Functional Cause of * Failure Effect/ P Probability/ S P R Current Maintenance Recommended and Function Failure (Loss Failure Consequence r Frequency that r Strategies/ Tasks Maintenance of Function) ( Failure ( What Happens when it / the Cause Could / Strategies / Tasks Mode) Fails) (Severity) F Result in F r Funct.) Bearing unit. failures.125 ANNEXURE 12 (Contd.) Damaged liners and totally enclosed.

126 a V-Drive ( No Variable drive) .

it Pr 1. 2.3) 1 in 10 years 8 4 4 @R54/sample. 2. 2.3) 1 in 10 years 8 4 4 127 .1) Lack of totally enclosed.1) 4 in 1 year 8 3 7 1. Costs 2 hrs@R10000/hr = R 20000 Total costs R30 488-00 Env. the mill will stand . . PLUS 2. costs = R15 450 2. Component Code: Lubrication. P.2) 1 in 5 years 4 3 30 1. x 4hrs @ R45 2./Failure r Mat. 1) 6 Monthly oil analysis D Frame Pump 2. it may cause damage to .1) 1 in 5 years 4 3 30 the shaft.1) 4 in 1 year 4 3 30 the costs will be: 1.1) 1 in 5 years 8 3 7 2.) 3 art.1) 1 in 5 years 8 3 7 Weekly lubrication checks.3) 1 in 10 years 4 4 25 1.) Bearing unit. tasks.2) 1 in 1 year 4 4 25 Eq.) 1 in 5 years 8 3 7 Daily look feel and listen. Pr 2. 1. 2. 2. impeller. 1. ANNEXURE 12 (Contd. Costs = R10488 1.) 4 in 1 year 8 3 7 environment.3) 4 in 1 year 8 3 7 Unit/Equipment no: Total Failure: 2.2) Pump surge. Eq.) 1 in 5 years 4 3 30 fails.3) Misalignment 2) Monthly vibration of V-Belts. Pr 2. 2.2) 1 in 5 years 8 3 7 2.2) 1 in 5 years 8 3 7 Run to failure.2) 1 in 1 year 8 4 4 1.3) 4 in 1 year 4 3 30 Mat.) 4 in 1 year 4 3 30 will causing a production loss.1) 1 in 5 years 4 3 30 . If or when the wet end fails .causing a production loss of 4 2.) 1 in 5 years 4 3 30 check (No Charge) fails.) Mat costs = 4 x R10 000/hr = R40 000 Total costs = R55 450-00 Env. . Schedule condition-monitoring AM-M1-P1 2. . etc.) 1 in 5 years 8 3 7 . If or when the bearing unit Pr 2.) 1 x bearing unit = R15 000 Total costs = R15450 Mat. the bearing unit Pr 2. Low conseque4nce on Pr 1.) Unit/component Functional Cause of * Failure Effect/ P Probability/ S P R Current Maintenance Recommended s and Function Failure (Loss Failure Consequence r Frequency that r Strategies/ Tasks Maintenance of Function) (Failure Mode) ( What Happens when it / the Cause Could / Strategies / Tasks Fails) (Severity) F Result in F r Funct.2) 1 in 5 years 4 3 30 hr s the costs will be: 2. 2.) Eq. If or when. Low consequence on people.3) 1 in 10 years 4 4 25 = R450 2.

5) 1 in 10 years 5 4 19 2.) 1 in 5 years 8 3 7 area. AM-M1-P1 3.)Mat costs = 3.3) Misalignment 3. Pr 3. If the drive fails. will stand 3.3) 1 in 10 years 8 4 4 overhauled.1) 1 in 5 years 8 3 7 3.2) 1 in 10 years 8 4 4 Belts are inspected when pump is intervals at a costs of D Frame Pump 3. loss: 3. If or when the v-belts fails.128 ANNEXURE 12 (Contd.) 1 in 5 years 4 3 30 mill will stand causing a .) Unit/component Functional Cause of * Failure Effect/ P Probability/ S P R Current Maintenance Recommended s and Function Failure (Loss Failure Consequence r Frequency that r Strategies/ Tasks Maintenance of Function) (Failure Mode) ( What Happens when it / the Cause Could / Strategies / Tasks Fails) (Severity) F Result in F r Funct.) Eq.4) 1 in 5 years 5 3 24 = R180 3. 3. Change V-belts on yearly Component Code: 3. the pump will Pr 3.5) 1 in 10 years 8 4 4 .) 1 in 5 years 8 3 7 Daily look feel and listen.4) Unmatched 3.5) 1 in 10 years 4 4 25 = R20 000 Total costs = R25 700-00 Env.1) 1 in 5 years 8 3 7 Weekly routine inspection.3) 1 in 10 years 5 4 19 1.3) 1 in 10 years 4 4 25 = R15 540 2.2) 1 in 10 years 5 4 19 for 2 hrs.4) 1 in 5 years 4 3 30 2 x R10 000/hr 3.) Vee-belts. costs 3.2) 1 in 10 years 8 4 4 3.1) Worn belts. totally enclosed guards.3) 1 in 10 years 8 4 4 3.5) Overheating.) 1 in 5 years 5 3 24 stop working and the belts will . . R1980-00 3. Low consequence on people.) 1 x set belts = R1800 1 x motor pulley = R 1100 1 x pump pulley = R 2700 Total costs = R 5 700-00 Mat. 3./Failure r Unit/Equipment no: Total Failure: 3. 3.1) 1 in 5 years 5 3 24 have to be changed.5) 1 in 10 years 8 4 4 3. 3. x 2hrs @ R45 3.4) 1 in 5 years 8 3 7 sets. 3. Eq.2) 1 in 10 years 4 4 25 The costs will be: 1.2) Worn pulleys.4) 1 in 5 years 8 3 7 3. Low consequence. 3.contained Pr 3. the Pr 3. .1) 1 in 5 years 4 3 30 production loss of 2 hrs: 3. P.) 2 art. Schedule discard task.

) 1 in 15 years 4 5 20 mill will stand & production 4. ANNEXURE 12 (Contd. the motor Pr. Low consequence on people.1) 1 in 15 years 4 5 20 artisans ( No costs ) will stop to operate.1) 1 in 15 years 8 5 2 . Schedule condition-monitoring AM-M1-P1 4. If the shaft fails. Pr.) Shaft P. task.) Motor o/haul = R21 000 Total costs = R 21 405-00 Mat.2) 1 in 15 years 4 5 20 1.2) 1 in 15 years 8 5 2 1 Yearly service order Monthly temperature and D Frame Pump 4. 4. 4.1) 1 in 15 years 8 5 2 4. Low consequence – contained Pr./Failure r Unit/Equipment no: Total Failure: 4. 4.) 3 art.1) Coupling key motor totally enclosed.) 1 in 15 years 8 5 2 Daily look feel and listen.Cost: 4. 4.1) 1 in 15 years 4 5 20 will be lost: 4. 4. 4. Component Code: failure. the Pr. will be damaged and pump 4. costs = R21 405 2.) 1 in 15 years 4 5 20 vibration to be taken by failure. x 3hrs @ R45 = R405 2.)Mat costs = 3 x R10 000/hr = R30 000 Total costs = R51 405-00 Env.2) 1 in 15 years 4 5 20 the cost will be: 1. 4. If or when the shaft fails.) Unit/components Functional Cause of * Failure Effect/ Pr Probability/ S P R Current Maintenance Recommended and Function Failure (Loss Failure Consequence /F Frequency that r Strategies/ Tasks Maintenance of Function) (Failure ( What Happens when r the Cause Could / Strategies / Tasks Mode) it Fails) (Severity) Result in F Funct.2) 1 in 15 years 8 5 2 129 ..)Eq.2) Bearing Eq.) 1 in 15 years 8 5 2 area.

1. Envirotech D Frame 1. Low consequence on people – Pr. Schedule a condition- WP2321 1.6) 1in 10 years 8 4 4 pole motor running at 1.) Rotor lubrication.4) 1 in 10 years 5 5 14 mill discharge to the 1 x Set of bearings = R 1100 1.5) Overheating 1485./Failure r Unit/Equipment no: Total Failure: 1. may cause damage to the 1. 1.) KPA (Plant) : WGP PROCESS AREA Milling DATE : 1998/05/28 LEGEND (Section) : Pr = Probability (Qualitative Data) (EQUIPMENT/LOCATION) Fr = Frequency ( Quantitative Data) SYSTEM : Pump Systems Nº AM-M1-P1 S = Severity UNIT/EQUIPMENT : Motor Nº WP2321 R = Risk CONSEQEUNCE/EFFECT * PEOPLE * EQ = EQUIPMENT * MAT = MATERIAL * ENV = ENVIRONMENT (PROCESS LOSS) Unit/components Functional Cause of * Failure Effect/ Pr Probability/ S P R Current Maintenance Recommended and Function Failure (Loss Failure Consequence /F Frequency that r Strategies/ Tasks Maintenance of Function) ( Failure ( What Happens when r the Cause Could / Strategies / Tasks Mode) it Fails) (Severity) Result in F Funct.) 1 in 5 years 5 4 19 induces power to set bed plate. the bearings fail.) Bearings 1.6) Looseness on Eq.4) Water.5) 1 in 10 years 5 4 19 cyclone. 1.6) 1in 10 years 5 4 19 . test/analyses Function: 4. etc.3) 1 in 15 years 5 4 19 pump slurry from the 4 art. RPM.) Stator 1. 1.3) 1 in 15 years 8 4 4 Weekly lubrication. Total cost=R1640 1.1) Lack of totally enclosed. installation. stator.1) 1 in 5 years 5 4 19 the cyclone transfer.4) 1 in 10 years 8 4 4 . x 3hrs @R45= R540 1. motor shaft. 1. 1.2) 1in 10 years 5 4 19 pump in motion to Bearing cost+labour. If or when.) Bearings P. which 1. 1.) 1 in 5 years 8 4 4 Daily inspection. 1. Component Code: 2.2) 1in 10 years 8 4 4 1 Yearly S/O Monthly vibration Motor 3.3) Vibration.1) 1 in 5 years 8 4 4 3Monthly S/O monitoring task.2) Incorrect 1. 1.5) 1 in 10 years 8 4 4 140 kW Siemens 4 1. Pr.130 ANNEXURE 12 (Contd.) Shaft.

4) 1 in 10 years 4 5 20 Mat.1) 1 in 15 years 3 5 26 the mill will stand for 4hrs.3) 1 in 15 years 3 5 26 the costs will be: 3. P. costs = R21405 4. 2.2) 1in 10 years 4 4 25 cost will be: 1.) 1 in 15 years 3 5 26 the motor and the pump fails.2) 1in 20 years 4 5 20 1.3) 1 in 15 years 8 5 2 vibration test. Eq.2) 1in 10 years 8 4 4 1. motor will be damaged and 2.4) 1 in 10 years 8 5 2 1./Failure r Mat.) Unit/components Functional Cause of * Failure Effect/ Pr/ Probability/ S P R Current Maintenance Recommended and Function Failure (Loss Failure Consequence Fr Frequency that r Strategies/ Tasks Maintenance of Function) (Failure Mode) ( What Happens when the Cause Could / Strategies / Tasks it Fails) (Severity) Result in F Funct. If or when the motor bearings Pr.2) Loose rotor 2.. 1. 2.3) 1 in 15 years 4 4 25 Eq.) 1 in 15 years 4 5 20 2.) Mat costs = 4 x R10 000/hr = R40 000 Total costs = R61 405 131 .2) 1in 20 years 3 5 26 production will be lost.3) 1 in 15 years 8 4 4 1. it will cause a 1.1) Damaged motor totally enclosed. If or when the bearings fails.2) 1in 20 years 8 5 2 1 Yearly S/O. x 3hrs @ R45 2. Low consequence on Pr. Low consequence on people. the Pr. 2. Costs = R1640 1. 1.) Rotor Failure. 2. Monthly temperature and D Frame Pump Motor 2. monitoring task.5) 1 in 10 years 4 4 25 = R 30000 1.1) 1 in 15 years 8 5 2 Weekly routine inspection.) 3 art.3) Vibration..6) 1in 10 years 4 4 25 Total costs R31 640-00 Env.) 1 in 5 years 8 4 4 environment.) 1 in 15 years 8 5 2 Daily look feel and listen.( No costs ) bars. Pr. Pr.1) 1 in 5 years 8 4 4 1.1) 1 in 15 years 4 5 20 have to be changed (3 hrs ) 2. 2. 2. 1.5) 1 in 10 years 8 4 4 1. Schedule condition- WP2321 2.) 1 in 5 years 4 4 25 fails.contained area. If or when the rotor fails. 2.3) 1 in 15 years 4 5 20 = R405 2. Costs = 3xR10 000/hr 1. ANNEXURE 12 (Contd.1) 1 in 5 years 4 4 25 production loss of 3 hrs .) Eq.6) 1in 10 years 8 4 4 Unit/Equipment no: Total Failure: 2.) Motor o/haul = R21 000 Total costs = R 21 405-00 Mat. 2. Component Code: bearings. the 1.

3) 1in 20 years 4 5 20 1. the Pr. 2. Eq.) 1 in 15 years 4 5 20 3.3) Vibration. 3. Schedule on condition task. If the rotor / stator fails. Pr. P. Low consequence . costs = R21 405 2. Production loss 3. Low consequence on Pr.1) 1 in 15 years 4 5 20 change motor.1) 1 in 15 years 8 5 2 3.1) Damaged motor totally enclosed. If or when the stator fails.3) 1in 20 years 4 5 20 Cost: 1.contained Pr.) 1 in 15 years 4 5 20 mill will stand for 3-hrs..to 3. 3. vibration test to be done by 3.1) 1 in 15 years 4 5 20 operate.) Motor o/haul = R21 000 Total costs = R 21 405-00 Mat.3) 1in 20 years 4 5 20 artisans ( No costs ) bars.)Mat costs = 3 x R10 000/hr = R30 000 Total costs = R51 405-00 Env.1) 1 in 15 years 4 5 20 Weekly routine inspection. Low consequence on people. 3.) Rotor Failure.2) 1 in 15 years 4 5 20 for 3 hrs.)Eq.2) 1 in 15 years 8 5 2 3.2) 1in 20 years 8 5 2 2.to change motor. 2.1) 1 in 15 years 8 5 2 2./Failure r Env. the Pr.3) 1in 20 years 8 5 2 . motor and pump stop to 3. The mill will stand 3.) 3 art.2) Loose rotor 3.3) 1 in 15 years 8 5 2 Unit/Equipment no: Total Failure: 3. Monthly temperature and D Frame Pump Motor Bearings. 3.) 1 in 15 years 4 5 20 Daily look feel and listen.) 1 in 15 years 8 5 2 environment. 3.) 1 in 15 years 8 5 2 area..contained area.132 ANNEXURE 12 (Contd. 3. 3. WP2321 Code: 3.) Unit/components Functional Cause of * Failure Effect/ Pr/ Probability/ S P R Current Maintenance Recommended and Function Failure (Loss Failure Consequence Fr Frequency that r Strategies/ Tasks Maintenance of Function) (Failure Mode) ( What Happens when the Cause Could / Strategies / Tasks it Fails) (Severity) Result in F Funct. 3.2) 1 in 15 years 4 5 20 cost will be: 3.2) 1 in 15 years 4 5 20 1 Yearly S/O. x 3hrs @ R45 = R405 2.

) Control circuit.3) 1in 10 years 5 5 35 mills which is controlled Spares = R1000 1. 1. 1. 1. .pump on the 1 x Tech.2) Fuses AC2 Siliconics Speed 3.5) 1in 10 years 8 5 47 1. A) 3 Monthly earth leakage Component Code: 2.2) 1in 10 years 5 5 35 discharge.1) Diodes.) Cooling fan. pump with components are 1.4) 1in 10 years 8 5 47 blower.) KPA (Plant) : WGP PROCESS AREA Milling DATE : 1998/05/28 LEGEND (Section) : Pr = Probability (Qualitative Data) (EQUIPMENT/LOCATION) Fr = Frequency ( Quantitative Data) SYSTEM : Pumping Nº AM-M1-P1 S = Severity UNIT/EQUIPMENT: Siliconics variable Nº WP2321 R = Risk speed drive.4) Control guard. 1.)Converter P. Function: 1. 4.4) 1in 10 years 5 5 35 from the mill discharge Total costs = R2 090-00 1. CONSEQEUNCE/EFFECT * PEOPLE * EQ = EQUIPMENT * MAT = MATERIAL * ENV = ENVIRONMENT (PROCESS LOSS) Unit/components Functional Cause of * Failure Effect/ Pr/ Probability/ S P R Current Maintenance Recommended and Function Failure (Loss of Failure Consequence Fr Frequency that r Strategies/ Tasks Maintenance Function) ( Failure ( What Happens when the Cause Could / Strategies / Tasks Mode) it Fails) (Severity) Result in F Funct. Schedule routine task.1) 1in 10 years 8 5 47 3Monthly earth leakage.1) 1in 10 years 5 5 35 the second stage 1 art. On the production loss will be: 1.) Inverter totally enclosed.) 1 in 10 years 8 5 47 Daily inspection.) Converter.5) Loose wiring. AM-M1P2 1. Pr. Siliconics R1000 1. 1. Siliconics AC2 – motor. Low consequence on people – Pr. x 2hrs @R45= R90 1. Eq. 1.3) Cooling fan control./Failure r Unit/Equipment no: Total Failure: 1. test. If and when the covertor fails. 1.5) 1in 10 years 5 5 35 sump level.133 ANNEXURE 12 (Contd.2) 1in 10 years 8 5 47 6 Monthly S/O.3) 1in 10 years 8 5 47 B) Clean out system with 1.) 1 in 10 years 5 5 35 speed control used. 1.

panel enclosed in substation. 2./Failure r Mat.8) 1 in 3 years 8 4 45 Eq.6) 1 in 10 years 8 5 47 2. If or when the converter fails: Pr.5) 1 in 10 years 5 5 35 2.4) 1 in 5 years 8 4 45 2.134 ANNEXURE 12 (Contd.1) 1in 10 years 8 5 47 1. Costs = R1000 2.3) 1in 10 years 8 5 47 1.) Inverter.4) Control guard 2.3) 1 in 10 years 8 5 47 control. 2.3) 1in 10 years 4 5 29 line pump. At r1000 2.1) Diodes. 2.2) 1 in 3 years 5 4 30 Eq.1) 1in 5 years 5 4 30 1 x Tech. If or when the converter fails.5) 1 in 10 years 8 5 47 2.) 1 in 5 years 8 4 45 Daily inspection.7) Cable faulty. 1.8) 1 in 3 years 5 4 30 .6) 1 in 10 years 5 5 35 2. R10 000 1. x 4hrs @ R180 2.5) 1in 10 years 4 5 29 Total costs = R 12 090-00 Env. 2.5) 1in 10 years 8 5 47 Unit/Equipment no: Total Failure: 2.3) 1 in 10 years 5 5 35 Total costs = R 2 180-00 2.4) 1in 10 years 4 5 29 Eq. 2.2) 1in 10 years 4 5 29 To change over to direct on 1.3) Cooling fan.) 1 in 10 years 8 5 47 a controlled area. As per converter recommended AM-M1P2 2. 2.) 1 in 5 years 5 4 30 1 art. Low consequence spillage in Pr.7) 1 in 10 years 5 5 35 2. Component Code: 2. P. 2. Pr.) 1 in 10 years 4 5 29 it will cause a 1hr mill 1.7) 1 in 10 years 8 5 47 2. Costs = R2090 1.8) Fuses.2) 1 in 3 years 8 4 45 AC2 Siliconics Speed 2. 1. 2. Low consequence on people.1) 1in 5 years 8 4 45 maintenance.1) 1in 10 years 4 5 29 stoppage at R10 000/hr: 1.5) Loose wiring. 2.2) 1in 10 years 8 5 47 1. 1.4) 1 in 5 years 5 4 30 2. Pr.4) 1in 10 years 8 5 47 1.6) Motor faulty. 2.2) Thyristors.) Unit/components Functional Cause of * Failure Effect/ Pr/ Probability/ S P R Current Maintenance Recommended and Function Failure (Loss of Failure Consequence Fr Frequency that r Strategies/ Tasks Maintenance Function) (Failure Mode) ( What Happens when the Cause Could / Strategies / Tasks it Fails) (Severity) Result in F Funct.

3) 1 in 10 years 8 5 47 2. 3. If or when the inverter fails it Pr.2) 1 in 3 years 8 4 45 2.1) 1in 10 years 8 5 47 Change fan every 8 years at a Component Code: 3.7) 1 in 10 years 4 5 29 2. 2. 3.1) 1in 5 years 8 4 45 2.) 1 in 10 years 8 5 47 Daily inspection. Eq.2) 1 in 3 years 4 4 24 000/hr and changing direct on 2.) 1 in 10 years 8 5 47 Daily inspection. AM-M1P2 fan. Schedule discard task.) 1 in 5 years 8 4 45 a controlled area.5) 1 in 10 years 8 5 47 2. Schedule discard task.2) 1 in 15 years 8 5 47 costs of R 1 208-00 AC2 Siliconics Speed failure. at R45/hr for 2 hrs 3. = R 1208 Total costs = R 1 298-=00 135 . Costs R 2180 2.4) 1 in 5 years 4 4 24 Eq.) Unit/components and Functional Failure Cause of Failure * Failure Effect/ Consequence r/P Probability/ S P R Current Maintenance Recommended Maintenance Function (Loss of Function) (Failure Mode) ( What Happens when it Fr Frequency that the r Strategies/ Tasks Strategies / Tasks Fails) (Severity) Cause Could Result / in Funct.3) 1 in 10 years 4 5 29 line. Low consequence – totally Pr.2) 1 in 15 years 8 5 47 costs of R 1 208-00 = R90 Fan replacement.1) 1in 5 years 4 4 24 1 hr mill stoppage at R10 2.8) 1 in 3 years 8 4 45 Unit/Equipment no: Total Failure: 3.6) 1 in 10 years 4 5 29 2. ANNEXURE 12 (Contd. 2. control.4) 1 in 5 years 8 4 45 2./Failure F r Mat. 3.)Stalk cooling P.7) 1 in 10 years 8 5 47 2.1) Bearing 3. If or when the cooling fan Pr.2) Windings. enclosed in panel.8) 1 in 3 years 4 4 24 Env.1) 1in 10 years 8 5 47 Change fan every 8 years at a 1 art.6) 1 in 10 years 8 5 47 2.) 1 in 5 years 4 4 24 will cause a: 2. Low consequence spillage in Pr. 2.5) 1 in 10 years 4 5 29 Total costs = R 12 180-00 2. fails: 3. 2. 3.

Eq.4) 1 in 10 years 8 5 47 4. 4.) Unit/components Functional Cause of * Failure Effect/ Pr/ Probability/ S P R Current Maintenance Recommended and Function Failure (Loss of Failure Consequence Fr Frequency that r Strategies/ Tasks Maintenance Function) (Failure Mode) ( What Happens when the Cause Could / Strategies / Tasks it Fails) (Severity) Result in F Funct. 3.) 1 in 10 years 4 5 29 fails: 3.) 1 in 10 years 8 5 47 Daily inspection.2) 1 in 15 years 4 5 29 000/hr and changing direct on line.1) 1 in 15 years 8 5 47 Change fan every 8 years at a Component Code: unit.1) 1 in 15 years 5 5 35 1 art.4) Loose 4.) Control circuit. 4.5) Circuit breakers Eq.) 1 in 10 years 5 5 35 fails: 4. 3.5) 1in 15 years 8 5 47 connections. 3. P. ANNEXURE 12 (Contd. Low consequence spillage in Pr. Schedule discard task.1) Protection totally enclosed.4) 1 in 10 years 5 5 35 Total costs = R 4 135-00 4. AM-M1P2 4. Low consequence panel Pr. = R 4000 4. 4. If or when the control circuit Pr.3) 1in 15 years 8 5 47 control./Failure r Mat.1) Contactors. at R45/hr for 3 hrs 4. 4. If or when the cooling fan Pr.5) 1in 15 years 5 5 35 136 . 4. 4.1) 1in 10 years 4 5 29 1 hr mill stoppage at R10 3.20 1in 15 years 5 5 35 = R135 4.) 1 in 10 years 8 5 47 a controlled area.1) 1in 10 years 8 5 47 3. 4.20 1in 15 years 8 5 47 costs of R 1 208-00 AC2 Siliconics Speed 4.3) Relay’s 4.2) 1 in 15 years 8 5 47 Unit/Equipment no: Total Failure: 4. Costs R 1298 Total costs = R 11 298-00 Env.3) 1in 15 years 5 5 35 Eq.

4) 1 in 10 years 8 5 47 4.3) 1in 15 years 4 5 29 = R 30 000 .) 1 in 10 years 8 5 47 a controlled area.) 1 in 10 years 4 5 29 fails: 4. Low consequence spillage in Pr.20 1in 15 years 4 5 29 R10 000/hr x 3 hrs 4.3) 1in 15 years 8 5 47 4. 4. ANNEXURE 12 (Contd.5) 1in 15 years 4 5 29 Total costs = R 4 135-00 Env.20 1in 15 years 8 5 47 4. Costs R 4000 4./Failure r Mat. 4.) Unit/components Functional Cause of * Failure Effect/ Pr/ Probability/ S P R Current Maintenance Recommended and Function Failure (Loss of Failure Consequence Fr Frequency that r Strategies/ Tasks Maintenance Function) (Failure Mode) ( What Happens when the Cause Could / Strategies / Tasks it Fails) (Severity) Result in F Funct. If or when the control circuit Pr.5) 1in 15 years 8 5 47 137 . 4.1) 1 in 15 years 4 5 29 1 hr mill stoppage at 4.1) 1 in 15 years 8 5 47 4. 4.4) 1 in 10 years 4 5 29 Eq.

ANNEXURE 13 138 .

59 Shifts 5 34 29 24 19 14 10 Lost 1-5 Shifts 6 28 23 18 13 9 6 Lost No Time Loss 7 22 17 12 8 5 3 Near Miss 8 16 11 7 4 2 1 139 .599 4 39 35 30 25 20 15 Shifts Lost 6 . (16-26) B Requires action when reasonably practicable (1-15) C Maintain Risk Probable events Probable events Probable events Probable events Probable events Probable events less at this level.) ANGLOGOLD RISK INDEX MATRIX (Nº 1) Risk Index Action Category (28-48) A Immediate More than 100 Between 100 events Between 10 events Between 1 event per Between 1 event in Less than 1 event remedial events per year per year and 10 per year and 1 event year and 1 event in 10 years and 1 event per 100 years action events per year per year 10 years in a 100 years required. more than 100 per between 100 and 10 between 10 and 1 between 1 per year between 1 in 10 than 1 per 100 years year per year per year and 1 in 10 years years and 1 in 100 years Class of injuries to Frequency 1 2 3 4 5 6 people  Factor Multiple Fatal > 1 48 47 45 42 38 33 6000 Shifts Lost 1 Fatal 6000 2 46 44 41 37 32 27 Shifts Lost 600 . ANNEXURE 13 (Contd.5999 3 43 40 36 31 26 21 Shifts Lost 60 .

59 M 3 43 40 36 31 26 21 R 6 000 .R 0. (16-26) B Requires action when reasonably practicable Probable events Maintain Risk Probable events Probable events Probable events Probable events Probable events more than 100 per at this level.R 59 7 22 17 12 8 5 3 Low Consequence 8 16 11 7 4 2 1 .R 5 999 5 34 29 24 19 14 10 R 60 .R 59 999 4 39 35 30 25 20 15 R 600 .6 . between 100 and 10 between 10 and 1 between 1 per year between 1 in 10 less than 1 per 100 year per year per year and 1 in 10 years years and 1 in 100 years years Class of loss Frequency 1 2 3 4 5 6 events occurred Factor  R6M+ 1 48 47 45 42 38 33 R 0.R 5.) ANGLOGOLD RISK INDEX MATRIX (Nº 2) Risk Index Action Category (28-48) A Immediate More than 100 Between 100 events Between 10 events Between 1 event per Between 1 event in Less than 1 event remedial events per year per year and 10 per year and 1 year and 1 event in 10 years and 1 event per 100 years action events per year event per year 10 years in a 100 years required.9 M 2 46 44 41 37 32 27 R 60 000 .R 599 6 28 23 18 13 9 6 R 6 .140 ANNEXURE 13 (Contd.

ANNEXURE 14 141 .

142 ANNEXURE 14 (Contd. Assessment equipment& tasks EFFECTIVENESS Performance measurement (labour productivity) Production hours lost to maint Preventive Maintenance Planned hours vs paid hours Missed schedules On-condition requirement follow up Financial management (cost control) Maint cost vs production budget Maint labour cost vs total cost Maint cost vs budget Cost of planned work vs budget TECHNICAL ADMINISTRATIVE MEASURABLE DETAIL .) MEASUREMENT OF MAINTENANCE EFFECTIVENESS USING KPA’s & KPI’s KPA’s KPI’s Information management Risk Assessments done /workload management Scheduled maint work done Backlog (forward workload) Breakdown work done After hour work done Safety & health work done Work planning & scheduling Scheduled work planned Failure Analysis Planned / improved work planned Condition Monitor Emergency / safety work allowance Modification & Achievement of work Design out CMMIS Risk.

ANNEXURE 14 (Contd. Maintenance organisation and manpower relation to work load  Skill levels of maintenance staff etc  Training program and evaluation 143 . Maintenance management/ strategy  Effectiveness of CMMIS infrastructure  Store’s and spares availability and buying function  Structure of CMMIS department / plant labour  Responsibility levels and manning in 2. Criticality and availability of equipment 1. Policies and Procedures.) OTHER KPA’s KPI’s Goals.

ANNEXURE 15

144

ANNEXURE 15 (Contd.)

CORPORATE ENGINEER CMMIS/ RISK MANAGEMENT DUTIES

- Develop Methods, standards and systems
- Put maintenance strategies and plan in place. Keep it up to standard.
- Develop and implement maintenance strategies and techniques
- Benchmarking of other systems, maintenance methodologies and Risk Management system
- Benchmark CMMIS / risk management standards in Anglogold
- Liaise with Training Department on training needs for Engineers, Foreman, and artisans on maintenance
systems and Risk management systems also learners
- Assist in training in maintenance / risk management techniques at business services and mines.
- Co-ordinate RCM / FMECA
- Co-ordinate Analysis
- Co-ordinate techniques/methodologies
- Co-ordinate training and task procedures at mines and business services
- Do Audits on maintenance systems
- Ensure legal compliance through CMMIS / risk management system
- Management / co-ordination of CMMIS / risk management systems.

CORPORATE CMMIS CO-ORDINATOR DUTIES

- Assist mines / business services loading maintenance strategies and tasks on CMMIS systems
- Give guidance on use of CMMIS system
- Liaise with IBM on system
- Co-ordinate user needs
- Assist in developing methods to load assets and equipment standards on CMMIS system
- Co-ordinate system charges
- Audit system compliance
- System user support
- Cost benefit analysis

MINES / BUSINESS SERVICES SYSTEMS CO-ORDINATOR DUTIES
 Facilitate

- Base line risk assessments
- Issue based risk assessments on equipment to determine maintenance strategies and tasks
- Issue based risk assessment on repetitive failures and yearly / two yearly re-assessments as the law
requires
- Co-ordinate and scrutinize standard of risk assessments, business units, contractors and suppliers
- Maintain system standards “KPA’s” “KPI’s”
- Implement maintenance strategies
- Procedure writing (Tasks / Standards) Co-ordination
- Audits (System compliance)
- Implement / co-ordinate legal (C.O.P.s) and special work rules.
- Equipment performance monitoring.

145

ANNEXURE 15 (Contd.)

MINE / BUSINESS SERVICES CMMIS PLANNER DUTIES

 Day to day running of the system

 Monitoring performance of equipment

- Equipment availability
- Equipment utilization
- Equipment production rate
- Component failure rates
- Equipment production cost
- Equipment cost
- Condition monitoring results
(Monitored against standards and history)

 Analysis of Data

- Cost – Stores – repetitive failures
- M.T.B.G. – Maintain strategies

 Over inspection of Critical items

 Team member of FMECA/RCM (to determine maintenance strategies and tasks)

 Assist in writing of schedules and procedures of Service orders

 Work Management

- Prepare task documentation (job cards, checklists and work permits)
- Insure of such documents to the responsible personnel
- Generate management reports
- Work order structure and flow
- Plan plant shutdowns critical path scheduling using part diagram / methods

CMMIS ASSISTANT PLANNER DUTIES

 Schedule tasks (preventive maintenance)

 Control spares (Critical and Normal) for maintenance tasks

 Incorporate unplanned work

- Safety related, job request and breakdowns
- Schedule re-active and pro-active tasks

 Prioritize task / work according to risk assessment Risk Ranking System

 Scrutinize job / services order cards for correctness

 Loading of tasks and data if no data input clerk is available

 Follow up on recommended controls and actions

 Team member of maintenance strategy team (FMECA/RCM)

 Load risk assessments on OMM program

146

therefore an input data clerk will be needed to do some of the work of the assistant planner and all production and maintenance related data. ASSISTANT PLANNER DUTIES: . ANNEXURE 15 (Contd. With no co-ordinator the loading on the CMMIS Planner and assistant will be high. 2. Must incorporate CMMIS Planner duties. CMMIS PLANNER DUTIES: .) IF NO MINES / BUSINESS SERVICES SYSTEMS CO-ORDINATOR THEN 1. such as performance management and work management duties. Must incorporate the co-ordinator duties accept facilitation of risk assessments and assessments/evaluation to determine maintenance strategies/tasks. 3. 147 .

e.) RECOMMENDED CMMIS STRUCTURE FOR ANGLOGOLD MINES / BUSINESS SERVICES CORPORATE MANAGER ENGINEERING SYSTEMS ENGINEERCMMIS /RISK MAN IBMSUPPORT SERVICES CORP CMMIS CO-ORDINATOR MINES / BUSINESS SERVICES D1/2 C5 SYSTEMS CO-ORDINATOR OR CMMIS PLANNER C5 C4 C5 CONDITION CMMIS ASSISTANT C3 ASSISTANT ASSISTANT DATA INPUT CONDITION C5 MONITORING PLANNER PLANNER PLANNER PLANNER CLERK MONITORING C4 TECH C1 TECH C4 B2/3 NOTE AT LARGE MINES / BUSINESS SERVICES MAY NEED TWO ASSISTANT PLANNERS i. ONE FOR HORIZONTAL TRANSPORT AND ONE FOR VERTICAL TRANSPORT AND SERVICES 148 . ANNEXURE 15 (Contd.