Commercial Mining Booster Infrastructure Project A novel approach - PowerPoint PPT Presentation

AMA-T-00014 Commercial Mining Booster Infrastructure Project A novel approach to the manufacture of Boosters for the Mining Industry

The Background AMA-T-00014 • In 2016 Australian Munitions and Orica signed contract for the manufacture of Commercial Mining Boosters • This required the development of a new capability to be installed at Australian Munitions’ Benalla facility. 2 4/12/2017 OPEN

The Plan AMA-T-00014 • What is a Mining Booster? • The Existing Benalla Facility • The Design Process • New Explosives • The New Production Facility • Logistics • The Benefits to our Customers • The Wrap Up • Thank You 3 4/12/2017 OPEN

What is a Mining Booster? AMA-T-00014 • Small Explosive Device comprising: A plastic shell • A sensitiser bottle (filled with PETN) • Cast Mix Fill of RDX/TNT • • Used to help detonate large charges (typically bulk emulsion) • Used extensively across Australia’s Mining and Construction Industry. Image Courtesy of Orica Limited 4 4/12/2017 OPEN

The Existing Benalla Facility AMA-T-00014 Satellite imagery courtesy of Google Earth. • Utilises two existing buildings in Benalla – S05 and S03 • New capability had to integrate with existing infrastructure And allow for quick changeover between • Booster Manufacture and Traditional Defence Stores. • Uses the existing Meissner Shell Filling Plant in S03 5 4/12/2017 OPEN

The Design Process AMA-T-00014 • Requirements Specifications Developed • Supplier Selection Process – Chorus 2.0 • Multi Stage Risk Assessment Process HAZOP Studies • Plant Risk Assessments • Input from Orica Subject Matter Experts • Particular emphasis on PETN – New to Benalla • • Need for High Levels of Automation Minimise exposure of personnel • Ability to compete with overseas labour rates • Image Source: https://www.graphicproducts.com/articles/what-is-hazop/ • Use of modern control systems in Hazardous Areas 6 4/12/2017 OPEN

The Design Process AMA-T-00014 Weekly Design Reviews with sub-contractors Input from Orica SMEs when required Independent Detailed Concept HAZOP CHAZOP Explosives Design Safety Validation Three day Five day workshop An Internal workshop with validation of the with input from input from Orica project Orica SMEs, Thales SME, Thales SMEs, management and SMEs, Machine and Machine Designers and safety principals Designers – Operators. being used. focussed on control systems. 7 4/12/2017 OPEN

The Design Process AMA-T-00014 Frequent Site Visits, Acceptance Tests and Communication between Project team and Designers Factory Install Build Factory Acceptance Commissioning A series of tests to confirm that all elements of the machine meet the original specification (or any agreed to changes) Involves attempting to break the safety systems to ensure they are robust. An opportunity to test in a workshop environment and confirm machine functionality 8 4/12/2017 OPEN

The Design Process AMA-T-00014 External Safety Plant Risk Inert Live Assessment Commissioning Audit Commissioning Risk assessment Completed by focussing on plant Internationally safety renowned explosive (entanglement, safety specialist cutting etc.) 9 4/12/2017 OPEN

New Explosives AMA-T-00014 As well as a new Production Facility, New Explosives were introduced. Bodies of work were conducted to understand these. PETN: Crude RDX/TNT: • Separation Distance Trials • Lab Testing of Crude RDX Composition to • Conducted with and without Baffles confirm long term stability between samples • Performance Testing • Probit and FISH Data sourced from Orica • Boosters filled with Crude RDX/TNT were X- • Testing of “high speed” Near Infrared Rayed and Fired against witness plates . Moisture sensing for Dried PETN 10 4/12/2017 OPEN

The New Production Facility – PETN Drying AMA-T-00014 • 24 Stations, each holding 13kg PETN Warm air drawn through • PETN by Scrubber • Approximately 6 Hour dry cycle • Typically Operated during silent hours to minimise Operator exposure. • Instant Moisture Content Reading from NIR sensor • Container used for drying also used in Bottling process 11 4/12/2017 OPEN

The New Production Facility – PETN Bottling AMA-T-00014 • Manned section and Unmanned (remote) section • Handling Empty Bottles, Dried PETN and Caps • Automated Quality Assurance Checks • Single Shift operation to match 3 shift LAP. 12 4/12/2017 OPEN

The New Production Facility – Load, Assemble, Pack AMA-T-00014 13 4/12/2017 OPEN

Logistics AMA-T-00014 • Increase in HE throughput for Benalla and Mulwala Management of Magazines • Management of Building and Bay NEQs • Update to DG Manifest • • Large volumes of raw materials Management of Incoming goods and returnable • packaging Transport of parts to workstations • • Introduction of 24 hour HE operation in Benalla Recruitment and training of new staff • Technical, Mechanical and Electrical support for • afternoon and night shift 14 4/12/2017 OPEN

The Benefit to our Customers – Australian Defence Force AMA-T-00014 • Maintain Skillsets for manufacture of defence munitions Keeping staff (and plant) in a state of readiness • Maintaining knowledge and a safety mindset ensure we • are always operationally ready for a shift to Defence Manufacture. • Increase the utilisation of assets in Benalla and Mulwala that had been underutilised in the past Underused machines tend to develop reliability • challenges such as corrosion, erosion, blockages etc. Using the plant frequently helps overcome these • challenges 15 4/12/2017 OPEN

The Benefit to our Customers – Orica AMA-T-00014 • Improved Quality Including 100% automated checks for weight and • cleanliness Consistency of finished product through the use • of Automation • Shorter supply chains Product for the Australian Market is made in • Australia • Improved logistics Location of the Benalla and Mulwala Sites with • respect to Orica’s Storage Facilities 16 4/12/2017 OPEN

The Wrap-Up AMA-T-00014 • Australian Munitions now has a world class Booster Manufacturing Facility Highly automated • Incorporating existing infrastructure • • The design process worked through concept – detailed design – build – install – commission Input from SMEs • Thorough Risk Assessment process • • Resulting in benefits to the ADF and to Orica 17 4/12/2017 OPEN

Thank You AMA-T-00014 • Thanks to the following for input to and content for this presentation (in no particular order): Orica Limited • Ryan Krake – LAP Video • Ken Horne – PETN Bottling Content • James Halacas – Meissner Plant Content • Mulwala Trials Team • The Benalla operations team – in particular, those featured in photos or videos • 18 4/12/2017 OPEN