ISSUE 121 Friday 9th December 2016

In this weeks edition

Green Banner Savings $1.24 Million this Year!

Blocked Fluewall Detection Software Installed
IC Automation Project
Tomago - A Diverse Place of Work
Rotary Breaker change out Success
New Micros Deliver Improved Environmental Performance & Reduced Risk to Operators

Green Banner Savings $1.24 Million this Year!!

The final month of 2016 is here and through 43 Green Banner
submissions the Green Banner Savings is up to $1.24 Million!
Thanks again to those who have submitted the Banners throughout 2016. With still a month to go lets
finish the year strong with a few more Banners over the festive period!
Please contact Luke Rankovich in Finance with any initiatives that could be a Green Banner Cost Reduction, as theres still time to finish the year strong!

Blocked Fluewall Detection Software Installed!

One of the biggest risks to explosion in the Bake
This is a major safety improvement for
Ovens is blocked fluewalls. Blocked fluewalls occur the Bake Ovens! Well done to all inwhen packing coke or debris infiltrates a fluewall. It
volved in the project!
blocks the passage of gases and volatiles through
to the exhaust manifold.
If undetected, blocked fluewalls present a major
explosion risk. Detection of a blockage is relied upon fire controllers linking several critical parameters
to identify a potential blockage.
The solution was to implement blocked fluewall detection software into the existing firing system. The
new system monitors damper percentage, pressure
and temperature and alerts a Fire Controller of a
potential blockage.

This will be used as a secondary monitoring system to the primary checks that our Fire Controllers
conduct on a daily basis for blockages.
The software was installed with the help of Ryan
Bromley (BO Process Engineer), Yan Zhu
(Automation Engineer) and Christian Coulaud from
Fives Solios (FRA).
The final installation occurred on Tuesday night.
With testing now completed the system is fully operational and is able to detect a blockage given the
correct parameters.

Story Submitted by : Ryan Bromley

IC Automation Project
Operators are the Stars!
The commencement of training on Ingot Chain 6
has shown how valuable our people and culture at
Tomago are. High value improvements have come
straight from our operators, with flexible and positive attitudes generating highly productive training
sessions.

IC3 electrical panel is undergoing commissioning,

IC4 and IC5 have both had concrete cutting work
completed and IC6 is live with training in progress.
Great work!

A big THANKYOU to all of our Ingot

Chain Operators and IMF Supervisors for
all their help and assistance in making
this project a reality.
The Ingot Chain Automation Project has gained extra momentum, with work currently in progress on
all ingot chains simultaneously.

Casthouse Operator Michael Anderson

Story Submitted by : Phillip Bartlett

New FTA Anti Collision System

Over the past 12 months in the Bake Ovens, a project was carried out by Tomago Engineering to replace the old anti collision cameras on Bake Ovens 1, 2 and 3 FTAs and service cranes. This gives us a
more reliable, failsafe system, which requires minimal maintenance. A special thanks to Phil Weston and
Michael Mueller for all their efforts. Great work!

Story Submitted by : Martin Nicholls

Tomago - A Diverse Place of Work!

Tomagos Equal Employment
Opportunities!
With diversity continuing to receive a high
focus here at Tomago, women from across
different shifts have been getting together to
get to know each other and broaden their
networks.

Over the past 6 weeks we have held lunches to catch up with women across different
shifts on the plant. Its great to see that we
have more women working here now as apprentices, tradespersons and operators.
Its been important for us to ensure they are
fitting into the workplace, enjoying their work
and ensuring appropriate facilities are available. We are working on ensuring more female facilities are available across all departments.
As most of our female employees are fairly
new to site, its been great for them to meet
other women here on site in support roles
such as Administration, HR, Payroll, Health
& Safety.
Story Submitted by : Kristy Baldwin

Rotary Breaker Change out Success

The Rotary Breaker in the Rod Shop was identified
as requiring urgent repairs and was coordinated to
be removed in six days. The removal was organised through Major Maintenance, Worley, Rig and
Temco. The Rod Shop sourced a temporary crusher unit to continue to operate the Bath Handling Facility.
Support from Instant Access and the Filter Maintenance Team helped erect a large enclosure around
the temporary crusher to minimise the release of
bath dust. Unfortunately the bath stocks did not
perform as anticipated and everyone onsite was
engaged to innovate and create methods of crushin screening the product and also speeding up the
ing bath.
process.

A temporary conveyor feeder was setup to feed additional product into the bath processing circuit.
Paul James and the Rod Shop Team designed and
manufactured a chute to eliminate product spillage
on the tail of BS4 conveyor.
Once again thank you to all Departments for staying in touch and supporting one another to successfully reinstate the Rotary Breaker, a massive
effort by everyone!
LMO, Carbon, and the Environment Teams got together to coordinate pacman bath deliveries from
the Potlines and an additional storage shed was
temporarily provided to store the product. Thanks to
the Bake Ovens for the temporary storage of product in the brick bunker.
The Environment team quickly engaged Regain
Services to start pre-crushing the bath stored in
Warehouse 3 and this product was fed back into
the silos.
LMO Services Department and Carbon worked
together to introduce material at the missing Rotary Breaker (BS7) and
also manually loading a
crush bath tanker proving advantageous. This
effectively reduced
offsite storage of under
pot material, basement
under pot material and
the onsite storage at
Warehouse 3, while raising silo stock levels. The
team improved the process safely and addressed manual handling
issues, one being a
screening tool, totally eliminating the manual efforts

Story Submitted by : Simon Bowles & Ben Heil

New Micros Deliver Improved Environmental

Performance & Reduced Risk to Operators
When we talk about our environmental &
safety performance being our Licence to
Operate, its fair to say that Tomago is investing in exactly the right areas to ensure a
strong future for the plant and our people.

With the support of Downer Electrical and Programmed Services, the Liquid Metal Process &
Automation teams, together with our Engineering team, have successfully installed the remaining 500 APM1 pot micro controllers over
the past 6 months.
Our old Sycolog controllers were becoming obsolete and spare parts were no longer readily
available. To ensure the lowest risk to the process was maintained, an investment of almost The November results for our key anode ef$7 million was made to purchase and install the fect and greenhouse gas emission performance indicators were the best Tomago has
new pot micros.
ever seen with the seconds over 8 volts
Another important factor in making such a large down to only 6.08 seconds..A new Tomainvestment was the improved alumina feeding go record!
logic the controllers provided.
Thank you to all involved in installing the miThis logic not only significantly decreases the
cros, and to all our operating teams who work
overall number and size of anode effects, it al- tirelessly to treat and minimise anode effects.
so improves cell current efficiency. There are
now fewer anode effects that need to be manually treated, significantly reducing risk to operators.
Story Submitted by : Michelle Whyte