Page 6 - GlobalEyes Edition 6 Dec 2011

Basic HTML Version

globaleyes / edition 6
The Alberta Oil Sands is the third
largest proven crude oil reserve
in the world, behind only Saudi
Arabia and Venezuela. A major
contributor to the production from
this region is Canadian Natural
Resources Limited (CNRL).
The CNRL owned Horizon oil
sands mine began production
in 2008 and in 2010 was
responsible for producing roughly
90,000 barrels per day or 6% of
Canada’s oil sands output. With
such large volumes and millions
of dollars at stake, it is critical that
the equipment and machinery
used in the production of oil be in
full working order at all times. To
ensure minimal downtime, CNRL
performs scheduled maintenance
shutdowns during which
equipment is inspected and
repaired or replaced as needed.
CNRL are great planners
and Bradken began contract
negotiations with them in late
2010 for maintenance on the
two existing Apron Feeders
during a scheduled shutdown in
2012. This will be the first time
Bradken performs this service
for CNRL, thus providing ample
time for inspection, contract
development, negotiations,
crew recruitment and training,
repair procedure development,
reverse engineering and part
manufacturing to be carried out.
On Thursday, 6 January, 2011
a serious incident occurred at
the Horizon site, immediately
shutting down production and
injuring three CNRL employees.
Due to the extensive damage
and resultant unscheduled
downtime, CNRL decided that
a number of projects slated for
the 2012 shutdown would be
bought forward and performed
during the unplanned outage.
Bradken’s Edmonton facility
was awarded the C$2.8 million
repair and maintenance contract
on 17 February 2011 with a
target completion date of 1
May 2011. This meant that all
preparations, recruitment and
planning would need to be
conducted in the space of 10
weeks. In addition to the original
scope, Bradken would also be
required to develop, fabricate,
machine and install two sets of
impact beam slide rails and 356
fabricated apron feeder pans.
Such a large project on a short
deadline required the combined
effort of both the Edmonton (35%)
and Tacoma (65%) facilities.
The process also presented
a series of other challenges
including the recruitment, training
and site orientation of a 26
person field service crew to work
the shutdown. Additionally, the
operation of the equipment in
extreme temperatures during
the Canadian winter months
required the use of cold weather
impact resistant steel for pan
manufacturing, which is difficult to
source, and during the installation
process, Bradken workers battled
temperatures exceeding -40°C.
Epitomising Bradken’s “Proud to
Belong” mantra, the cooperation
of the teams in Edmonton
and Tacoma resulted in the
completion of the project on 29
April 2011, two full days ahead
of schedule. Furthermore, over
16,000 hours were logged on
the project both on-site and in-
house with no lost time incidents
or near misses encountered.
Superintendent of Ore Prep
Maintenance for CNRL, Greg
Anstey was instrumental in
Bradken being awarded this
contract. Upon completion,
Greg said, “It was fantastic,
safe, productive and
exceeded all expectations.”
Edmonton’s Regional Sales
Manager, Steve Roshko said
that successfully completing the
scope of work in the allotted time
“opened the doors” for Bradken
to offer solutions for wear loss
through product development
including the first time use of
Bradken Vidaplate V37 at CNRL.
"It was fantastic, safe,
productive and exceeded
all expectations"