Improving Dragline Reliability Through a Complex Shutdown
Delivering Reliability When It Matters Most
At Richglen Maintenance Services, successful shutdowns are not measured by how closely reality follows the original plan.
They're measured by how teams respond when challenges emerge, how effectively they adapt, and ultimately, the value they deliver for the client.
Recently, Richglen's Shutdowns Division completed a major dragline shutdown, delivering critical reliability upgrades and structural repairs designed to improve machine availability and support long-term operational performance.
What began as a planned reliability improvement shutdown evolved into a significantly larger project as additional defects were identified during execution.
A Shutdown Focused on Reliability
The shutdown centred on two primary objectives aimed at improving the reliability of a critical production asset:
Upgrading the dragline's propel system with an improved final drive pinion design.
Replacing a cracked section of flooring beneath the drag drum pedestal.
To achieve these outcomes, Richglen delivered a comprehensive scope of work that included:
Propel girder crack repairs
Replacement of final drive pinions and pedestals
Alignment and machining of propel bores
Replacement of the drag pedestal floor
Overhaul of multiple gearcases
These works were critical to supporting the machine's ongoing reliability and operational performance.
Responding When the Scope Changes
As work progressed and inspections continued, additional cracking was identified throughout key propel structures that sat outside the original shutdown scope. The findings highlighted the extent of repairs required to support the long-term reliability of the dragline and presented new challenges for both the client and project team.
Rather than postponing the repairs to a future outage, Richglen worked closely with site stakeholders to assess the defects, adapt the execution strategy and complete the additional works while the machine was already offline.
By project completion, the team had delivered more than 4,000 additional labour hours, representing approximately 20% more work than originally planned. As additional defects were uncovered throughout the shutdown, the scope continued to expand, creating a far more complex project than originally anticipated. Through close collaboration with the client and a flexible approach to execution, Richglen successfully delivered the additional works and addressed critical issues while the asset was offline.
While the expanded scope extended the shutdown beyond the original schedule, completing the additional repairs during the outage enabled critical defects to be addressed immediately rather than becoming future reliability risks.
Projects like this highlight the importance of having experienced shutdown teams capable of adapting when conditions change, scaling resources when required and maintaining focus on delivering the right outcome for the client.
Powered by Our People
Large-scale shutdowns rely on skilled people working together towards a common goal.
To deliver the project, Richglen mobilised approximately 260 personnel, including Richglen team members and specialist subcontractors, to safely execute the evolving scope of work.
The shutdown also provided valuable development opportunities for the next generation of industry professionals, with all five Richglen shutdown apprentices contributing throughout the project and gaining hands-on experience alongside experienced tradespeople, supervisors and leaders.
At Richglen, building capability is about more than delivering today's projects. It's about investing in the people who will deliver tomorrow's.
Think Safe. Work Safe. Home Safe.
Safety remained a constant focus throughout every stage of the shutdown.
Structural repairs within the dragline's propel girders required detailed planning and specialised controls to maintain safe working conditions. To support the work, the team implemented a comprehensive ventilation strategy and continuously monitored airflow throughout the repair process to ensure a safe atmosphere was maintained.
At Richglen, safety is more than a process.
It's a commitment to our people, their families and the communities we serve.
Think Safe. Work Safe. Home Safe.
Because every shutdown, every task and every decision starts with ensuring our people return home safely at the end of the day.
Delivering a Stronger Asset
Following completion of the shutdown, the dragline successfully returned to service with upgraded propel final drive components designed to improve machine availability and support ongoing reliability.
While the original scope delivered important reliability improvements, the project's defining achievement was the team's ability to identify, manage and complete substantial additional repairs when emerging defects were uncovered.
The result was a more comprehensive outcome for the client, with critical structural issues addressed during the shutdown and the asset returned to operation in a stronger position for the future.
At Richglen, that's what successful shutdown delivery looks like: adapting to changing conditions, solving problems as they arise and helping clients maximise the performance and reliability of their critical assets.
Driven by Progress. Powered by Our People.