Case Study 1
Machine Type:
'Gove' Type Ship Loader
Facility:
RG Tanna Coal Terminal, Gladstone
QLD, Australia
Capacity:
6,000tph into Cape Size vessels (55m beam)
Machine Name:
RG-Tanna SL3
Material:
Coal
Description:
Shuttling chute, high Luffing boom, long travelling
Commissioned:
2007
Client:
Central Queensland Ports Authority
PROJECT SUMMARY
To achieve a major upgrade for the RG Tanner Coal Terminal, two existing ship loaders were upgraded from 4,000tph to 6,000tph, and a complete new ship loading stream was constructed. On the strength of having designed the previous ship loader at the facility, Mayer International was selected to undertake engineering design, technical supervision and commissioning for both the upgrades of the existing machines and the installation of a new 6,000tph ship loader needed for the new stream.
The new machine was designed to comply with AS4324.1, the Australian Standard for bulk handling machines, which had been introduced since the commissioning of Ship Loader 2. The design process additionally took a modern risk assessment based approach, which is not yet part of that machine standard, and introduced safety design and Safety PLC technology to the electric control system.
THE PROJECT INCLUDED:
Structural Analysis: Evaluation of machine strength, serviceability and stability to AS4324.1.
Fatigue Analysis: Evaluation of peak stresses for nominal fatigue life capacity as indicated in AS4324.1 and AS4100.
Design Risk Assessments and HAZOP.
Detail drawings for all structural and mechanical parts, generally in the form of detailed assemblies, including material lists (cutting lists), Drawing index, reference structure for arrangements and detailed drawings.
Pre-commissioning Audit of Machine: Detailed and comprehensive Mechanical and Structural Audit to AS4324.1.
Preparation of tender documentation, Evaluation of expressions of interest and recommended list of invitee, Issue of tender documents to invited bidders, Evaluation of bids and recommendations.
Technical supervision of Construction.
Additionally, similar work was done for the upgrade of existing ship loaders (1 and 2) to match the capacity of the new ship loader.
Case Study 2
Machine Type:
'Gove' Type Ship Loader
Facility:
RG Tanna Coal Terminal, Gladstone
QLD, Australia
Capacity:
6,000tph into Cape Size vessels (55m beam)
Machine Name:
RG-Tanna SL2
Material:
Coal
Description:
Shuttling chute, high Luffing boom, long travelling
Commissioned:
1994
Client:
Gladstone Ports Authority
PROJECT SUMMARY
To double its capacity, the Gladstone Ports Authority (now the Gladstone Ports Corporation) developed the Clinton Coal Terminal by adding a second ship loading stream. HMIDE, now Mayer International, was selected to prepare the design and detail design documentation for a new 4,000 tph ship loader with a design based on the existing ship loader but exhibiting a variety of design improvements.
THE PROJECT INCLUDED:
Structural Analysis: Evaluation of machine strength, serviceability and stability to ISO5049.1.
Fatigue Analysis: Evaluation of peak stresses for nominal fatigue life capacity as indicated in SO5049.1 and AS4100.
Detail drawings for all structural and mechanical parts, generally in the form of detailed assemblies, including material lists (cutting lists), Drawing index, reference structure for arrangements and detailed drawings.
Technical support during Construction.
Case Study 3
Machine Type:
Luffing Coordinate Stacker
Facility:
Millennium Coal Mine
QLD, Australia
Capacity:
2 x 1,700tph Stackers onto 250,000 tonne stock pile
Machine Name:
Millennium 1 and Millennium 2
Material:
Coal
Description:
Luffing boom, long traveling with offset yard conveyors and tripper on shared rails
Commissioned:
2005
Client:
Millennium Coal Pty Ltd, now Peabody Pacific Pty Limited
PROJECT SUMMARY
The development of a coal preparation plant was awarded to ACT. A critical component in the daily operation of the coal preparation plant are two 1,200 tph product coal stackers. Mayer International, then HMIDE, was engaged to design, develop detail design documentation and design audit these stackers.
THE PROJECT INCLUDED:
Structural Analysis of stacker structure for stress and buckling to AS4324.1.
Fatigue Analysis: Evaluation of structural stresses for nominal fatigue life capacity as indicated in AS4324.1 and AS4100 or alternatively BS7608.
Mechanical analysis of stacker components for stress and serviceability to AS4324.1 and/or AS1418.
Structural and mechanical detailing in the form of detailed assemblies, including equipment designations and material lists.
Pre-commissioning Audit of the stacker (mechanical and structural components) to AS4324.1 and Commissioning
Case Study 4
Machine Type:
Luffing Coordinate Stacker
Facility:
Goedgevonden Colliery (GGV)
Republic of South Africa
Capacity:
1 x 1,600tph and 1 x 2,200tph Stackers onto 250,000 tonne stock pile
Machine Name:
GGV Primary and GGV Secondary
Material:
Coal
Description:
Luffing boom, long traveling with offset yard conveyors and tripper on shared rails
Commissioned:
2009
Client:
Xstrata Coal South Africa
PROJECT SUMMARY
The development of a new coal mine was undertaken by Xstrata Coal South Africa in Alliance with ARM Coal. A critical component in the daily operation of the coal preparation plant are two stackers for two grades of product, export coking coal and domestic thermal coal. Mayer International was engaged to complete a design, supply and construct contract under EPCM terms, The machines' design focused on the existing, well performing design of Xstrata's Mt Owen Mine in the Hunter Valley of NSW, Australia.
THE PROJECT INCLUDED:
Full structural and mechanical detailing in the form of detailed assemblies, including equipment designations and material lists.
Mechanical analysis of stacker components for stress and serviceability to AS4324.1
Structural Analysis of stacker structure for stress and buckling to AS4324.1.
Fatigue Analysis: Evaluation of structural stresses for nominal fatigue life capacity as indicated in AS4324.1 and AS4100.
Evaluating Machine structural stresses to AS4324.1 for strength and buckling capacity.
Complete EPCM supply, construct, commission, Mayer International used our operations in RSA to complete the turnkey supply contract using the best of local talent and international products.
Pre-commissioning Audit of the stacker (mechanical and structural components) to AS4324.1
Case Study 5
Machine Type:
Overburden Spreader
Facility:
Mae Moh
Thailand
Capacity:
12,500 tph
Machine Name:
Overburden Spreader
Material:
Overburden
Description:
Crawler mounted, slewing and luffing spreader
Commissioned:
1989
Client:
Client Electricity Generating Authority of Thailand
PROJECT SUMMARY
The Mine connected to the power station facility required a overburden disposal system to support its 3,500 tph finished coal facility. The HMIDE design (now Mayer International), resolved this problem with a 65m boom, 3 stage drag conveyor system and featured a Slewing deck to allow the machine to spread material on both sides.
THE PROJECT INCLUDED:
Full structural and mechanical detailing in the form of detailed assemblies, including equipment designations and material lists.
Mechanical analysis of stacker components for stress and serviceability to BS7608
Structural Analysis of stacker structure for stress and buckling to BS7608.
Fatigue Analysis: Evaluation of structural stresses for nominal fatigue life capacity as indicated in BS7608.