Client and background
Two IHI 8000 tph bucket wheel reclaimers have been in operation at the Kooragang Coal Terminal (KCT) since late 1982. In 1997, under a program of potential port expansion, PWCS sought to validate the structural capacity of the two existing machines in accordance with AS4324 Part 1, with the objective of incorporating the review results in the design of a third machine.
Services provided by Sinclair Knight Merz
Sinclair Knight Merz was commissioned to analyse the structural integrity of the entire reclaimers under the spectrum of load cases defined in AS4324. This assessment included:
- design load review,
- complete static load strength assessment of all major structural components,
- dynamic load strength assessment (including seismic and collision load conditions),
- a fatigue analysis and remaining life assessment,
- risk assessments,
- a comprehensive modification and cost estimate schedule designed to result in code compliance for structure found to be under capacity.
Combined analysis and testing facilities provided a value added service
Advanced Finite Element Analysis (FEA) techniques and software was used to facilitate the structural evaluation, including in-house developed code for completing the seismic analysis with very large, high number of d.o.f. FEA models. In addition to analysis to AS4324 loads, site testing (incorporating multi-channel strain gauging and accelerometer monitoring) and data analysis performed by Sinclair Knight Merz also identified the key operational factors contributing to machine loading and machine fatigue life consumption, allowing a significantly more representative conclusions to be drawn specifically for the KCT Reclaimers.