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Sinclair Knight Merz undertook the feasibility study, engineering design, procurement, construction management (EP CM) and commissioning for up-rating two iron ore shiploading systems at Nelson Point from a nominal 7,500 t/h to 10,000 t/h capacity. The work was carried out to enable iron ore carriers to be loaded faster, to reduce maintenance and improve plant availability.
The work carried out by SKM included engineering for 16 conveyors of up to 650 m in length, 1.8 m wide, 1,050 kW drive, and 4.9 m/s belt speed. Included were two luffing boom conveyors, two trippers, four shuttle head conveyors and two sample cutters.
Conveyor up-rating was generally achieved by belt speed and power increase involving cascade remanufacture and up-rating of original gearboxes to ‘new’ warranted condition, in parallel with cascade overhaul and replacement of existing motors. One 90 m long 1.5 m wide conveyor, which was partially underground, was completely dismantled and rebuilt as a 1.8 m conveyor, with all new fittings and loading arrangements.
The project was a management challenge because of the high cost of down time with a major export facility of this size handling 40 Mt/a of ore, the paramount importance of safety in operating plant and the need for interstate cascade remanufacture of major drive plant.
The client’s shiploading operation was shut down for only three days for implementation, with scheduled partial restrictions managed to coincide with shipping needs and limited to a total of 28 days. The A$15 million project earned commendations from the Institution of Engineers Australia and the Association of Consulting Engineers Australia.
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