PT SMM — Vibrating Screen Replacement Project
Owner’s Engineering, Equipment Replacement & Project Management | Indonesia | 2022
Project Overview
Client: PT Suprabari Mapanindo Mineral (PT SMM)
Location: Indonesia
Industry: Coal Mining & Mineral Processing
Project Year: 2022
Services: Owner’s Engineering, Equipment Procurement, Quality Assurance, Installation & Commissioning Management
Contracting Entity: Eptoscore (Pty) Ltd, South Africa
Project Status: Completed
As part of its ongoing technical and advisory services to PT Suprabari Mapanindo Mineral (PT SMM), Eptoscore identified the deteriorating condition of a major vibrating screen within the coal processing plant as a significant operational and equipment reliability risk.
Following the technical assessment, PT SMM appointed Eptoscore to manage the replacement project, acting as the client’s owner’s engineer and project management team.
The assignment encompassed the engineering evaluation, OEM selection, equipment design review, manufacturing quality assurance, international logistics coordination, installation planning, commissioning and handover of the replacement vibrating screen.
The project was successfully completed within the plant’s planned annual shutdown period, enabling the replacement equipment to be installed, commissioned and returned to operational service.
Scope of Services
Eptoscore provided integrated engineering and project management services throughout the equipment replacement programme.
The scope included:
- Equipment Condition Assessment: Evaluation of the existing vibrating screen’s condition, reliability and expected remaining service life.
- Engineering Requirements & Design Review: Establishment and evaluation of technical requirements for the replacement equipment, including compatibility with the existing plant infrastructure.
- OEM Evaluation & Selection: Technical evaluation of equipment suppliers and coordination of the preferred original equipment manufacturer’s design development.
- Manufacturing Quality Assurance: Inspection and quality-control activities during manufacturing, assembly and shop testing at the OEM’s South African facilities.
- Procurement & Logistics Coordination: Management of equipment manufacturing interfaces, packing, transportation, international shipping and delivery to the Indonesian project site.
- Installation & Shutdown Planning: Coordination of the equipment replacement activities within the client’s scheduled annual maintenance shutdown.
- Commissioning & Handover: Coordination of installation verification, commissioning, performance testing and documented handover for beneficial use.
Engineering & Project Execution
Engineering Assessment & OEM Selection
The replacement project commenced with an assessment of the existing vibrating screen and the establishment of technical requirements for a suitable replacement.
Critical design considerations included the existing equipment footprint, installed power, processing capacity and screening efficiency, spray-water arrangements, equipment service life and the transmission of vibration into the supporting steel structure.
Following a technical evaluation of the available solutions, Kwatani was selected as the preferred original equipment manufacturer.
Kwatani developed the replacement screen design, incorporating the identified engineering improvements and optimisation requirements. Eptoscore and PT SMM jointly participated in the systematic review and approval of the proposed design.
Manufacturing & Quality Assurance
Following design approval, manufacturing commenced at Kwatani’s South African facilities.
Eptoscore provided manufacturing quality-control and assurance services, including inspection of the assembled equipment and verification of key technical requirements.
The replacement vibrating screen was fully assembled and tested under controlled workshop conditions, with relevant measurements recorded and compared against the specified design requirements.
International Logistics & Installation Planning
Following manufacturing and shop testing, the equipment was prepared for international transportation and delivery to Indonesia.
Eptoscore coordinated the associated procurement, logistics and installation planning activities to align equipment delivery with the scheduled plant shutdown.
The replacement required close coordination between the client’s operational team, the OEM and the installation contractor to minimise disruption to production.
Installation, Commissioning & Handover
The removal of the existing screen and installation of the replacement equipment were undertaken during PT SMM’s planned annual maintenance shutdown.
The site execution team included representatives from Eptoscore, PT SMM, PT Lintech and Kwatani.
Installation and commissioning were completed within the scheduled shutdown period without safety or other incidents.
Commissioning, performance testing and handover for beneficial use were completed using Eptoscore’s structured commissioning and acceptance procedures.
Technical Challenges & Project Highlights
Replacement Within Existing Plant Constraints
The replacement equipment had to be integrated into the existing processing plant without unnecessary modifications to the available footprint, supporting structures or installed electrical infrastructure.
These constraints formed essential considerations during OEM evaluation and design development.
Equipment Reliability & Structural Vibration
Improving the expected service life of the replacement screen was an important engineering objective.
The technical evaluation also considered reducing the transmission of equipment vibration into the existing steel support structure, while maintaining the required screening performance.
Process & Spray-Water Optimisation
The project provided an opportunity to review and optimise the screening arrangement, including its processing capacity, efficiency and spray-water configuration.
These requirements were incorporated into the replacement equipment’s design development and technical review process.
International Manufacturing & Shutdown Coordination
Manufacturing and quality assurance were undertaken in South Africa, while installation and commissioning took place at the operating plant in Indonesia.
Successful execution required coordinated international logistics, equipment readiness, detailed shutdown planning and collaboration between the client’s personnel, OEM and installation contractor.
Successful Project Completion
The replacement vibrating screen was installed and commissioned within the planned annual shutdown period.
Performance testing and formal handover for beneficial use were completed, with the replacement equipment operating in accordance with the specified design requirements and client expectations.
The project demonstrates Eptoscore’s engineering and project management capabilities in industrial equipment replacement, technical procurement, manufacturing quality assurance, international logistics, shutdown coordination and commissioning management.
Project Gallery
Selected photographs illustrating the original and replacement vibrating screens, manufacturing and quality assurance activities, site installation, commissioning and the completed equipment replacement.
