ANGLO GOLD Maintenance Manual

REFERENCE MANUAL
JULY 1999
REV1
0
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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1. INTRODUCTION
From a systems perspective, Risk Management in the Maintenance Domain is a

management process, which establishes new management strategies by transforming
the present strategies.
Optimal maintenance strategies depend on the integrative functioning of management,
supervision and the employees. A high degree of synergistic functioning of them is a
prerequisite for Entrepreneurship.
The equipment used for production is extremely costly, high technology and
sophisticated. These technical systems need to be operated safely and economically.
Failures of such systems have an impact and consequences on people's safety and
health, production loss, equipment loss and environmental in certain areas.
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. It is,
therefore, 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. This system/process is a framework to address the development and
implementation of a maintenance plan, risk management system and assessment
techniques for continued improvement in systems and equipment reliability.
The Mine Health and Safety Act (Promulgated on the 15th of January 1997). 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, and
requires the elimination, minimizing and control of risks to health and safety
by: identifying and recording hazards, determination and implementation of
protective measures and controls, etc.
3
Risk Management methodologies and techniques integrated into a Maintenance
Management Information System, will provide a sound basis in setting proper
equipment maintenance strategies and tasks. Management, supervisors and employees
will be part of a team doing assessments on equipment and tasks. The process to get
the people involved, are:
Commitment from management.
Development of a comprehensive plan.
Introduce system to workforce
Commitment and participation from all levels, then implementation of system.
According to Hellriegel Slocum "Management" (seventh edition: 240) we can broadly
classify the conditions under which decisions are made as certainty, risk, and
uncertainty. When individuals can identify developments and events and their
potential impact with great confidence, they make decisions under the condition of
certainty. As information dwindles and becomes ambiguous, the condition of risk
enters into decision-making. Individuals begin to base their decisions on either
objective (clear) or subjective probabilities (intuition and judgment). The condition of
uncertainty occurs when individuals have little or no information about developments
and events on which to base a decision. Because of that uncertainty, the decision
makers may be able to make only a reasonable guess rather than an informed decision.
Certainty is the condition under which individuals are fully informed about a problem,
alternative solutions are obvious, and the possible results of each solution are clear.
Risk is the condition under which individuals can define a problem, specify the
probability of certain events, identify alternative solutions, and state the probability of
each solution leading to the desired results.
Probability: The percentage of times that a specific outcome would occur if an

individual were to make a particular decision, a large number of times.
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). It also
provides a sound basis of the implementation of such integrated systems and
techniques in setting proper equipment maintenance strategies and tasks.
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2. MAINTENANCE DEFINITION
To achieve the agreed Business Services and Mines operating process, product output
and quality, within the accepted AngloGold Maintenance Standard for longevity and
safety at optimum resource cost.
3. POLICIES
3.1 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.
All critical maintenance functions will be identified through risk assessments

and suitable procedures and standards will be developed, formalised and
reviewed on a regular basis.
Critical systems and processes will be evaluated by risk assessment to ensure

continuity and optimisation. Maximum use will be made of cost effective
computerised systems to support management decisions and control.
All statutory requirements including those negotiated with the authorities will
be fully complied with.
For each equipment/item or system types, and units, a conscious decision will
be made to select a maintenance strategy, by applying Issue Based Risk
Assessment Equipment (based on RCM/FMECA techniques), which will guide
all future actions towards achieving the maintenance function/risk management
objectives.
5
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.
I.D.MENZIES - HEAD OF ENGINEERING ANGLOGOLD.
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4. 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, safety is managed in
a pro-active manner rather than reactive as in the past.
In the mining and process plants, current trends are for a "safety case" to be prepared,
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.
Although Risk Assessment can play an important role in providing advice on safety, it
does not itself make an operation any more safe or efficient. That is achieved through
good planning and operational procedures and a proper Maintenance Management
Information System. 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 risks to personnel arise from a variety of sources, some more hazardous than
others. Risks in mining can be categorised as: major hazards and occupational
accident hazards. The major hazards are the high consequence/severity hazards, such
as, falls of ground, haulage and transport systems, in-rushes, fires, explosives,
radiation, dust, heat, noise and hazardous chemicals, some of these are also applicable
to surface operations.
Occupational accident hazards are the hazards associated with everyday work
activities, such as operations and maintenance of equipment, materials handling, etc.
This would include stumbling and falling and contact with machinery.
Risk Assessment is the major prerequisite for the development of an effective safety
management and maintenance management system. It is the systematic examination
of an operation, and maintenance strategy, the purpose of which is to identify the
potential for hazards, failures and their causes. In other words, it can answer the
following questions:
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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, the underlying
methodology is universal for tasks, process, incidents, accidents, new equipment, etc
and consist of the following process:
Hazard identification,
Estimation of causes,
Estimation of probabilities/frequencies,
Estimation of consequences/severities,
Evaluation and identification of unacceptable risks,
Identification of risk reducing, termination or transfer measures.
To reduce the risk, measures are taken to:

Reduce the probability/frequency of the event, or
Reduce the severity of the consequences by appropriate measures
As risk is a function of consequence (severity) and probability, a degree or index of

risk (see matrix on Page 136 & 137 ) can be calculated using estimates of these two
properties. Such estimates can be quantitative depending on the nature of the study.
There is no universal formula for rating risk in relative importance but a number of
techniques have been developed to assess decision-making. We are using a matrix to
rank risks.
Quantitative Risk assessment is common in the high technology operations,
which requires a complex mathematical approach using credible values of
readily available component reliability data. This approach is needed to
determine the correct maintenance strategies if data is available and reliable.
In qualitative (subjective) risk assessments, it is common practice to rate the
probabilities using a subjective or simple numerical scale. The level of risk is
then calculated by combining these two values according to "Risk =
8
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
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carried out with sufficient experience and knowledge and the management,
operators, miners and artisans are comfortable with the scale used (matrix).
These requirements have necessitated a three tier strategy, namely: Baseline Risk
Assessment; 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). (See Risk Assessment sheets/methodologies of AngloGold,
Annexure 4, 5 and 6 Pages 49, 54 & 57).
5. 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; 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, maintenance, Health and Safety and Environment
Be cost effective and more efficient.
Be legally compliant.
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.
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6. MAINTENANCE MANAGEMENT SYSTEM (CYCLE)
Maintenance; Objectives;
Policy, System, Maintenance Plans
Design
Maintenance Audit; Management Planning;

Maint Performance, Organisation, Manpower,
Maint Man Reports, Resources, Financing
System compliance,
Standards
7. MAINTENANCE PROCESS (OPERATIONAL SYSTEM)
Maintenance Strategies; Maintenance Planning;

Preventive: (Use based, Shutdowns, Preventive
Predictive) Maint, Inspections
Scheduled: Restoration (Safety)
& Discard Maint Admin;
Routine Service Scheduling,
Opportunistic Task Planning,
On Condition & Procurement
Condition Monitoring
Task Execution &

Strategy List Results
Management;
Optimisation; Performance
Performance Management
Risk assess, results, Maint
Quality Management Task
FMECA / RCM, history, Cost
Feedback Task detail &
Data Analysis results
Inspection Reports
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8. 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
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4. MAINTENANCE MANAGEMENT INFORMATION SYSTEM
ACTIVITIES/FUNCTIONS
a) Determine high cost areas and equipment.

b) Flag system for repetitive failures.
c) Schedules/frequencies based on risk priority.
d) Risk Assessment to be loaded on system.
e) Work loadings (work packages) per artisan group/per process area per risk
assessment (matrix) priority.
f) Service orders outstanding, to be flagged based on high-risk priority and legal
requirement tasks.
g) Spares/Components needed for every restoration or discard task.
h) Re-order spares used after every restoration or discard task or on condition
tasks.
i) Condition monitoring (trends, etc) and generate a work card when needed.
j) Do loadings according to available persons on shop floor per process area.
k) Movement of equipment/units to date (asset register up to date!)
l) Asset register listed according to risk assessment, critical areas, critical
equipment and critical components.
m) Keep record of equipment sent for off-site repairs, (w/shops or contractors).
n) Contractor work and costs.
o) Total management module for projects, i.e. Plant Shutdowns.
5. TYPE OF JOB/WORK ORDER CARDS TO BE GENERATED
11.1 Scheduled restoration task

Generated service order card
11.2 Scheduled discard task
Maintenance; Objectives;
Policy,
Generated service order card
System, Maintenance Plans
Design
11.3 Routine service card/sheet
Generated sheet for normal services and service order cards for legal's
11.4 On-condition
Maintenancetask sheet
Audit; Management Planning;
Maint Performance, Organisation, Manpower,
Maint Man Reports, Resources, Financing
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System compliance,
Standards
On-condition generate sheet and responsibility daily/weekl
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11.5 Condition monitoring card/sheets
Daily/weekly sheets/card
Service order card if limits are reached/parameters
(See Annexure 7 on Page 61 - for job/work order cards and sheets).
6. JOB CARDS
12.1 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.
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, i.e. new installation or process changes: use daily
job report card.
12.2 DATA NEEDED ON A JOB CARD/SERVICE ORDER

a) Date, KPA, process area, equipment location, equipment description.
b) Foreman name and code, artisans name and code.
c) Type of maintenance strategy/task.
d) Component lists (Bill of materials).
e) Maintenance strategy codes.
f) Failure mode (causes) and codes.
g) Maintenance schedules (time based/used based) Ref No.
h) Maintenance task procedure (steps to carry out work)
i) Quantity of components used.
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j) Component stock code or workshop order number.
k) Hours worked.
l) Responsible signatures.
m) Date planned, completed, status, etc.
n) Equipment number, activity code, unit number, etc.
7. RISK ASSESSMENT TECHNIQUES
Base line Risk Assessment (Identification of Critical Process Areas and

equipment, 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.
(Pro-active).
Issue Based Risk Assessment Equipment (to determine maintenance strategies

based on the root causes and tasks).
Issue Based Risk Assessment Tasks, Incidents, Accidents and processes. (To
draw up proper task procedures to address root causes of hazards, draw up
maintenance schedules and controls to control the hazards).
Continuous Risk Assessment. This is the most important form of risk

assessment, which should take place continually, as an integral part of day-to-day
management. This is a line driven approach and comprises of On-Condition
tasks/inspections (planned general inspections and critical part/component
inspections). From the issue based risk assessment checklists are being drawn up
to control or eliminate hazards associated with equipment and tasks. These
checklists are used in On-Condition tasks, and Routine service tasks. Task
observations by the supervisor. This approach determines sub-standard conditions
and acts at the source.
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8. BASE LINE RISK ASSESSMENT PROCESS
(See Annexure 1 & 4 Pages 34 and 49 for questionnaire and format).
Conduct Base Line Identify Major Hazards

Risk Assessment (Impact on Business)
Gather facts,
frequency costs,
incidents, 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. 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
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10. ISSUE BASED RISK ASSESSMENT EQUIPMENT PROCESS
(See Annexure 2 & 5 Pages 38 and 54, for Questionnaire and format)
Conduct Issue Based Gather facts, costs,

Risk Assessment on incidents, frequencies,
Critical Equipment etc.
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, process change
and repetitive failures
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11. ISSUE BASED RISK ASSESSMENT TASKS, PROCESSES, INCIDENTS,
ACCIDENTS, ETC
(See Annexure 3 & 6 Pages 45 and 57 for Questionnaire and format).
Conduct Issue Based Gather facts, costs,

Risk Assessment on incidents, frequencies,
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, Project, Implement Task

Modifications, Process Change Procedure
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12. 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 5
Reports, Audits)
Training and Development (Risk Man,

Phase 6 CMMIS, Safety, etc)
18.1 PHASE 1: LIST ASSETS (INVENTORY)

The first step before all assets are listed, break down the mine, business unit, or
plant into workable process areas and responsibility structures.
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
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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
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12.1.1 Asset inventory (all assets including buildings, special tools, special
equipment, etc.
12.1.2 Business unit/services - breakdown into process areas. (See above
structure)
12.1.3 Responsibility structure - who is responsible for what process areas and
equipment.
12.1.4 Equipment inventory. (List of all equipment per process area)
12.1.5 Component Inventory. (Bill of material)
12.1.6 Technical specifications of equipment.
12.1.7 Process specifications.
12.1.8 Equipment number identification and equipment location number
identification. (See Annexure 11 Page 96 for examples).
12.1.9 Physical numbering of equipment locations and equipment.
12.1.10 Loading numbers into CMMIS System.
12.2 PHASE 2: BASE LINE RISK ASSESSMENT

12.2.1 Conduct base line risk assessment. (See annexure 1& 5 Pages 34 and
54, for questionnaire and format)
12.2.2 Identify criticalities
- Process areas
- Major equipment
- Equipment vulnerability
12.3 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, consequences and frequencies/
Probabilities of failures. (See Annexure 2 & 5 Pages 38 and 54 for
Questionnaire and format).
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Step 2
Determine maintenance strategies/tasks using the maintenance strategy
diagram. (RCM diagram). (See Annexure 3 Page 45).
Step 3
Conduct Issue Based Risk Assessment on tasks identified in step 2. (See
Annexure 3 & 6, Pages 45 and 57).
Step 4
Write Maintenance Task procedures, stating the hazard for each step that has to
be followed/executed and why it must be done, in other words the consequence
of the hazard and the risks which people are exposed to when performing the
maintenance task.
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.
Next, draw up maintenance strategies improvement plan.
Execution/implementation of new strategies, by updating of schedules and
standards, for the new maintenance requirements (schedules/frequencies). (See
Annexure 10 Page 94).
18.4 PHASE 4: WORK MANAGEMENT

18.4.1 Planning and control of maintenance activities:
- Task scheduling
- Workload, balancing
18.4.2 Data capturing

- Quality data (data selection)
- Compare with existing (add or delete)
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18.4.3 Control documents and information
- Job cards, Service order cards, work sheets and checklists.
- Feedback information must be correct to do proper analysis.
- Documentation flow system.
- Work order/Service order structure.
Loading of schedules and maintenance strategies/tasks can now be

loaded into the CMMIS System. (See Annexure 7 Page 61 for cards
and sheets).
18.5 PHASE 5: MAINTENANCE PERFORMANCE

18.5.1 Performance Measurement
- Set performance criteria (KPA's, KPI's, Benchmarking
standards, Overall equipment effectiveness).
- Performance measurement implementation.
- Maintenance system performance using "Pareto Chart" or
"Pragma" audit system.
- Implement new performance measurement system. (See
Annexure 14 Page 139 for KPAs).
18.5.2 Maintenance Management Reports

18.5.2.1 Management Report
Labour (Manpower)
Spares (Stores)
Costs (Finances)
Maintenance Information (OMM)
Training
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18.5.2.2 Working Reports
Foreman
As per Management Report for his section.
Artisan
Stores
Costs
Maintenance (OMM)
- Backlog
- Call outs
- Breakdowns
- Safety tasks
18.5.2.3 Financial Report

Plant cost/tons treated
Section P.A.
System High Costs
Equipment High Costs
Labour
Contractor
Modifications
Projects
18.5.2.4 Training Reports
18.5.2.5 Management Reports

Labour (Manpower)
- Complement/strength
- Manpower requirements (loading)
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- Total available man-hours vs. outstanding
workload (includes Planned, unplanned work and
overtime)
- Manpower available
- R/Ton/Employee costed
- Overtime worked
- Ad-hoc Reports (leave rosters).
Materials Management
- Strategic spares consumed
- Strategic spares in use
- Strategic spares in for repair
- Stores control (inventories): Working report for
the Foremen
- Turn-around: Working report for the Foremen
- Items outstanding: Working report for the
Foremen
- Total value of spares on shelve
- Emergency orders processed.
Finance
- Total Rand/ton
- Budget vs. actual
Total plant budget vs. total expenditure:
R/ton - YTD/Month
Eng plant budget vs. Eng Plant Actual:
R/ton - YTD/Month
Maintenance Information
- Planned work issued - Hours
- Outstanding Service Orders
- Total available month vs. Total workload
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18.5.2.5 Standard Report Data
Production
- Tons treated (target vs. actual)
- Tons milling (target vs. actual)
- Milling (availability vs. utilisation)
- kWh/tons milled (target vs. actual)
- kWh /tons treated (target vs. actual)
- kWh /gold recovered (target vs. actual)
- Compressed air/tons broken or processed
- Potable water consumption
- Gold recovered/tons treated
- Uranium recovered/tons treated
- Chemical consumption
- Cyanide - m3/tons treated
- HCL - m3/tons treated
- Sulphuric - m3/tons treated
- Pyrite - m3/tons treated
- Calcine - m3/tons treated
- Flocculants - m3/tons treated
- Collector - m3/tons treated
- Frotter - m3/tons treated
- Coal - m3/tons treated
- Manganese - m3/tons treated
- Ammonia - m3/tons treated
- Ad-hoc reports
- River water consumption
- River water - R/Ton milled
- River water - R/Ton treated
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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
29
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
30
- Maintenance cost per process area
- Plant improvement cost analysis (modifications)
- New installation cost analysis
- Redundant equipment resale analysis
- Scrap material/equipment analysis
- Reconditioned equipment cost analysis
- Equipment replacement cost analysis
- Major repair cost analysis
- Repetitive maintenance cost analysis
- Breakdown cost analysis
- Call-out cost analysis
- Token travelling cost analysis
- Occasional travelling cost analysis
- Training courses cost analysis
- Additional bonus cost analysis
- Metallurgy bonus cost analysis
- Personal protective equipment cost analysis
- Property damage cost report
- Ad-hoc reports
Training and Development

- Inventory of Engineering employees
- Development plan for each Engineering
employee
- Scheduling of training courses per Engineering
employee
- Training progress monitoring system
- Training progress reporting system
- Training effectiveness monitoring (productivity)
- Ad-hoc reports
- S.A.M.S. Modules
31
18.5.3 Maintenance Management Audits
18.5.3.1 Maintenance System Compliance (Technical strategies)
18.5.3.2 Maintenance System Performance (@PRAGMA)
18.5.3.3 Maintenance Cost efficiencies
18.5.3.4 Identification/execution of maintenance improvement
plans
18.5.3.5 Establish frequencies of audits (i.e. 6 monthly)
18.5.3.6 Set benchmarking standards to measure your business
strategies and maintenance strategies.
18.5.3.7 Set KPA's and KPI's for above mentioned audit
contents.
18.6 PHASE 6 : TRAINING

18.6.1 Risk Management
Training to be given to all employees in Risk Assessment techniques
and methodologies related to their level of work standard. The training
must enable them to do the risk assessments required by the Mine
Health and Safety Act.
18.6.2 CMMIS
Training to be given to Engineers, Foremen and artisans on how the
maintenance system works and what reports it can generate, production
people to be inducted. Training to Artisans i.e. job card flow systems,
what information is needed back and why, the work order structure and
work packages and their prioritising what it means, and the
documentation flow.
18.6.3 Technical
Training to be selective to the technology and equipment standard used,
and all related maintenance on the equipment, etc.
18.6.4 Task
Personnel to be trained on all the tasks he will be exposed to in the
working place/area. The task must address the hazard and risks
associated with the equipment and the consequences if he does not
comply with the standards.
32
18.6.5 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.
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, reliability and safety
Longer equipment life (cost saving)
Improve Team Work, knowledge, motivate and empower.
CONCLUSION
The challenge facing maintenance and risk management can be met by implementing
the methodologies and techniques as set out in this document.
I.D.Menzies Head of Engineering
A.J.Brokke Manager Engineering Systems
33
REFERENCES (Biography)
1. Hellriegel Slocum. Management. 7th Edition.
2. Chris Chapman and Stephen Ward. Project Risk Management on (Processes,

Techniques and Insets)
3. Anthony C Valsamakis, Robert W Vivigan and Gawie S du Toit. The theory

and principle of Risk Management
4. Jasper L Coetzee Maintenance. Maintenance Publisher 1997
5. John Moubray. RCMII Reliability - Centered Maintenance, 1995
34
ANNEXURE 1
35
ANNEXURE 1
QUESTIONNAIRE: BASE LINE RISK ASSESSMENT
QUESTIONS
Identify all the major hazards that effect the Mine or Business Service.
What causes the hazard?
What will the impact/effect/consequences of the hazard be on people, safety, equipment,

material (process loss) and environment?
What will the severity of that hazard be on people (injury), equipment (costs),
environment and material (costs of process loss)?
What controls must be put in place to control or eliminate hazards i.e. (Code of Practices
and emergency procedures and hazard elimination)?
Major equipment/systems is a hazard, when people operate or do maintenance on the units of

the major equipment (system).
QUESTIONS (MAJOR SYSTEMS: TASK RELATED)
What causes the equipment to become a hazard? (i.e. exposure to, physical contact,
physical condition to the equipment when doing maintenance or operating it, the units are
the causes)
What will the impact/effect/consequences of that hazard be on people, material (Process

loss) and environment (i.e. when operating or maintaining it)?
What will the severity be on people, material and environment?
36
ANNEXURE 1 (Contd.)
What is the probability/frequency of the event occurring?
Controls to be put in place i.e. COP's and standards.
List the significance of risks.
MAJOR HAZARDS
* Fire
* Power failure
* Flammable gas explosion
* Hazardous chemicals
* Flooding
* Dust
* Noise
* Radiation
* Major Equipment (Systems)
* Tramming
* Transporting
* Explosives
* F.O.G.
QUESTIONS ON EQUIPMENT/UNITS TO DETERMINE THE VULNERABILITY
To identify the vulnerability/criticality of the equipment/units, the following process/questions

are to be followed/asked:
* List all the equipment/units and spares.
* What causes the equipment/units to fail?
(Any failure causes the equipment to be a hazard).
37
ANNEXURE 1 (Contd.)
What causes the spare equipment (e.g. winder ropes) to be a hazard?

What is the impact/effect/consequences of that failure (winder rope) on people safety, the
equipment itself, production (material/process loss) and the environment?
What is the impact/effect/consequences for not having a spare (winder rope) on people
safety, the equipment itself, 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.O.Ps
* Standards.
38
ANNEXURE 2
39
ANNEXURE 2
BASIC QUESTIONS ON THE EQUIPMENT
TO DETERMINE MAINTENANCE STRATEGIES/TASKS
FUNCTION:
Performance standard; output, product quality, environmental issues, operating costs and
safety.
QUESTION:
What are the functions and associated performance standards of the asset in its present
operating context?
FUNCTIONAL FAILURES:
Is, the inability of an asset to meet the desired standard of performance (unsatisfactory
condition)?
Total loss of function: item stops working.
Partial loss of function: fails to meet specific performance standard.
QUESTION:
In what ways does it fail to fulfil its functions?
FAILURE MODES (CAUSE):

Are reasonably likely to cause each loss of function (failure). (At this level, we manage
failures by applying maintenance strategies/tasks).
QUESTION:
What causes each functional failure?
FAILURE EFFECTS (CONSEQUENCES):

What would happen if the item fails to fulfil its function, i.e?
Downtime (production loss/process)
Effect on equipment (damage)
Effect/consequence on people (safety and health)
Effect/consequence on environment.
These effects/consequences determine what preventative maintenance (if any) is needed.

QUESTION:
What happens when failure occurs?
(The impact on people, material, equipment and the environment).
40
ANNEXURE 2 (Contd.)
PROBABILITY/FREQUENCY:
Is the rate at which the events (causes) that create an accident, incident, 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, material,
equipment and environment (i.e. cost implication and injuries).
QUESTION:
In what way does each failure matter? (Cost and injuries i.e. days lost).
CURRENT MAINTENANCE STRATEGIES:

List all present maintenance strategies (preventive) and tasks related to the Failure Modes
(Causes).
QUESTION:
What can be done to prevent each failure?
RECOMMENDED MAINTENANCE STRATEGIES/TASKS:

The failure modes (causes), and failure effect/consequences (severity) and
frequency/probability determine what preventive maintenance is needed. (Using RCM
decision diagram, i.e. when risk is high in that impact areas.). Who must do it and how
frequent.
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.
On condition task is look, feel listen and repair if faulty, also construction repairs.
Condition Monitoring is monitoring the condition i.e. vibration, oil analysis, etc.
measure it and draw trends.
Scheduled restoration (Use Based Maintenance):

Re-manufacturing a component. Overhauling an assembly, at or before a specified age
limit, regardless of its condition at the time.
Scheduled discard Tasks (Use Based Maintenance):

Discarding an item at or before a specified life limit, regardless of its condition at the
time (scheduled replacement i.e. component or block).
41
ANNEXURE 2 (Contd.)
Routine Service Tasks:

Routine Service Tasks is do it, at a frequency, i.e. change oil, change filters, set v-belts,
etc., i.e. weekly, monthly etc. Also doing legal requirement tasks, i.e. testing safety
equipment and devices, testing brakes, pre-use inspections, etc.
Opportunistic Maintenance Tasks:

When the opportunity is there to apply either restoration or discard tasks, Plant
shutdowns, etc.
Corrective Maintenance Tasks:

After hour breakdowns (call-outs) and during working hours breakdowns, performing
restoration or discard tasks on equipment that failed.
Redesign/Design out Maintenance:

When preventative maintenance tasks could not be found to prevent a failure or it
affects safety or the environment. Discarding an item at or before a specified life
limit, regardless of its condition at the time and replace with new design, or modified
equipment to prevent risks to safety of people and environmental impact, also
production and equipment.
DECISION DIAGRAM (MAINTENANCE STRATEGIES/TASKS) IMPACT

AREAS:
On the evaluation sheet (Risk Assessment) the risks are identified and quantified. If the
risk is high on the following impact areas; people safety, equipment, material (production
loss), environment, then to determine the maintenance tasks/strategy from the diagram, go
down the tree as described here under.
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. Most of these failures are associated with protective devices,
which are not fail safe - PLC's, electrical, etc). If the risk is not reduced/prevented,
then a scheduled failure finding task is to be performed (routine service) i.e. test
equipment, to determine if there are any functional failures, if no suitable routine
service task, redesign, depending on risk.
(People) Safety, Health and Environmental: (When Risk is high on people or

safety, go down the tree)
A proactive task to prevent the failure, which has safety and health or environmental
consequences, is worth doing if it reduces the risk of that failure on its own to a
reasonably practicable low level or eliminates it (causes).
Note:
If task cannot reduce the risk the item must be redesigned or the process must be
changed.
42
ANNEXURE 2 (Contd.)
(Material loss) Operational consequences: (When Risks is high on material

production loss, 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. If not, then redesign or modify.
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, go down the tree)
If a failure has non-operational (production loss) consequences, 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. If it is not justified, then no scheduled maintenance and if
the repair cost is to high, redesign is an option.
Note:
Cost of task = Labour cost per year on that item/unit plus spares when it fails plus
production loss, i.e. hours standing due to the breakdown/failure.
Cost of task (breakdown) = Labour cost + spares cost + production loss.
Cost of Repair = Labour cost per year on that item/unit plus spares cost (the number of
times the item has been repaired).
Cost of Repair = Labour cost + spares cost.

Pro-active maintenance is to be applied if the risks are high (i.e. consequence/severity
and frequency/probability of failure) on the impact areas - equipment, safety,
production and environment. Proactive tasks are scheduled restoration, discard and
predictive maintenance tasks.
43
42
ANNEXURE 2 (Contd.)
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, SET SHUTDOWN. INSPECT THE PHYSICAL TESTS, OIL ANALYSIS,
SPECIFIC TIME, I.E. BLOCK REPLACEMENT. TENSION, ETC. ASK CONDITION OF IT, I.E. TEMPERATURE
3 OR 6 MONTHLY THE ITEMS OR TIME INTERVALS. SEE, FEEL, LISTEN AND (RECORD), PRESSURE
MAINTENANCE, ETC. COMPONENTS ARE (DAILY, WEEKLY, SMELL. CHECK (RECORD), FLOW
AND COMPONENTS REPLACED/DISCARDED MONTHLY, ETC.). DO IT. TEMPERATURE, (RECORD), ETC. YOU
REPLACED WHICH ARE NO MATTER THE LEGAL REQUIREMENT PRESSURE, FLOW, ETC. HAVE TO RECORD TO
WORN OR DAMAGED. CONDITION. I.E. TASKS I.E. TESTING, WHEN FAULTY, REPAIR GET A TREND ON A
RESTORE AS NEW. CHANGED WITH SAFETY UNIT/ITEM ALSO GRAPH TO DETERMINE
NEW/OVERHAULED DEVICES/EQUIPMENT. REPAIRING HANDRAILS, WHEN TO DO
ONES OR STRUCTURES, MAINTENANCE, TIME
REPLACED/DISCARD WALKWAYS WHEN RELATED, I.E. DAILY,
COMPONENT. WHEN: FAULTY, I.E. CORRODED, WEEKLY, MONTHLY,
THIS TASKS ARE ETC. 6 MONTHLY & YEARLY.
CARRIED OUT WHEN
PARTICULAR FAILURE
OCCURS. NOT OPERATE
TO DESIGN STANDARD.
42
ANNEXURE 2 (Contd.)
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, quality, 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
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.g. Yes
Routine Service
Notasks No
Yes Redesign may
Redesign may Be desirable
Scheduled failure- 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
ANNEXURE 3
ISSUE BASED OPERATIONS (Tasks, incidents, accidents, process, new equipment)
From Base Line Major Hazards, i.e. Fire, power failure, flooding, etc, emergency &task
procedures must be compiled/written and reviewed. This process is as follows:
All the causes that are task related and resulted in the hazard in the Base Line Risk
Assessment (e.g. Fire). 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. (e.g. Significance A, 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. Evaluate step by step, using
hazard criteria for Issue Based Assessments, as per the CMMIS Risk Management Reference
Manual and the emergency procedure which controls the Hazard. (e.g. Fire)
Assess/Evaluate the causes that are task related on the major equipment/systems, using the
two different Issue Based techniques, as per the CMMIS Risk Management Reference Manual.
BASIC QUESTIONS ON ISSUE BASED RISK ASSESSMENT ON TASKS, INCIDENTS

AND ACCIDENTS
HAZARD DEFINITION
A source of danger that may cause loss, damage or injury in the domain of safety,
(tasks); the unwanted event is a situation with the potential to cause harm; to the person
operating or performing a maintenance task on the machine, equipment. (Everyday
work activity - materials handling - falling/stumbling - contact with machinery etc).
QUESTIONS: (NEW EQUIPMENT, MODIFICATIONS, PROCESS or TASKS)
Note: Before assessing a task, list all the steps that have to be followed to
perform/execute a task (operation and maintenance). For each step ask the following
questions:
With what can the person, operating or maintaining that machine or equipment ,
come in contact , that could cause harm? (Physical contact with; equipment, tools,
external rocks).
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.
What can go wrong? (What if?)
- People (Human errors)
- Equipment (material errors i.e. malfunctions)
- External (i.e. activities, other people in same area, legal, etc).
What causes the hazard?
What will the impact/effect/consequences of that hazard be on people safety,
equipment, material (Process loss), 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
accident could happen on people and result in the hazard?
ANNEXURE 3 (Contd.)
What are the existing controls, standards and procedures?

What are the recommended controls, standards and procedures to control, 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.e. operating equipment or maintaining equipment or travelling to or from his
workplace.
What was the physical condition of the machine/equipment, tools, area, etc?
What went wrong?

People (Human errors)
Equipment/machine (Material errors and malfunction)
External (Activities, other people in same working area, environmental,
legal, etc)
Unsafe acts and conditions.
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
- Fall of ground
- Ionising radiation
Inrushes
Ventilation
46
- Temperature
- Irreparable atmosphere
- Respirable dust
ANNEXURE 3 (Contd.)
Fires and explosives

- Explosive atmosphere
- Explosives
- Fire
- Flammable dust
- Sources of ignition
- Spontaneous combustion
Transport Systems
- Conveyors
- Trackless equipment
- Locomotives
- Shafts
Occupational Hazards
- Contact with electricity
- Entrapment
- Lifting
- Machines
- Noise
- Stumbling, falling, etc
RESOURCES TO CONDUCT AN ASSESSMENT (THE TEAM)
ISSUE BASED - EQUIPMENT ISSUE BASED - TASK
- FACILITATOR - 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.
47
ANNEXURE 4
48
49
ANNEXURE 4 (Contd.)
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, Production, Environment Occupation S Fr R
(ABC)
For last Page see Page 50
50
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
ANNEXURE 5 (Contd.)
EQUIPMENT ISSUE BASED RISK ASSESSMENT/EVALUATION ON FAILURE MODE/EFFECT AND CRITICALITY ANALYSIS
KPA (Bus.Unit) : PROCESS AREA (Section) : DATE : LEGEND

Pr = Probability(Qualitative)
EQUIPMENT/LOCATION Fr = Frequency ( Quantitative)
SYSTEM : N S = Severity
UNIT/EQUIPMENT : N 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./ Failure
Unit/Equipment no: ***** Failure:
Component Code:
Function:
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
60
ANNEXURE 6 (Contd.)
Hazard Analysis sheet, there could be many of them, 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, B, C)
Consequence Effect on People Recommended Controls
Cause Safety, Equipment, and Mat. Existing Controls S FR R (Re-engineering of Process) S FR R
(Production), Environment. (Re-organization of work)

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

after completion
61
ANNEXURE 7
62
ANNEXURE 7 (Contd.)
SRT. 1
SERVICE ORDER : PREVENTIVE MAINTENANCE

Task Description:
SCHEDULED RESTORATION TASK JOB N:
Description and function: Work type:
K.P.A.: P.A.: EQUIP. LOC.:
Equipment N: Unit N:
Schedule Ref. N:
(Activity version)
Foreman's Name: Foremans code:
Artisans Name: Artisans 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.)
63
SRT. 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, MOTORS, 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.)
SDT. 1
64
Task Description:
SCHEDULED DISCARD TASK JOB N:
Schedule Ref. N:
(Activity version)
Planned date:
Date completed:
Operation time: H
Engineering: H
Spares: H
TASK DESCRIPTION:
ANNEXURE 7 (Contd.)
SDT. 2
65
MATERIAL
ETC)

WORK SCHEDULE/TASKS STEPS DESCRIPTION Y N CODE FAILURE COMPONENT STOCK CODE
CODE DESCRIPTION
1. ARRANGE TO HAVE PUMP STOPPED AND ISOLATED.
2. REMOVE PUMP FROM SUMP.

3. INSTALL NEW PUMP.
ANNEXURE 7 (Contd.)
RST. 1

66
Task Description:
SCHEDULED ROUTINE SERVICE TASK JOB N:
Schedule Ref. N:
(Activity version)
Planned date:
Date completed:
Operation time: H
Engineering: H
Spares: H
TASK DESCRIPTION:LEGAL INSPECTION/TEST
ANNEXURE 7 (Contd.)
RST. 2

67
MATERIAL
ETC)
FAULTS IDENTIFIED AND ACTIONS TAKEN

FAULTS IDENTIFIED (FUNCTIONAL FAILURES) CAUSE (CODE) ACTION

WORK SCHEDULE/TASKS STEPS DESCRIPTION Y N CODE FAILURE COMPONENT STOCK CODE
CODE DESCRIPTION
68
ANNEXURE 7 (Contd.)
PREDICTIVE MAINTENANCE
CONDITION MONITORING TASKS
K.P.A. P.A. EQUIPMENT LOCATION:
FOREMAN'S NAME: FOREMANS CODE:

ARTISANS NAME: ARTISANS CODE:
MONTH: WEEK END DATE:
JOB N EQUIP. UNIT N TASK DESCRIPTION ACTIVITY ACTIVITY JOB TIME START DATE DATE
N CODE VERSION STATUS COMPLETED
C O HRS MIN
69
70
ANNEXURE 7 (Contd.)
ROUTINE SERVICE TASKS

C O HRS MIN
ANNEXURE 7 (Contd.)
ON CONDITION TASKS

C O HRS MIN
71
72
ANNEXURE 7 (Contd.)
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.E. STRUCTURES, WALKWAYS,
HANDRAILS, 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.E. (BEARINGS, SHAFTS, SEALS, GEARS, IMPELLER, LINER, SLEEVE, GATE, DOCS, VALVE, PLC'S,
UFS'S, RADIOS, CIRCUIT BREAKERS, EARTH LEAKAGES, OVERLOADS, CONTACTORS, 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.R. NO
DESCRIPTION OF MAINTENANCE STRATEGY:
NOTE: ONLY BREAKDOWNS AND CALL-OUTS HAVE PRODUCTION/PROCESS LOSS CONSEQUENCE:
EQUIPMENT SENT TO WORKSHOP, W/O NO:
DATE SEND:
DATE RECEIVED: ASSISTANTS HOUR METER DOWN TIME

LOSS PRODUCTION TIME NORMAL AFTER HOUR
ARTISAN SIGNATURE FOREMAN SIGNATURE

ANNEXURE 7 (Contd.)
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, MOTORS, 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
ANNEXURE 7 (Contd.)
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
SHIFTFOREMANS 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: ..
FAILURE MODE (CAUSE)

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, Lime etc.)
07 BURNT (V-Belts, Motors etc.) 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
15 INCORRECT COMPONENT/MATERIAL
ANNEXURE 7 (Contd.)
SHIFT FOREMAN AND ARTISANS 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 MANAGERS COMMENTS
SIGNATURE:
PPS/MET. DOMAIN MANAGERS COMMENTS or MINE OVERSEER / SHIFT BOSS
SIGNATURE:
MANAGERS COMMENTS:
SIGNATURE:
ENGINEERS COMMENTS:
SIGNATURE:
75
ANNEXURE 8
76
77
ANNEXURE 8 (Contd.)
Hidden Process Area Process Area Hidden E.L E.L. Unit Comp.
Ore Handling Ore Handling 1 Conveying Conv. 1A Idlers Frame

Rollers
Belt Clips
Stringers
Pulleys
Conv. 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
79
ANNEXURE 8 (Contd.)
Pumping
Power Supply HT (MCC1) Breaker
Feeder
LT (MCC2 Breaker
Feeder
Leach Leach 1 Agitation Tank 1 - 8 Valves Spindle

Diaphragm
Body
Pumping Pump1 - 4 Motor
Pump
Fluid drive
Leach 2 Agitation Tank 1 - 8 Valves Spindle

Diaphragm
Body
Pumping Pump1 - 4 Motor
Pump
Fluid drive
ANNEXURE 8 (Contd.)
Hidden PA PA Code Hidden Eq Loc Code Eq Loc.

Ore Handling Ore Hand 1 Conveying 1 Conv. No. 1 - 5
Ore Hand 2 Pumping 2 Pump No. 1 - 4
Lubricating 3 Lub No. 1 - 5
ore handling Drive 4 Drive No. 1 - 5
Power Supply 5 HT Sub No. 1/LT Sub No. 1
Lifting 6 Pump No. 1/Crane No. etc.
Storage 7 Bin No. 1/Bin No. 2
Feeding 8 Silo No. 1/Silo No. 2
Structures 9 Mill Silo No. 1 - 6
10 Plough Feeder No. 1
11 Brute Force Feeder No. 1 - 20
Sorting Sorting 1 Conveying Vibrator No. 1 - 6
Sorting 2 Pumping Bridge 1 - 2
Lubricating Hyd Pump No. 1 - 8
Drive Loop No. 1
Power Supply Magnet No. 1
Lifting Detector 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. 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. Loops
Mill 13 Barring
Mill 14 Cooling
Mill 15 Structures
Mill 16 Cycloning
Thickening Thick 1 Pumping

Thick 2 Lubricating
Thick 3 Drive
80
ANNEXURE 8 (Contd.)
Thick 4 Power Supply
Thick 5 Lifting
Thick 6 Storage
Feeding
Inst. Loops
Cooling
Structure
Sampling
Leaching Leach 1 Pumping
Leach 2 Power Supply
Lifting
Storage
Inst. Loops
Screening
Structure
Cooling
Sampling
Lubricating
Agitation
CIL CIL 1 Pumping
CIL 2 Power Supply
CIL 3 Lifting
CIL 4 Storage
CIL 5 Inst. 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
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
ANNEXURE 8 (Contd.)
Compressors Compressors Pumping
Compressor 1 Lubricating
Compressor 2 Drive
Compressor 3 Power Supply
Compressor 4 Lifting
Compressor 5 Cooling
Compressor 6 Inst. Loops
Structure
Filtering
Drying
Flocculent Flocculent Pumping

Floc 1 Lifting
Floc 2 Storage
Feeding
Inst. Loops
Power Supply
Sampling
Mixing
Structure
Water Treatment W Treatment Pumping

Power Supply
Lifting
Feeding
Inst. Loops
Structure
Sampling
Lime Slaking Lime Slake 1 Conveying

Lime Slake 2 Pumping
Lubricating
Drive
Power Supply
Lifting
Storage
Feeding
Inst. Loops
Structure
Mixing
Extraction
Agitation
Cyanide Cyanide Pumping
Power Supply
Lifting
Storage
Inst. Loops
Structure
Heating
Caustic Caustic Pumping
Power Supply
Lifting
Storage
Inst. Loops
Structure
83
ANNEXURE 8 (Contd.)
Heating
Agitation
HCL Storage HCL Storage Pumping
Power Supply
Lifting
Storage
Inst. Loops
Structure
Extraction
Water Dams Water Dams Pumping

Power Supply
Lifting
Inst. Loops
Structure
Pump Cells Pump Cells Conveying

Pumping
Drive
Power Supply
Lifting
Storage
Feeding
Vibrating
Inst. 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. 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. Loops
Screening
Structure
Sampling
Agitation
84
ANNEXURE 8 (Contd.)
Solvent SX 1 Pumping
Extraction
SX 2 Power Supply
SX 3 Lifting
SX 4 Storage
SX 5 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. Loops
Structure
Sampling
Extraction
Water Plant Water Plant Pumping

Power Supply
Lifting
Storage
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
Filtering
Sampling
Agitation
Lifting
85
ANNEXURE 8 (Contd.)
Mixing
Vacuum
Neutralizing Neutralizing Pumping
Power Supply
Lifting
Storage
Inst. Loops
Structure
Agitation
Roasting Roasting Pumping

Power Supply
Lifting
Storage
Inst. Loops
Structure
Screening
Sampling
Agitation
Feeding
Heating
Conversion Converter Inst. Loops

Blower Power Supply
Pumping
Lubricating
Drive
Lifting
Cooling
Structure
Sampling
Acid Storage Acid Storage Pumping
Power Supply
Lifting
Inst. Loops
Structure
Storage
Carbon Columns Carbon Columns Pumping
Power Supply
Lifting
Inst. Loops
Structure
Screening
Conditioning Conditioner Pumping

Power Supply
Lifting
Storage
Inst. Loops
Drive
Screening
Structure
ANNEXURE 8 (Contd.)
86
Slimes Dams Grassdam Feeding
Decanting
Distribution
Return Water Return Water Pumping
Power Supply
Lifting
Inst. Loops
Structure
Monitoring Monitoring Pumping

West Paydam Drive
Conveying
Power Supply
Lifting
Storage
Screening
Structure
Inst. 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
Screening
Cooling
Structure
Sampling
Agitation
Heating
Rectifying
Cells
Extraction
Ovens
Filter press
Separation
Washing
Filtering
Mixing
Vacuum
Swing Mill
Pulverizing
87
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
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. No. 1 - 5
Ore Hand 02 2 Agitating 2 Pump No. 1 - 4
Ore Hand 3 Barring 3 Lub No. 1 - 5
Sorting Sorting 01 4 Cells 4 Drive No. 1 - 5
Sorting 02 5 Conveying 5 HT Sub No. 1/LT Sub No. 1
Sorting 6 Cooling 6 Pump No. 1/Crane No. etc.
Crushing Crusher 01 7 Cycloning 7 Bin No. 1/Bin No. 2
Crusher 02 8 Decanting 8 Silo No. 1/Silo No. 2
Crusher 03 9 Distributing 9 Mill Silo No. 1 - 6
Crusher 04 10 Drive 10 Plough Feeder No. 1
Crusher 05 11 Drying 11 Vibrator No. 1 - 6
Crushing 12 Electrical Workshop 12 Bridge 1 - 2
Milling Mill 01 13 Eluting 13 Hyd Pump No. 1 - 8
Mill 02 14 Extracting 14 Loop No. 1
Mill 03 15 Feeding 15 Magnet No. 1
Mill 04 16 Filter Press 16 Detector No. 1
Mill 05 17 Filtering 17 Brute Force Feeder No. 1 - 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.)
Carbon In Leach CIL 01 40 Steam Generating 40

CIL 02 41 Storage 41
CIL 03 42 Stores 42
90
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.)
Lime Slaking Lime Slaking 89

Lime Slak01 90
Lime Slak02 91
Cyanide Cyanide 92
91
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.)
Slimes Dams Grassdam 136

N 1 Comp 137
N 2 Comp 138
A Gulley 139
W Ext Dam 140
SE Dam 141
92
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
N 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
ANNEXURE 10 (Contd.)
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 - CMT
ORDER OF PRIORITY
1. P = PEOPLE 2. EQ = EQUIPMENT 3. PR = PRODUCTION (MATERIAL) 4. ENV = ENVIRONMENT
RISK
UNIT RISK CLASS
ASSESS. UNIT No. OLD TASK FREQ. SCHED No. NEW TASK FREQ. SCHED No.
DESCRIPTION ABC
No.
96
ANNEXURE 11
97
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.T. BREAKER SF6B
CURRENT TRANSFORMER CT SF6 H.T. 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
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 - White White White

Flame Proof EP X White Blue Blue
Spark Proof EP Y White Brown Brown
A.F.L. Standard AFL - Cream Red Cream
8# Gold Standard SP - Green Green Green

Flame Proof SP - Green Blue Blue
South Uranium Standard SP - Cream Cream Cream

Spark Proof SP SS Cream Brown Brown
9# Gold Standard 9-GP - International

Orange Orange Orange
No 9 Uranium Standard WUP - Red Red Red

Flame Proof WUP - Red Blue Blue
Spark Proof WUP - Red Brown Brown
No 1 North Standard WP - Red Red Red

Flame Proof WP - Red Blue Blue
NOTE:
Flameproof motors, fan cowls and terminal boxes are to be painted aircraft blue - CKS279D38.
Spark proof motors, fan cowls and terminal boxes are to be painted dark brown - STK021-8F-5.
99
ANGLOGOLD PLANTS
NOTE: A FEW EXAMPLES OF HOW TO APPLY THE NUMBER IDENTIFICATION SYSTEM
E.g.: If a hand valve stands separate from a loop, 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.g.: To identify an alarm: XA-001

A specific alarm: Flow/Pressure/pH will thus be indicated as such: FA-001, PA-001, pH-001
E.g.: To number a Timer/Solenoid: Timer, Timer/Solenoid, Level Solenoid, Flow Solenoid.

Timer: K-001, Timer/Solenoid: KY-001, Level Solenoid: LY-001,
Flow Solenoid: FY-001.
E.g.: Voltage to current converter: EX-001
E designates the measured variable and X the computed or read out, passive or output function, ALTHOUGH
WE KNOW IT IS E/I..
Volume Booster: PB-001

Power supply: JX-001
Prog. 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.A. Machine: AI-001
Cycad: AI-002
Redox Transmitter: OT-001
100
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, CONVERTER
X RELAY, COMPUTER, SOLENOID
DRIVE, ACTUATE, UNCLASSIFIED
Y
Z POSITION OR STATUS
pH HYDROGEN ION CONC
101
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
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
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
ANGLOGOLD PLANTS
EQUIPMENT IDENTIFICATIONS: INSTRUMENTATION
ANALYSER RECORDER AR FLOW INDICATOR CONTROLLER FIC
CONDUCTIVITY CONTROLLER AC FLOW MULTIPLIER UNIT FU
P.H. BENCH METRE AM FLOW INDICATOR RECORDER FIR
SO2 ANALYSER AA FLOW INDICATOR TRANSMITTER FIT
P.H. LOW ALARM ALA FLOW TOTALISER FQ
P.H. CONTROL VALVE ACV FLOW PRESSURE RECORDER FPR
BLOW OFF UNIT BOU I.P. RECORDER IPR
COMPRESSOR CONTROL UNIT CU I.P. 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
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
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
108
ANGLOGOLD PLANTS
NEW EQUIPMENT IDENTIFICATION
EQUIPMENT
FEED BOX FB
LOOP &
109
ANNEXURE 12
110
111
VAAL RIVER METALLURGY
METALLURGY
EQUIPMENT ISSUE BASED EVALUATION ON FAILURE MODE/EFFECT AND CRITICALLY ANALYSIS
KPA (Plant) : N 9 Gold Plant PROCESS AREA MILLING DATE : LEGEND
(Section) :
Pr = Probability (Qualitative Data)
(EQUIPMENT/LOCATION) Fr = Frequency ( Quantitative Data)
SYSTEM : LIFTING N S = Severity
UNIT/EQUIPMENT : OVERHEAD R = Risk
HOIST MILL BUILDING (50T)
N 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./Failure F
r r
Unit/Equipment no: Total Failure: 1. Long and P If or when gearboxes fails the Pr 1. 1 in 20 years 8 5 2 1. Weekly inspection 1. Schedule on condition task
9G1AMBUH1D 1. Long travel cross travel consequence to people will be a 1.1 1 in 20 years 8 5 2 Fitter, Electrician monthly: Rigger, Fitter and
gearbox / gearboxes. near miss. 1.2 1 in 25 years 8 5 2 and Rigger. Electrician. Inspecting all
Cross travel 1.1 Lack of 8 5 2 2. Monthly causes of the total failures.
1.3 1 in 20 years
Component Code: gearbox lubrication 8 5 2 Electrician, Fitter, 2. Schedule Routine Service
2. Hoist gearbox 1.2 Incorrectly 1.4 1 in 25 years 8 5 2 Rigger. Check task / i.e. Fitter lubrication,
3. Hoist drum assembled 1.5 1 in 25 years 8 5 2 hook sizes. testing brakes & operation
Function : 4. Hook 1.3 Bearing 1.6 1 in 25 8 5 2 3. 3 Monthly check etc. Electrician testing safety
Lifting and lowering 5. Rope failure years operation and devices and pendent. Rigger
of equipment in the 6. Brakes 1.4 Gear failure Eq If and when the gearboxes fail it Pr 1. 1 in 20 years 5 5 14 lubricate Fitter, to take hook measurement.
mill building for 7. Hoist motor 1.5 Shaft failure will result in the long and cross 1.1 1 in 20 years 5 5 14 Electrician and 3 Monthly.
maintenance and 8. Pendant 1.6 Loose or travel of the hoist becoming 5 5 14 Rigger. 3. By-yearly Routine sevice ie
1.2 1 in 25 years
construction 9. Rope guides broken bolts stationary. The gearbox will have 5 5 14 4. 6 Monthly service load test by Rigger and
purposes. 10. Control 1.3 1 in 20 years by outside safety tests by Fitter and
to be repaired. 5 5 14
Safe working load supply and Equipment cost will be 1.4 1 in 25 years 5 5 14 company. Electrician..
50 ton. safety circuits R 5 500.00 1.5 1 in 25 years 5 5 14
11. Wheels / Labour : 1 Art @ R45/hr x 4hrs = R 1.6 1 in 25 years 5 5 14
structure 180.00
1 Assist @ R20/hr x 4hrs = R 80.00
Total = R 5 760.00
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./Failure F
r r
Mat If or when gearbox fail no material Pr 1. 1 in 20 years 5 5 14
loss will occur. The only cost 1.1 1 in 20 years 5 5 14
would be that of the equipment. 1.2 1 in 25 years 5 5 14
Total = R 5 500.00 1.3 1 in 20 years 5 5 14
1.4 1 in 25 years 5 5 14
1.5 1 in 25 years 5 5 14
1.6 1 in 25 years 5 5 14
Env If or when the gearbox fails the Pr 1. 1 in 20 years 8 5 2
consequence will be low. Totally 1.1 1 in 20 years 8 5 2
enclosed area. 1.2 1 in 25 years 8 5 2
1.3 1 in 20 years 8 5 2
1.4 1 in 25 years 8 5 2
1.5 1 in 25 years 8 5 2
1.6 1 in 25 years 8 5 2
2. Main hoist P If and when gearbox fails it could Pr 2. 1 in 15 years 5 5 14 Maint strategies as per ones task.
gearbox have serious consequences on 2.1 1 in 15 years 5 5 14 (See previous page
2.1 Shearing people as load or hook can cause 2.2 1 in 20 years 5 5 14 recommendations.)
pins injury to people 6 59 shift lost. 2.3 1 in 25 years 5 5 14
2.2 Lack of 2.4 1 in 20 years 5 5 14
lubrication 2.5 1 in 25 years 5 5 14
2.3 Incorrectly 2.6 1 in 25 years 5 5 14
assembled 2.7 1 in 25 years 5 5 14
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 2.1 1 in 15 years 4 5 20
2.5 Gear failure perform its duty the gearbox will 2.2 1 in 20 years 4 5 20
2.6 Shaft failure have to be overhauled. Cost of 2.3 1 in 25 years 4 5 20
2.7 Loose or equipment = R 12 500.00 2.4 1 in 20 years 4 5 20
broken bolts. Labour 2 Art @ R45/hr x 4hrs = 2.5 1 in 25 years 4 5 20
R 360.00 2.6 1 in 25 years 4 5 20
2 Assist @ R20/hr x 4hrs = R 2.7 1 in 25 years 4 5 20
160.00
Total = 13 020.00
Mat If or when gearbox fails no Pr 2. 1 in 15 years 4 5 20
production loss will occur. The 2.1 1 in 15 years 4 5 20
cost will be that of Equipment only. 2.2 1 in 20 years 4 5 20
Total = R 13 020.00 2.3 1 in 25 years 4 5 20
2.4 1 in 20 years 4 5 20
2.5 1 in 25 years 4 5 20
2.6 1 in 25 years 4 5 20
2.7 1 in 25 years 4 5 20
112
113
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./Failure F
r
Env If and when gearbox fails the Pr 2 1 in 15 years 8 5 2
consequence to the environment is 2.1 1in 15 years 8 5 2
low. 2.2 1 in 20 years 8 5 2
2.3 1 in 25 years 8 5 2
2.4 1 in 20 years 8 5 2
2.5 1 in 25 years 8 5 2
2.6 1 in 25 years 8 5 2
2.7 1 in 25 years 8 5 2
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.
3.1 Loose on consequence will be low Near 3.1 1 in 20 years 8 5 2 (See previous page
broken bolts miss. 3.2 1 in 15 years 8 5 2 recommendations.)
3.2 Bearings 3.3 1 in 25 years 8 5 2
3.3 Worn Eq If or when drum fails the hoist will Pr 3 1 in 15 years 4 5 20
(grooves) stop operating. It will have to be 4.1 1 in 20 years 4 5 20
overhauled or repaired. The cost 4.2 1 in 15 years 4 5 20
will be equipment = R 20 000.00 4.3 1 in 25 years 4 5 20
Labour: 3 Art @ R45/hr x 8hrs =
R1080.00
4. Assist @ R20/hr x 8hrs = R
640.00
Total = R 21 720.00
Mat If or when drum fails no production Pr 3 1 in 15 years 4 5 20
loss will occur. The only cost will 3.1 1 in 20 years 4 5 20
be that of the equipment. 3.2 1 in 15 years 4 5 20
Total = R 21 720.00 3.3 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, as the 3.1 1 in 20 years 8 5 2
area is totally enclosed. 3.2 1 in 15 years 8 5 2
3.3 1 in 25 years 8 5 2
5. 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.
5.1 Incorrect serious injuries to people 60 599 4.1 1 in 15 years 4 5 20 (See previous page
operation days lost. 4.2 1 in 15 years 4 5 20 recommendations.)
5.2 Safety 4.3 1 in 25 years 4 5 20
catch / spring 4.4 1 in 25 years 4 5 20
failure
5.3 Distortion of
hook
5.4 Sheaves
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./Failure
Mat If and when the hook fails no Pr 4 1 in 15 years 4 5 20
material loss will occur. The only 4.1 1 in 15 years 4 5 20
cost would be that on equipment = 4.2 1 in 25 years 4 5 20
R 23 180.00 4.3 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 4.1 1 in 15 years 8 5 2
fails. Enclosed area. 4.2 1 in 25 years 8 5 2
4.3 1 in 25 years 8 5 2
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.
5.1 Sheaves serious consequence on people 60 5.1 1 in 25 years 4 5 20 (See previous page
5.2 Rope guides 599 days lost. 5.2 1 in 15 years 4 5 20 recommendations.)
5.3 Incorrect 5.3 1 in 15 years 4 5 20
operation 5.4 1 in 15 years 4 5 20
5.4 Worn drum 5.5 1 in 25 years 4 5 20
installation Eq If or when rope fails the crane will Pr 5 1 in 15 years 4 5 20
5.6 Faulty unit stop operating. The rope will have 5.1 1 in 25 years 4 5 20
switches to be changed. Equipment cost 5.2 1 in 15 years 4 5 20
(safety (rope) = R 10 000.00 5.3 1 in 15 years 4 5 20
devices) Labour: 2 Art @ R45/hr x 8hrs = 5.4 1 in 15 years 4 5 20
R720.00 5.5 1 in 25 years 4 5 20
2 Assist @ R20/hr x 8hrs = 5.6 1 in 15 years 4 5 20
R320.00
Total = R 11 040.00
Mat No material loss will occur if or Pr 5 1 in 15 years 4 5 20
when rope fails. The only cost will 5.1 1 in 25 years 4 5 20
be that of equipment = R 11 040.00 5.2 1 in 15 years 4 5 20
5.3 1 in 15 years 4 5 20
5.4 1 in 15 years 4 5 20
5.5 1 in 25 years 4 5 20
5.6 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 5.1 1 in 25 years 8 5 2
will be low. 5.2 1 in 15 years 8 5 2
5.3 1 in 15 years 8 5 2
5.4 1 in 15 years 8 5 2
5.5 1 in 25 years 8 5 2
5.6 1 in 15 years 8 5 2
114
and Function (Loss of Function) ( Failure Mode) ( What Happens when it Fails) r/ Frequency that the r/ Strategies/ Tasks Strategies / Tasks
r Result in r
Funct./Failure
6. Brakes P If or when brake fails the Pr 6 1 in 10 years 5 5 14 Maint strategies as per ones tasks.
6.1 Ingress of consequence could be serious 6 6.1 1 in 20 years 5 5 14 (See previous page
dirt (faces 59 shifts lost. 6.2 1 in 15 years 5 5 14 recommendations.)
worn) 6.3 1 in 20 years 5 5 14
6.2 Failure of 6.4 1 in 10 years 5 5 14
coil 6.5 1 in 15 years 5 5 14
6.3 Incorrectly Eq If or when brakes fail the crane will Pr 6 1 in 10 years 4 5 20
installed become inoperative. The brakes 6.1 1 in 20 years 4 5 20
6.4 Incorrect will have to be overhauled or 6.2 1 in 15 years 4 5 20
setting replaced. 6.3 1 in 20 years 4 5 20
6.5 Failure of Equipment cost = R 7 500.00 6.4 1 in 10 years 4 5 20
remote 1 Art @ R45/hr x 4hrs = R 180.00 6.5 1 in 15 years 4 5 20
control / 1 Assist @ R20/hr x 4hrs = R 80.00
pendant Total = R 7 760.00
Mat If or when brakes fail no material Pr 6 1 in 10 years 4 5 20
loss will occur. The only cost will 6.1 1 in 20 years 4 5 20
be equipment cost = R 7 760.00 6.2 1 in 15 years 4 5 20
6.3 1 in 20 years 4 5 20
6.4 1 in 10 years 4 5 20
6.5 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 6.1 1 in 20 years 8 5 2
till be low. Totally enclosed. 6.2 1 in 15 years 8 5 2
6.3 1 in 20 years 8 5 2
6.4 1 in 10 years 8 5 2
6.5 1 in 15 years 8 5 2
7. Hoist motor P If or when the motor fails the Pr 7 1 in 15 years 8 5 2 Routine service task by electrician
7.1 Rotor consequences will be a near miss. 7.1 1 in 15 years 8 5 2 3 monthly.
7.2 Stator 7.2 1 in 15 years 8 5 2
7.3 Bearings 7.3 1 in 15 years 8 5 2
7.4 Shaft 7.4 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. The motor will have to 7.1 1 in 15 years 4 5 20
be overhauled. Equipment cost = 7.2 1 in 15 years 4 5 20
R 17 000.00 7.3 1 in 15 years 4 5 20
Labour: 2 Art @ R45/hr x 4hrs = 7.4 1 in 20 years 4 5 20
R360.00
2 Assist @ R20/hr x 4hrs =
R160.00
Total = R 17 520.00
115
r Result in r
Funct./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 7.1 1 in 15 years 4 5 20
be that of equipment only = 7.2 1 in 15 years 4 5 20
R 17 520.00 7.3 1 in 15 years 4 5 20
7.4 1 in 20 years 4 5 20
Env If or when motor fails the Pr 7 1 in 15 years 8 5 2
will be low. Totally enclosed. 7.2 1 in 15 years 8 5 2
7.3 1 in 15 years 8 5 2
7.4 1 in 20 years 8 5 2
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 8.1 1 in 5 years 5 4 19 3 monthly.
control stuck) 6 59 days lost. 8.2 1 in 10 years 5 4 14
8.1 Buttons 8.3 1 in 5 years 5 4 19
8.2 Cable failure 8.4 1 in 10 years 5 4 14
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. The pendant 8.1 1 in 5 years 5 4 19
8.4 Moisture will have to be repaired or 8.2 1 in 10 years 5 5 14
replaced. Cost will be equipment R 8.3 1 in 5 years 5 4 19
3 500.00 8.4 1 in 10 years 5 5 14
R 90.00
Total = R 3 590.00
Mat If or when pendant fails no material Pr 8 1 in 5 years 5 4 19
loss will occur. The cost will be 8.1 1 in 5 years 5 4 19
that of equipment only = R 3 8.2 1 in 10 years 5 5 14
590.00 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. Enclosed 8.1 1 in 5 years 8 4 4
area. 8.2 1 in 10 years 8 5 2
8.3 1 in 5 years 8 4 4
8.4 1 in 10 years 8 5 2
116
117
r Result in r
Funct./Failure
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
9.1 Rope failure consequence to people will be a 9.1 1 in 15 years 8 5 2 monthly and on- condition as per
9.2 Lack of near miss. 9.2 1 in 15 years 8 5 2 failure one.
lubrication 9.3 1 in 20 years 8 5 2
9.3 Foreign Eq If or when guides fail it can Pr 9 1 in 15 years 5 5 14
objects (dirt, damage the rope. The guides will 9.1 1 in 15 years 5 5 14
etc.) have to be replaced. Cost of 9.2 1 in 15 years 5 5 14
equipment = 9.3 1 in 20 years 5 5 14
R 3 700.00
R 90.00
1 Assist @ R20/hr x 2hrs = R 40.00
Total = R 3 830.00
Mat If or when guides fails no Pr 9 1 in 15 years 5 5 14
production loss will occur. The 9.1 1 in 15 years 5 5 14
cost would be that of equipment 9.2 1 in 15 years 5 5 14
only = R 3 830.00 9.3 1 in 20 years 5 5 14
Env If or when guides fail the Pr 9 1 in 15 years 8 5 2
will be low. Enclosed area. 9.2 1 in 15 years 8 5 2
9.3 1 in 20 years 8 5 2
10. Control, 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 10.1 1 in 10 years 5 4 14 devices 3 monthly.
safety in injuries 6 59 days lost. 10.2 1 in 5 years 5 4 19
circuits 10.3 1 in 5 years 5 4 19
10.1 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. 10.1 1 in 10 years 5 5 14
10.2 Contractors The hoist will not operate. Repairs 10.2 1 in 5 years 5 4 19
10.3 Earth will have to be done. Cost of 10.3 1 in 5 years 5 4 19
leakage unit equipment will be = R 5 000.00
10.4 Over-wind Labour: 1 Art @ R45/hr x 4hrs =
mechanical R 180.00
switch Total = R 5 180.00
r Result in r
Funct./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 10.1 1 in 10 years 5 5 14
that of equipment only = R 5 10.2 1 in 5 years 5 4 19
180.00 10.3 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 10.1 1 in 10 years 8 5 2
when circuits fail. 10.2 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. 11.4 1 in 50 years 8 5 2
11.1 Corrosion 11.5 1 in 50 years 8 5 2
operation Eq If or when wheels and structure Pr 11 1 in 50 years 4 5 20
11.3 Poor quality fails the hoist will stop operating. 11.1 1 in 50 years 4 5 20
of material The equipment will have to be 11.2 1 in 50 years 4 5 20
repaired. The equipment cost will 11.3 1 in 50 years 4 5 20
be =
R 5 500.00
R 1 080.00
5 Assist @ R20/hr x 12 hrs =
R 960.00
Total = R 7 540.00
P If or when wheels and structure Pr 11 1 in 50 years 4 5 20
fails no production loss will occur. 11.1 1 in 50 years 4 5 20
The cost will be that of equipment 11.2 1 in 50 years 4 5 20
= 11.3 1 in 50 years 4 5 20
R 7 540.00
Eq If or when wheels and structure Pr 11 1 in 50 years 8 5 2
fails the consequence to the 11.1 1 in 50 years 8 5 2
environment will be low. 11.2 1 in 50 years 8 5 2
11.3 1 in 50 years 8 5 2
118
119
VAAL RIVER METALLURGY

ISSUED BASED (PROCESS) RISK ASSESSMENT. (QUALITATIVE & QUANTITATIVE) LEGEND
TASKS, INCIDENTS AND ACCIDENTS. PR = PROBABILITY (QUALITATIVE DATA)
FR = FREQUENCY (QUANTITATIVE DATA)
S = SEVERITY
R = RISK
* NOTE: Severity/Frequency ranking from matrix
P = People Eq. = Equipment Sec = Security 1. People Severity and Frequency is from matrix 1 (Days lost per event).
En = Environment Mat = Material (Process Loss ) 2. Environment, Equipment, Material and Security Consequential loss/Frequency are from matrix 2 (Rand lost per
event).
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.) Moving crane P. 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
1.1) Not locked out, fall to a lower level/ onto moving ISRS program. procedure., in task
contact: people can actually equipment, and into ropes and Minerals Act Reg. N.. procedure and isolate.
1. Moving crane start and operate the accessories. Wear safety belt.
( Equipment) crane.
Eq. No effect on equipment. Pr 1 in 20 years 8 5 2
Mat. No process loss or effect Pr 1 in 20 years 8 5 2
Env. No effect Pr 1 in 20 years 8 5 2

HAZARD CAUSE * EFFECT / CONSEQUENCE Pr PPPROBABILITY / S Pr EXISTING CONTROLS RECOMMENDED S P R

INTO A HAZARD
Equipment: 1.2.1) Not locked out P. May cause severe injuries to hands, Pr 1.2.) 1 in 20 years 3 5 26 Lock out procedure as per Enforce lock out 5 5 141
People can/may start arms, leg, and body when caught Fr 1.2.2) 1 in 2 years 3 4 31 ISRS program. procedure. In task 5 4 919
1.2 Ropes
crane. between ropes & drum. Fr 1.2.3) 1 in 2 years 3 4 31 Minerals Act Reg. N procedure and isolate. 5 4 191
Drum of hoist
1.2.2.) When changing Fr 1.2.4) 1 in 5 years 3 4 31 Wear safety belt; use 5 4 4
ropes/adjusting brakes (60 day T loss) Pr 1.2.5) 1 in 15 years 3 5 26 correct PPE, gloves when 5 5
remove motors. changing rope, drum,
1..2.3) Removing Eq. Low consequence 8 5 2 brake, shoes etc.
guards.
1.2.4) Removing Mat. Low consequence 8 4 4
coupling pins.
1.2.5) Improper
Env. Low consequence 8 4 4
operation.
COMMENTS: For the ropes and the drum effects/ consequence on Equipment/ Material and Environment - Low consequence
HAZARD CAUSE * EFFECT / CONSEQUENCE Pr PROBABILITY / S Pr EXISTING CONTROLS RECOMMENDED S P

INTO A HAZARD
1.4 Bump into 1.4.1) Not locked out. P. 1.4.1) May fall to lower level - may Pr 1.4.1) 1 in 20 years 1 5 38 PTO, lockout procedure. 1) Enforce lockout 5 5 141
long/cross traverse Can operate and start. cause a fatal Pr 1.4.2) 1 in 20 years 1 5 38 As per ISRS & regulation. procedure. 414
1.4.2) Confined space. Pr 1.4.3) 1 in 20 years. 1 5 38 Lifting coarse, overhead 2) safety belt 5 5 14
1.4.3) Tripped over crane training. 3) Training on task 5 5
rails procedures.
Eq. Low consequence Pr 1 in 30 years 8 5 2 Stopper blocks, electric As existing 8 5 2

trips, limit switches.
Mat. Low consequence Pr 1 in 30 years 8 5 2
Env. Low consequence Pr 1 in 30 years 8 5 2
120
121
HAZARD CAUSE * EFFECT / CONSEQUENCE Pr PROBABILITY / S Pr R EXISTING CONTROLS RECOMMENDED S P R
INTO A HAZARD
1.5 Electric 1.5.1) Open boxes P. 525 Volt may cause electric shock and Pr 1.5.1) 1 in 30 years 1 5 38 Lock out procedure. Enforce task procedures 1 6 333
equipment. 1.5.2) Damaged cable burns. Which may lead to a fatal. Pr 1.5.2) 1 in 15 years 1 5 38 Screened cables. and lockout procedures. 1 6 333
1.4.3) Loose Pr 1.5.3) 1 in 15 years 1 5 38 On condition inspections On the job training to 1 6 333
connections , open Pr 1.5.4) 1 in 30 years 1 5 38 and tasks. know the consequence of 1 6 333
grommets Pr 1.5.5) 1 in 30 years 1 5 38 the hazard. 1 6
1.5.4) Power supply Pr 1.5.6) 1 in 30 years 1 5 38 1 6
rails. Eq. Low consequence
1.5.5.) Broken pendant
1.5.6) Inadequate
earthing /cable Mat. Low consequence
(Unscreened)
Env. Low consequence
1.6 Coupling 1.6.1) Removing of P. Minor injury, hands may be caught Pr 1.6.1) 1 in 12 years 5 5 14 PPE, leather gloves. Apply existing controls. 5 5 14
motor. between motor and steel structure, - can PTOs lockout procedure.
cause laceration of finger.
Eq. Low consequence
Mat. Low consequence
1.7 Fall to lower 1.7.1) Working on P. May cause a fatal because a person can Pr 1.7.1) 1 in 20 years 1 5 38 Lock out procedure. Interlocked access gate. 5 5 141
level. heights. fall to a lower level from that height. 1.7.2) 1 in 20 years 1 5 38 Access locked gates. Enforce the wearing of a 5 5 414
1.7.2) trip and fall 1.7.3) 1 in 20 years 1 5 38 PPE safety belts. safety belt. 5 5 141
1.7.3) Improper 1.7.4) 1 in 20 years 1 5 38 5 5 414
positioning 1.7.5) 1 in 20 years 1 5 38 5 5
1.7.4) Confined space 1.7.6) 1 in 20 years 1 5 38 5 5
1.7.5) No safety belt
1.7.6) Fail to lock out. Eq. Low consequence 8 5 2 Restoration task. On condition task and 8 5 2
scheduled.
Mat. Low consequence 8 5 2 8 5 2
Env. Low consequence 8 5 2 8 5 2
COMMENTS:
Redesign access gate to interlock electrical supply to isolate electricity when opening the gate.
HAZARD CAUSE EFFECT / CONSEQUENCE Pr PROBABILITY / S Pr R EXISTING CONTROLS RECOMMENDED S P R
* / FREQUENCY THAT THE / CONTROLS /
INTO A HAZARD
Physical contact: 2.1) Incorrect and P. When using incorrect tools, defective Pr 2.1) 1 in 1 year 4 3 30 1.) PTO Supply correct tools. 7 5 5
2. Tools improper tools tools incorrectly it may cause a serious Pr 2.2) 1 in 1 year 4 3 30 2.) PCR checklist Artisans to use correct 7 5 5
2.2) Defective tools injury to hands and the body. Pr 2.30 1 in 1 year 4 3 30 3.) Over inspection safety tools. 7 5 5
2.3) Incorrect using of training and refresher. Tools to be in a good
tools. condition. On the job
training on the task.
. Eq. May cause minor damage to the Fr 2.1) 1 in 2 year 5 3 24 7 5 5
equipment. 2.2) 1 in 2 years 5 3 24 7 5 5
2.3) 1 in 2 years 5 3 24 7 5 5
Mat. Low consequence Pr 2.1) 1 in 2 years 8 3 7 8 5 2

Pr 2.2) 1 in 2 years 8 3 7 8 5 2
Pr 2.3) 1 in 2 years 8 3 7 8 5 2
Env. Low consequence Pr 2.1) 1 in 2 years 8 5 2 8 5 2

Pr 2.2) 1 in 2 years 8 5 2 8 5 2
Pr 2.3) 1 in 2 years 8 5 2 8 5 2
Physical condition: 1.) Ropes & P. Damaged rope/hook and improper Pr 1.) 1 IN 5 years 4 4 25 On condition tasks and Proper on the job training 4 6 151
1.) Equipment Hooks utilization may cause a serious injury to 1.1.1) 1 in 5 years 4 4 25 schedules. tasks. 4 6 515
rope/hook , 1.1.1) Improper body and hands. 1.1.2) 1 in 10 years 4 4 25 Restoration task. Refresher and training 4 6 151
wear/damage. utilization 1.1.3) 1 in 10 years 4 4 25 PCR inspections and check competency tests. 4 6 515
1.2) Hoist 1.1.2) Rope guide 1.1.4) 1 in 15 years 4 5 20 lists. As above 4 6
wear/damage. damaged 1.1.5) 1 in 15 years 4 5 20 PTO inspections. 4 6
2.) Area 1.1.3) Incorrect
2.1) Structure, maintenance
Corrosion 1.1.4) Lack of Eq. Incorrect use and maintenance may Pr 1.) 1 in 5 years 4 4 25 4 6 151
walking surfaces. training cause serious damage to equipment. 1.1.1) 1 in 5 years 4 4 25 4 6 515
Poles and concrete 1.1.5) Used by Cost of rope +/- R16 000-00. 1.1.2) 1 in 10 years 4 4 25 4 6 151
surfaces. incompetent 1.1.3) 1 in 10 years 4 4 25 4 6 515
people. 1.1.4) 1 in 15 years 4 5 20 4 6
1.1.5) 1 in 15 years 4 5 20 4 6
Mat. Low consequence
COMMENTS:
122
123
* Fr CAUSE COULD RESULT Fr r
INTO A HAZARD
1.2) Hoist wear P. Low consequence Pr 1.2.1) 1 in 5 years 8 3 7 On condition task. Existing controls and 8 3 7
damage 1.2.1) Improper 1.2.2) 1 in 10 years 8 3 7 Scheduled restoration tasks. training to be enforced. 8 3 7
utilization. 1.2.2) 1.2.3) 1 in 10 years 8 3 7 PCR inspections and other 8 3 7
Incorrect maintenance. 1.2.4) 1 in 15 years 8 4 4 checklists. 8 4 4
1.2.3) Lack of training. PTO inspections.
1.2.4) Used by
incompetent persons. Eq. Can cause severe damage when used Pr 1.2.1) 1 in 5 years 3 3 36 8 3 7
improperly. 1.2.2) 1 in 10 years 3 3 36 8 3 7
1.2.3) 1 in 10 years 3 3 36 8 3 7
1.2.4) 1 in 15 years 3 4 31 8 4 4
Mat. Low consequence No effect on
process.
Env. Low consequence No effect on
environment.
2. Physical Condition 2.1) Normal wear of P. Holes in concrete and corroded steel. Pr 2.1.1) 1 in 15 years 4 4 25 Pcr checklists. Loss control Enforce existing controls. 4 6 15
Area steel /concrete. Walkways may cause a person to trip standards. Train people in hazard
2.1 Steel structure/ and fall- serious injury. On condition tasks awareness.
walkway corrosion. +/- 40 days off for a broken leg or arm.
Holes in concrete. Eq. Corroded structure and concrete to be Pr 2.1.1) 1 in 15 years 5 5 14 On condition tasks and PCR On condition tasks . PCR
(Corroded surfaces repaired +/- R5 000-00 inspections. inspections and training
and handrails) in hazard awareness.
Mat. Low consequence _ No process loss.
Env. Low consequence No effect on

environment / Therefore risks are
acceptable.
Hazardous N/A P. 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. protection in the Milling
Superfluous material. N/A area
Flammable N/A
substances N/A
Electricity N/A
Water N/A.
Pressure Running machinery
Noise N/A
Dust N/A
Radiation N/A
Vibration N/A
Temperature

* Fr CAUSE COULD RESULT Fr r
INTO A HAZARD
Ergonomics : P. When not properly illuminated it can Pr 1 in 10 years 4 3 30 Light surveys. Enforce existing controls. 4 4 25
* Illumination Lack of natural or cause a person to trip and fall, which On condition tasks. Hazard awareness
artificial light. may cause a serious injury. training.
Eq. Low consequence Pr 1 in 20 years 8 4 4 8 4 4
Mat. Low consequence Pr 1 in 20 years 8 4 4 8 4 4
Env. Low consequence Pr 1 in 20 years 8 4 4 8 4 4
COMMENTS: ALL NOT APPICABLE AS PER SURVEYS DONE.
124
125
KPA (Plant) : WGP PROCESS AREA Milling DATE : 1998/05/28 LEGEND

(Section) :
SYSTEM : Pump Systems N S = Severity
UNIT/EQUIPMENT : D Frame N AM-M1-P1 R = Risk
Pump
CONSEQEUNCE/EFFECT
(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./Failure r
Unit/Equipment no: Total Failure: 1. ) Damaged P. Low consequence on people Pr 1.) 4 in 1 year 8 3 7 1.) Daily routine inspection. Schedule a discard task to
AM-M1-P1 1.) Damaged liners and totally enclosed. . 1.1) 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. 1.2) 1 in 1 year 8 4 4 failure and the average UFE of the 11 weeks.
D Frame Pump liners 1.1) Coarse 1.3) 4 in 1 year 8 3 7 wet-end is +/-10-12 weeks.
Function: 2.) Bearing unit. material. Eq. If the wet end fails, the pump Pr 1.) 4 in 1 year 4 3 30
3.) Vee-belts. 1.2) Pump surging. will not deliver the required . 1.1) 4 in 1 year 4 3 30
Envirotech D Frame 4.) Damaged 1.3) Metal volume, and this will lead to 1.2) 1 in 1 year 4 4 25
pump, glands. Particles. impeller, suction liner, etc. 1.3) 4 in 1 year 4 3 30
Delivers 298 5.) Motor. failures.
l/sec at a 3 art. x 2hrs @R45= R270
22metre 1 x Impeller = R 4100
head @ 1,3 1 x suct. liner = R 2490
density from 1 x Insert = R 1127
the mill 1 x Eng. Liner = R2501
discharge Total costs = R 10 488-00
sump to the
cyclones.
Impeller
diameter
775mm and
pump speed
486RPM.
Driven by
140Kw
motor @
1485Rpm
by means of
126
a V-Drive
( No
Variable
drive)
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./Failure r
Mat. If or when the wet end fails , it Pr 1.) 4 in 1 year 4 3 30
will causing a production loss, . 1.1) 4 in 1 year 4 3 30
the costs will be: 1.2) 1 in 1 year 4 4 25
Eq. Costs = R10488 1.3) 4 in 1 year 4 3 30
Mat. Costs 2
hrs@R10000/hr
= R 20000
Total costs R30 488-00
Env. Low conseque4nce on Pr 1.) 4 in 1 year 8 3 7
environment. . 1.1) 4 in 1 year 8 3 7
1.2) 1 in 1 year 8 4 4
1.3) 4 in 1 year 8 3 7
Unit/Equipment no: Total Failure: 2.) Bearing unit. P. Low consequence on people- Pr 2.) 1 in 5 years 8 3 7 Daily look feel and listen. Schedule condition-monitoring
AM-M1-P1 2.1) Lack of totally enclosed. . 2.1) 1 in 5 years 8 3 7 Weekly lubrication checks. tasks.
Component Code: Lubrication. 2.2) 1 in 5 years 8 3 7 Run to failure. 1) 6 Monthly oil analysis
D Frame Pump 2.2) Pump surge. 2.3) 1 in 10 years 8 4 4 @R54/sample. PLUS
2.3) Misalignment 2) Monthly vibration
of V-Belts. Eq. If or when, the bearing unit Pr 2.) 1 in 5 years 4 3 30 check (No Charge)
fails, it may cause damage to . 2.1) 1 in 5 years 4 3 30
the shaft, impeller, etc. 2.2) 1 in 5 years 4 3 30
1.) 3 art. x 4hrs @ R45 2.3) 1 in 10 years 4 4 25
= R450
2.) 1 x bearing unit = R15 000
Total costs = R15450
Mat. If or when the bearing unit Pr 2.) 1 in 5 years 4 3 30
fails, the mill will stand . 2.1) 1 in 5 years 4 3 30
,causing a production loss of 4 2.2) 1 in 5 years 4 3 30
hr s the costs will be: 2.3) 1 in 10 years 4 4 25
1.) Eq. costs = R15 450
2.) Mat costs =
4 x R10 000/hr
= R40 000
Total costs = R55 450-00
Env. Pr 2.) 1 in 5 years 8 3 7
. 2.1) 1 in 5 years 8 3 7
2.2) 1 in 5 years 8 3 7
2.3) 1 in 10 years 8 4 4
127
128
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./Failure r
Unit/Equipment no: Total Failure: 3.) Vee-belts. P. Low consequence on people- Pr 3.) 1 in 5 years 8 3 7 Daily look feel and listen. Schedule discard task.
AM-M1-P1 3.1) Worn belts. totally enclosed guards. . 3.1) 1 in 5 years 8 3 7 Weekly routine inspection. Change V-belts on yearly
Component Code: 3.2) Worn pulleys. 3.2) 1 in 10 years 8 4 4 Belts are inspected when pump is intervals at a costs of
D Frame Pump 3.3) Misalignment 3.3) 1 in 10 years 8 4 4 overhauled. R1980-00
3.4) Unmatched 3.4) 1 in 5 years 8 3 7
sets. 3.5) 1 in 10 years 8 4 4
3.5) Overheating. Eq. If the drive fails, the pump will Pr 3.) 1 in 5 years 5 3 24
stop working and the belts will . 3.1) 1 in 5 years 5 3 24
have to be changed. will stand 3.2) 1 in 10 years 5 4 19
for 2 hrs; loss: 3.3) 1 in 10 years 5 4 19
= R180 3.5) 1 in 10 years 5 4 19
2.) 1 x set belts = R1800
1 x motor pulley = R 1100
1 x pump pulley = R 2700
Total costs = R 5 700-00
Mat. If or when the v-belts fails, the Pr 3.) 1 in 5 years 4 3 30
mill will stand causing a . 3.1) 1 in 5 years 4 3 30
production loss of 2 hrs: 3.2) 1 in 10 years 4 4 25
The costs will be: 1.) Eq. costs 3.3) 1 in 10 years 4 4 25
= R15 540 2.)Mat costs = 3.4) 1 in 5 years 4 3 30
2 x R10 000/hr 3.5) 1 in 10 years 4 4 25
= R20 000 Total
costs = R25 700-00
Env. Low consequence- contained Pr 3.) 1 in 5 years 8 3 7
area. . 3.1) 1 in 5 years 8 3 7
3.2) 1 in 10 years 8 4 4
3.3) 1 in 10 years 8 4 4
3.4) 1 in 5 years 8 3 7
3.5) 1 in 10 years 8 4 4
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./Failure r
Unit/Equipment no: Total Failure: 4.) Shaft P. Low consequence on people- Pr. 4.) 1 in 15 years 8 5 2 Daily look feel and listen. Schedule condition-monitoring
AM-M1-P1 4.1) Coupling key motor totally enclosed. 4.1) 1 in 15 years 8 5 2 . task.
Component Code: failure.. 4.2) 1 in 15 years 8 5 2 1 Yearly service order Monthly temperature and
D Frame Pump 4.2) Bearing Eq. If the shaft fails, the motor Pr. 4.) 1 in 15 years 4 5 20 vibration to be taken by
failure. will be damaged and pump 4.1) 1 in 15 years 4 5 20 artisans ( No costs )
will stop to operate.Cost: 4.2) 1 in 15 years 4 5 20
1.) 3 art. x 3hrs @ R45
= R405
2.) Motor o/haul = R21 000
Mat. If or when the shaft fails, the Pr. 4.) 1 in 15 years 4 5 20
mill will stand & production 4.1) 1 in 15 years 4 5 20
will be lost: 4.2) 1 in 15 years 4 5 20
the cost will be:
1.)Eq. costs = R21 405
2.)Mat costs =
3 x R10 000/hr
= R30 000
Env. Low consequence contained Pr. 4.) 1 in 15 years 8 5 2
area. 4.1) 1 in 15 years 8 5 2
4.2) 1 in 15 years 8 5 2
129
130
(Section) :
SYSTEM : Pump Systems N AM-M1-P1 S = Severity
UNIT/EQUIPMENT : Motor N WP2321 R = Risk
CONSEQEUNCE/EFFECT
(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
Funct./Failure r
Unit/Equipment no: Total Failure: 1.) Bearings P. Low consequence on people Pr. 1.) 1 in 5 years 8 4 4 Daily inspection. Schedule a condition-
WP2321 1.) Bearings 1.1) Lack of totally enclosed. 1.1) 1 in 5 years 8 4 4 3Monthly S/O monitoring task.
Component Code: 2.) Rotor lubrication. 1.2) 1in 10 years 8 4 4 1 Yearly S/O Monthly vibration
Motor 3.) Stator 1.2) Incorrect 1.3) 1 in 15 years 8 4 4 Weekly lubrication. test/analyses
Function: 4.) Shaft. installation. 1.4) 1 in 10 years 8 4 4 .
Envirotech D Frame 1.3) Vibration. 1.5) 1 in 10 years 8 4 4
140 kW Siemens 4 1.4) Water. 1.6) 1in 10 years 8 4 4
pole motor running at 1.5) Overheating
1485, RPM, which 1.6) Looseness on Eq. If or when, the bearings fail, Pr. 1.) 1 in 5 years 5 4 19
induces power to set bed plate. may cause damage to the 1.1) 1 in 5 years 5 4 19
the cyclone transfer, motor shaft, stator, etc. 1.2) 1in 10 years 5 4 19
pump in motion to Bearing cost+labour; 1.3) 1 in 15 years 5 4 19
pump slurry from the 4 art. x 3hrs @R45= R540 1.4) 1 in 10 years 5 5 14
mill discharge to the 1 x Set of bearings = R 1100 1.5) 1 in 10 years 5 4 19
cyclone. Total cost=R1640 1.6) 1in 10 years 5 4 19
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./Failure r
Mat. If or when the motor bearings Pr. 1.) 1 in 5 years 4 4 25
fails, it will cause a 1.1) 1 in 5 years 4 4 25
production loss of 3 hrs ; the 1.2) 1in 10 years 4 4 25
cost will be: 1.3) 1 in 15 years 4 4 25
Eq. Costs = R1640 1.4) 1 in 10 years 4 5 20
Mat. Costs = 3xR10 000/hr 1.5) 1 in 10 years 4 4 25
= R 30000 1.6) 1in 10 years 4 4 25
Total costs R31 640-00
Env. Low consequence on Pr. 1.) 1 in 5 years 8 4 4
environment- contained area. 1.1) 1 in 5 years 8 4 4
1.2) 1in 10 years 8 4 4
1.3) 1 in 15 years 8 4 4
1.4) 1 in 10 years 8 5 2
1.5) 1 in 10 years 8 4 4
1.6) 1in 10 years 8 4 4
Unit/Equipment no: Total Failure: 2.) Rotor Failure. P. Low consequence on people- Pr. 2.) 1 in 15 years 8 5 2 Daily look feel and listen. Schedule condition-
WP2321 2.1) Damaged motor totally enclosed. 2.1) 1 in 15 years 8 5 2 Weekly routine inspection.. monitoring task.
Component Code: bearings.. 2.2) 1in 20 years 8 5 2 1 Yearly S/O. Monthly temperature and
D Frame Pump Motor 2.2) Loose rotor 2.3) 1 in 15 years 8 5 2 vibration test.( No costs )
bars. Eq. If or when the rotor fails, the Pr. 2.) 1 in 15 years 4 5 20
2.3) Vibration. motor will be damaged and 2.1) 1 in 15 years 4 5 20
have to be changed (3 hrs ) 2.2) 1in 20 years 4 5 20
= R405
Mat. If or when the bearings fails, Pr. 2.) 1 in 15 years 3 5 26
the motor and the pump fails, 2.1) 1 in 15 years 3 5 26
the mill will stand for 4hrs, 2.2) 1in 20 years 3 5 26
production will be lost. 2.3) 1 in 15 years 3 5 26
the costs will be:
3.) Eq. costs = R21405
4.) Mat costs
= 4 x R10 000/hr
= R40 000
Total costs = R61 405
131
132
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
Funct./Failure r
Env. Low consequence on Pr. 2.) 1 in 15 years 8 5 2
environment- contained area. 2.1) 1 in 15 years 8 5 2
2.2) 1in 20 years 8 5 2
2.3) 1 in 15 years 8 5 2
Unit/Equipment no: Total Failure: 3.) Rotor Failure. P. Low consequence on people- Pr. 3.) 1 in 15 years 4 5 20 Daily look feel and listen. Schedule on condition task.
WP2321 Code: 3.1) Damaged motor totally enclosed. 3.1) 1 in 15 years 4 5 20 Weekly routine inspection.. Monthly temperature and
D Frame Pump Motor Bearings.. 3.2) 1 in 15 years 4 5 20 1 Yearly S/O. vibration test to be done by
3.2) Loose rotor 3.3) 1in 20 years 4 5 20 artisans ( No costs )
bars. Eq. If the rotor / stator fails, the Pr. 3.) 1 in 15 years 4 5 20
3.3) Vibration. motor and pump stop to 3.1) 1 in 15 years 4 5 20
operate. The mill will stand 3.2) 1 in 15 years 4 5 20
for 3 hrs.to change motor. 3.3) 1in 20 years 4 5 20
Cost:
1.) 3 art. x 3hrs @ R45
= R405
Mat. If or when the stator fails, the Pr. 3.) 1 in 15 years 4 5 20
mill will stand for 3-hrs.to 3.1) 1 in 15 years 4 5 20
change motor. Production loss 3.2) 1 in 15 years 4 5 20
cost will be: 3.3) 1in 20 years 4 5 20
1.)Eq. costs = R21 405
2.)Mat costs =
3 x R10 000/hr
= R30 000
Env. Low consequence - contained Pr. 3.) 1 in 15 years 8 5 2
area. 3.1) 1 in 15 years 8 5 2
3.2) 1 in 15 years 8 5 2
3.3) 1in 20 years 8 5 2
133

(Section) :
SYSTEM : Pumping N AM-M1-P1 S = Severity
UNIT/EQUIPMENT: Siliconics variable N WP2321 R = Risk
speed drive.
CONSEQEUNCE/EFFECT
(PROCESS LOSS)
and Function Failure (Loss of Failure Consequence Fr Frequency that r Strategies/ Tasks Maintenance
Function) ( Failure ( What Happens when the Cause Could / Strategies / Tasks
Funct./Failure r
Unit/Equipment no: Total Failure: 1.)Converter P. Low consequence on people Pr. 1.) 1 in 10 years 8 5 47 Daily inspection. Schedule routine task.
AM-M1P2 1.) Converter. 1.1) Diodes. pump with components are 1.1) 1in 10 years 8 5 47 3Monthly earth leakage. A) 3 Monthly earth leakage
Component Code: 2.) Inverter totally enclosed. 1.2) 1in 10 years 8 5 47 6 Monthly S/O. test.
1.2) Fuses
AC2 Siliconics Speed 3.) Cooling fan. 1.3) 1in 10 years 8 5 47 B) Clean out system with
1.3) Cooling fan
control. 4.) Control circuit. 1.4) 1in 10 years 8 5 47 blower.
1.4) Control guard.
Function: 1.5) 1in 10 years 8 5 47
1.5) Loose wiring.
Siliconics AC2 motor, Eq. If and when the covertor fails- Pr. 1.) 1 in 10 years 5 5 35
speed control used. On the production loss will be: 1.1) 1in 10 years 5 5 35
the second stage 1 art. x 2hrs @R45= R90 1.2) 1in 10 years 5 5 35
discharge- pump on the 1 x Tech. Siliconics R1000 1.3) 1in 10 years 5 5 35
mills which is controlled Spares = R1000 1.4) 1in 10 years 5 5 35
from the mill discharge Total costs = R2 090-00 1.5) 1in 10 years 5 5 35
sump level.
134
Function) (Failure Mode) ( What Happens when the Cause Could / Strategies / Tasks
Funct./Failure r
Mat. If or when the converter fails, Pr. 1.) 1 in 10 years 4 5 29
it will cause a 1hr mill 1.1) 1in 10 years 4 5 29
stoppage at R10 000/hr: 1.2) 1in 10 years 4 5 29
To change over to direct on 1.3) 1in 10 years 4 5 29
line pump. R10 000 1.4) 1in 10 years 4 5 29
Eq. Costs = R2090 1.5) 1in 10 years 4 5 29
Env. Low consequence spillage in Pr. 1.) 1 in 10 years 8 5 47
a controlled area. 1.1) 1in 10 years 8 5 47
1.2) 1in 10 years 8 5 47
1.3) 1in 10 years 8 5 47
1.4) 1in 10 years 8 5 47
1.5) 1in 10 years 8 5 47
Unit/Equipment no: Total Failure: 2.) Inverter. P. Low consequence on people- Pr. 2.) 1 in 5 years 8 4 45 Daily inspection. As per converter recommended
AM-M1P2 2.1) Diodes. panel enclosed in substation. 2.1) 1in 5 years 8 4 45 maintenance.
Component Code: 2.2) Thyristors. 2.2) 1 in 3 years 8 4 45
AC2 Siliconics Speed 2.3) Cooling fan. 2.3) 1 in 10 years 8 5 47
control. 2.4) Control guard 2.4) 1 in 5 years 8 4 45
2.5) Loose wiring. 2.5) 1 in 10 years 8 5 47
2.6) Motor faulty. 2.6) 1 in 10 years 8 5 47
2.7) Cable faulty. 2.7) 1 in 10 years 8 5 47
2.8) Fuses. 2.8) 1 in 3 years 8 4 45
Eq. If or when the converter fails: Pr. 2.) 1 in 5 years 5 4 30
1 art. x 4hrs @ R180 2.1) 1in 5 years 5 4 30
1 x Tech. At r1000 2.2) 1 in 3 years 5 4 30
Eq. Costs = R1000 2.3) 1 in 10 years 5 5 35
Total costs = R 2 180-00 2.4) 1 in 5 years 5 4 30
2.5) 1 in 10 years 5 5 35
2.6) 1 in 10 years 5 5 35
2.7) 1 in 10 years 5 5 35
2.8) 1 in 3 years 5 4 30
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./Failure F
r
Mat. If or when the inverter fails it Pr. 2.) 1 in 5 years 4 4 24
will cause a: 2.1) 1in 5 years 4 4 24
1 hr mill stoppage at R10 2.2) 1 in 3 years 4 4 24
000/hr and changing direct on 2.3) 1 in 10 years 4 5 29
line. 2.4) 1 in 5 years 4 4 24
Eq. Costs R 2180 2.5) 1 in 10 years 4 5 29
Total costs = R 12 180-00 2.6) 1 in 10 years 4 5 29
2.7) 1 in 10 years 4 5 29
2.8) 1 in 3 years 4 4 24
2.2) 1 in 3 years 8 4 45
2.3) 1 in 10 years 8 5 47
2.4) 1 in 5 years 8 4 45
2.5) 1 in 10 years 8 5 47
2.6) 1 in 10 years 8 5 47
2.7) 1 in 10 years 8 5 47
2.8) 1 in 3 years 8 4 45
Unit/Equipment no: Total Failure: 3.)Stalk cooling P. Low consequence totally Pr. 3.) 1 in 10 years 8 5 47 Daily inspection. Schedule discard task.
AM-M1P2 fan. enclosed in panel. 3.1) 1in 10 years 8 5 47 Change fan every 8 years at a
Component Code: 3.1) Bearing 3.2) 1 in 15 years 8 5 47 costs of R 1 208-00
AC2 Siliconics Speed failure. Eq. If or when the cooling fan Pr. 3.) 1 in 10 years 8 5 47 Daily inspection. Schedule discard task.
control.
3.2) Windings. fails: 3.1) 1in 10 years 8 5 47 Change fan every 8 years at a
1 art. at R45/hr for 2 hrs 3.2) 1 in 15 years 8 5 47 costs of R 1 208-00
= R90
Fan replacement.
= R 1208
Total costs = R 1 298-=00
135
Funct./Failure r
Mat. If or when the cooling fan Pr. 3.) 1 in 10 years 4 5 29
fails: 3.1) 1in 10 years 4 5 29
1 hr mill stoppage at R10 3.2) 1 in 15 years 4 5 29
000/hr and changing direct on
line.
Eq. Costs R 1298
3.2) 1 in 15 years 8 5 47
Unit/Equipment no: Total Failure: 4.) Control circuit. P. Low consequence panel Pr. 4.) 1 in 10 years 8 5 47 Daily inspection. Schedule discard task.
AM-M1P2 4.1) Protection totally enclosed. 4.1) 1 in 15 years 8 5 47 Change fan every 8 years at a
Component Code: unit. 4.20 1in 15 years 8 5 47 costs of R 1 208-00
AC2 Siliconics Speed 4.1) Contactors. 4.3) 1in 15 years 8 5 47
control. 4.3) Relays 4.4) 1 in 10 years 8 5 47
4.4) Loose 4.5) 1in 15 years 8 5 47
connections.
4.5) Circuit
breakers
Eq. If or when the control circuit Pr. 4.) 1 in 10 years 5 5 35

fails: 4.1) 1 in 15 years 5 5 35
1 art. at R45/hr for 3 hrs 4.20 1in 15 years 5 5 35
= R135 4.3) 1in 15 years 5 5 35
Eq. = R 4000 4.4) 1 in 10 years 5 5 35
Total costs = R 4 135-00 4.5) 1in 15 years 5 5 35
136
Funct./Failure r
Mat. If or when the control circuit Pr. 4.) 1 in 10 years 4 5 29
fails: 4.1) 1 in 15 years 4 5 29
1 hr mill stoppage at 4.20 1in 15 years 4 5 29
R10 000/hr x 3 hrs 4.3) 1in 15 years 4 5 29
= R 30 000 . 4.4) 1 in 10 years 4 5 29
Eq. Costs R 4000 4.5) 1in 15 years 4 5 29

a controlled area. 4.1) 1 in 15 years 8 5 47
4.20 1in 15 years 8 5 47
4.3) 1in 15 years 8 5 47
4.4) 1 in 10 years 8 5 47
4.5) 1in 15 years 8 5 47
137
ANNEXURE 13
138
ANGLOGOLD RISK INDEX MATRIX (N 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.
(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. 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 - 5999 3 43 40 36 31 26 21
Shifts Lost
60 - 599 4 39 35 30 25 20 15
Shifts Lost
6 - 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
140
ANGLOGOLD RISK INDEX MATRIX (N 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.
(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. 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 0,6 - R 5,9 M 2 46 44 41 37 32 27
R 60 000 - R 0.59 M 3 43 40 36 31 26 21
R 6 000 - R 59 999 4 39 35 30 25 20 15
R 600 - R 5 999 5 34 29 24 19 14 10
R 60 - R 599 6 28 23 18 13 9 6
R 6 - R 59 7 22 17 12 8 5 3
Low Consequence 8 16 11 7 4 2 1
ANNEXURE 14
141
142
MEASUREMENT OF MAINTENANCE
EFFECTIVENESS USING KPAs & KPIs
KPAs KPIs
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. 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
OTHER
KPAs KPIs
Goals, Policies and Procedures,

Criticality and availability of equipment
1. Maintenance management/ strategy Effectiveness of CMMIS infrastructure

Stores and spares availability and
buying function
Structure of CMMIS department / plant

labour
Responsibility levels and manning in
2. Maintenance organisation and manpower relation to work load
Skill levels of maintenance staff etc
Training program and evaluation
143
ANNEXURE 15
144
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 KPAs KPIs
- 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
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
IF NO MINES / BUSINESS SERVICES SYSTEMS CO-ORDINATOR THEN
1. CMMIS PLANNER DUTIES:
- Must incorporate the co-ordinator duties accept facilitation of risk assessments and
assessments/evaluation to determine maintenance strategies/tasks.
2. ASSISTANT PLANNER DUTIES:
- Must incorporate CMMIS Planner duties, such as performance management and work management
duties.
3. With no co-ordinator the loading on the CMMIS Planner and assistant will be high; 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.
147
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.e. ONE FOR
HORIZONTAL TRANSPORT AND ONE FOR VERTICAL TRANSPORT AND SERVICES
148

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REFERENCE MANUAL

COMPILED BY: JAKKIE CLAASSENS - ENGINEER CMMIS/RISK MANAGEMENT - FEBRUARY 1999.

From a systems perspective, Risk Management in the Maintenance Domain is a

Probability: The percentage of times that a specific outcome would occur if an

The objective of the reference manual is to provide the necessary theoretical

3.1 Maintenance Policy

The purpose of the Maintenance Management Information System/Risk

All critical maintenance functions will be identified through risk assessments

Critical systems and processes will be evaluated by risk assessment to ensure

We are committed to:

I.D.MENZIES - HEAD OF ENGINEERING ANGLOGOLD.

To reduce the risk, measures are taken to:

As risk is a function of consequence (severity) and probability, a degree or index of

5. OBJECTIVES OF RISK MANAGEMENT & CMMIS INTEGRATION

The key objective of a Maintenance Management Information System and Risk

Maintenance Audit; Management Planning;

7. MAINTENANCE PROCESS (OPERATIONAL SYSTEM)

Maintenance Strategies; Maintenance Planning;

Task Execution &

Planned Maint Tasks Planned Maint Task Frequencies

Spares needed Work packages, Task Tools and

Artisans Task Execution Plan Time

3. WORK ORDER FLOW (DOCUMENTATION FLOW SYSTEM)

Spares Procurement Work Packages

F/M verify & Artisan Complete Job Task Executed

CMMIS receive Data into CMMIS Gen Man

a) Determine high cost areas and equipment.

5. TYPE OF JOB/WORK ORDER CARDS TO BE GENERATED

11.1 Scheduled restoration task

12.2 DATA NEEDED ON A JOB CARD/SERVICE ORDER

7. RISK ASSESSMENT TECHNIQUES

Base line Risk Assessment (Identification of Critical Process Areas and

Issue Based Risk Assessment Equipment (to determine maintenance strategies

Continuous Risk Assessment. This is the most important form of risk

Conduct Base Line Identify Major Hazards

Conduct Issue Based Risk

9. MAINTENANCE STRATEGIES PROCESS

Issue Based Risk Assessment Equipment

Determine Maintenance Strategies/Tasks

Conduct Issue Based Gather facts, costs,

Describe function of Determine Functional Identify Failure Mode

Determine Risk Failure effect/ Determine Probability

Existing Maintenance Recommend new Load onto OMM/

Conduct Issue Based Gather facts, costs,

Identify hazards Identify Root Causes Consequences

Existing Determine Risk Determine Probability

Recommend new Rewrite Task Approve Task

New: Equipment, Project, Implement Task

Phase 1 List Assets (Inventory)

Phase 2 Base Line Risk Assessment

Phase 3 Maintenance Strategies/Plan

Maintenance Performance (Measurement,

Training and Development (Risk Man,

18.1 PHASE 1: LIST ASSETS (INVENTORY)

PA Mill 1 Mill 2 Mill 3

[Equipm Loc] Pumping Conveying Lubricating

Equip/Unit Motor Pump Fluid Coupling

Components Rotor Bearing Shaft

PA Rock 1 Rock 2 Rock 3

[Equipm Drive Braking Hydraulic

Equip/Unit Motor Gearbox Coupling

Components Rotor Bearing Shaft

[Equipment Locos Transfer

Equip/Unit Motor Gearbox Axle