MINING BROCHURE WORLDWIDE HEAVY TRANSPORTATION AND LIFTING

Transcription

1 MINING BROCHURE WORLDWIDE HEAVY TRANSPORTATION AND LIFTING

2 TOGETHER, WE ARE... Our people are at the heart of ALE s business: dedicated professionals who work with our clients to achieve the very best results. How do our people make us smarter? Because we employ imaginative people in every aspect of our business. People who work together to challenge the conventional, develop innovative solutions for complex problems and push the boundaries to make the unworkable work. ALE is a responsible business with a strong moral core. From the people who make up the ALE team, to the clients we work for across the world and the local community whose daily lives we may impact, the safety and well-being of these individuals and their environment is our most important concern. This ethos permeates every aspect of our business. By taking collective responsibility and working together to mitigate risk in every project we undertake, we can build a safer future. CONTENTS 04 Overview 06 Mining Operations and Process Facilities 08 Maintenance 12 Material Handling 18 Turnkey 20 Front End Engineering & Design (FEED) 21 Risk Management in ALE through HSQE 24 Sectors 25 Services 26 Equipment 27 Innovation Series We haven t become one of the world s foremost experts in heavy transportation and lifting by thinking small. By investing in the latest technologies and employing the best people in the business, we ve grown over more than 30 years, earning the fundamental reputation as a global leader across a breadth of sectors and markets. No matter the size or scale of a project, our people take a flexible approach that our clients can depend upon to deliver a bespoke and agile service unique for them. Our people work together to create innovative solutions, to achieve the unachievable and ultimately make it happen. 2 Together, we are Smarter, Safer, Stronger 3

3 OVERVIEW The mining sector is a key area for ALE and we provide a variety of techniques and services to address different mine development and operational challenges. With vast experience in mining projects and the engineering expertise to allow clients to explore more cost-effective construction methods and mining operations, ALE can provide complete solutions to the challenges faced in this industry. An appreciation of the control of loads and their distribution, a fleet of Self-Propelled Modular Trailers (SPMTs) and cranes, proven expertise in lifting, skidding and jacking techniques and meticulous project management means we are well equipped to move enormous structures with minute precision. ALE is always looking at innovative solutions and designing bespoke equipment to ensure that the best result for the client is found, this innovative thinking and close working with the client can often change the project to save on time and costs. 4 Together, we are Smarter, Safer, Stronger 5

4 MINING OPERATIONS AND PROCESS FACILITIES ALE has the transport equipment and experience to execute the movement and on-site relocation of modularised plant components and mobile mining plant and equipment. This typically includes manoeuvring crushers, conveyers, excavators, draglines and other process equipment when the mine or process facilities are being expanded or relocated according to the mining strategy. Our innovative equipment fleet allows us to reduce downtime of the tracked plant and relocate items safely between locations and provide cost savings on road preparation and maintenance. We also have the innovative solutions to work within confined spaces and to industry-leading safety standards. 6 Together, we are Smarter, Safer, Stronger 7 7

5 MAINTENANCE ALE has the specialist lifting equipment to perform on-site maintenance of different mining plant and equipment. Our high capacity cranes, lift n lock lifting systems and jacking systems are a more favourable option to traditional mobile jacking systems as mobilisation costs are reduced and safety risks are mitigated as loads are statically supported, alleviating any risk of working under suspended loads. Our unique and innovative Mega Jack, Mega Jack 800 and Mega Jack 300 systems provide a quicker and safer option as they are remote-controlled and minimise personal interaction and manual handling. 8 Together, we are Smarter, Safer, Stronger 9 9

6 Maintenance CASE STUDY Transportation and installation of flow enhancement hoppers, Australia OVERVIEW: ALE has completed the transportation and installation of two 145t hoppers for the TLO Fines Flow Enhancement Project in Western Australia. SERVICES REQUIRED: The hoppers had to be transported from a storage position of 1,100mm stool height, which was located 100m from the foundations, along a sloped path. The transport also included a 90 carousel to align the hoppers to the foundations. A multiple lashing system ensured the stability of the system for stand-by, including storm and wind issues, as well as for service condition. Spirit levels were installed to monitor the levelling of the assembly. The installation assembly was designed to minimise the work at height and other typical risks related to lifting operations. To provide the flexibility and manoeuvrability needed, ALE used 24 axle lines of SPMT in a 2 x 2 file 12 configuration to transport the hoppers. ALE used a lift n lock system mounted onto the trailers to install the hopper. ALE had to overcome the challenges of operating in a live BHP mine site, complying with very strict safety and environmental requirements. There was limited ground preparation permitted (levelling and compaction), due to the short time of the shutdown. Flexibility was needed to accommodate a limited site area and many interferences with other contractor activities. There was no allowance for the installation of tracks onto the ground, beside the foundations, because of the interference with the client activities on the foundations of the hoppers. Subsequently, the hoppers were installed just under the existing conveyor in a very small installation area. This avoided the use of any crane for the installation and the derigging of the hoppers. This was the first time this methodology had been executed so efficient engineering and operational experience was needed to obtain the permit to proceed from FAST and BHP. The hoppers, with approximate dimensions of 11m x 9m x 4m, were installed at ground level within the 10mm tolerance. The installation of both hoppers was safely performed within the client s timeframe, without any impact on the surrounding activities. ALE only had 48 hours only to complete the two installations and to leave the installation area. Each hopper was picked up, transported, positioned and derigged in a single shift. 10 Together, we are Smarter, Safer, Stronger 11

7 MATERIAL HANDLING ALE has a proven track record of installing, relocating, or decommissioning of heavy stock piling and handling of port infrastructure and components, such as stackers, reclaimers and shiploaders. ALE has a global fleet of equipment, with some of the most advanced SPMTs and cranes, to enable the safe and successful transportation, lifting and assembly of mining components at ports. CASE STUDY Transportation of a crusher, Chile OVERVIEW: ALE has completed the transportation of a crusher, weighing 720t, at Minera Escondida, near Antofagasta, Chile. SERVICES REQUIRED: The crusher was loaded onto 36 axle lines of SPMT in a configuration of 6 file 12. ALE transported the crusher a total of 6km on SPMTs. During the move, ALE overcame steep up-hill and down-hill gradients. At certain points on the route, ALE transported the crusher on an up-hill gradient of approximately 11.4% and down a slope of 12%. The manoeuvres took approximately five hours to complete. 12 Together, we are Smarter, Safer, Stronger 13 13

8 Material Handling CASE STUDY Excavator move, Australia OVERVIEW: ALE has successfully transported a 6060 excavator, weighing 570t, over 12km at the South Walker Creek Mine, near Strathfield in Queensland. SERVICES REQUIRED: ALE was also required to provide and lay-out the load-spreaders, mats and wedges. These enabled the loading and offloading of the excavator at both ends. ALE positioned the mats in the morning, before positioning the excavator on top of the mats. The excavator was then positioned on top of 27 axle lines of SPT and the loading platform was raised. The trailers were prepared for the move by lashing. The excavator was then transported over a distance of 12km over three hours. Once in position, the excavator was offloaded and ready for work. The move was completed within one working day. CASE STUDY Transportation of stacker and reclaimer modules for the Nammuldi mine project, Australia OVERVIEW: ALE received and transported 190 stacker and reclaimer modules as part of the Nammuldi mine expansion project. SERVICES REQUIRED: As part of the expansion of the Nammuldi iron mine, 190 modules were received at Port Hedland in two shipments between November 2013 and January Some of the modules have been received from the ship cranes directly on the road trailer arrangements, while some others have been received on self-propelled trailers and stooled-off at the port laydown. For most of the major modules, dedicated transport grillage had to be designed and checked by ALE engineers; the steelwork design for some items had to consider also the need for stooling off. The modules were then transported by road 500km from the port of Port Hedland to its final destination at Nammuldi mine site, where they would be assembled. A total of 20 steel beams and 60 steel stools were used to transport and store the modules. 42 of the modules measured up to 52m long, 10m wide, 7.5m high and weighed 150t. Because of the size, these were subject to road transport restrictions and the convoy required a pilot and a main road traffic warden escort. The biggest movement was of the 150t reclaimer boom, which measured 72m long, 7.4m high, 9.5m wide and weighed 297t gross mass. To move the boom, ALE utilised two prime movers, 18 axle lines of conventional trailers and 18m of deck spacers. The last of the counterweights and small cargo was delivered in early April Together, we are Smarter, Safer, Stronger 15 15

9 Material Handling CASE STUDY Transportation of an electric shovel, Australia OVERVIEW: ALE has successfully transported a 1,400t electric shovel within the Bowen Basin area of Queensland, Australia. SERVICES REQUIRED: The 1,400t electric shovel was moved approximately 35km using 54 axle lines of SPMT. As the onsite transportation had to be scheduled around the removal of powerlines to adjoining mines, ALE needed to ensure there was a swift turnaround by utilising the most time-effective method of relocating the electric shovel. ALE completed the transportation in seven days while overcoming the challenges that are part of working on an operating mining site. Movements of this nature, involving large mobile plant on SPMTs, results in significant savings in maintenance of the running gear of the plant and in down-time of high-value equipment on operating mine sites. CASE STUDY Jacking, transportation and load-out of two autoclaves, New Caledonia OVERVIEW: ALE has successfully performed the jacking and transportation of two autoclaves, weighing 605t each in New Caledonia. SERVICES REQUIRED: ALE first loaded the autoclaves onto the SPMTs at the New Caledonia storage site, using the SPMTs hydraulics to jack them up ready for onward transportation. The autoclaves were then transported from New Caledonia to the Port of Prony jetty using 72 axle lines of SPMT. The 3.8km route was particularly challenging as it involved travelling over 2km on a 10% gradient descent. They were then loaded-out onto a heavylift vessel, along with the SPMTs, and shipped to Port Pirie in South Australia. Once they arrived at the port, ALE loaded-in the autoclaves using the same SPMT configuration and transported them into storage. It took approximately one month to complete. 16 Together, we are Smarter, Safer, Stronger 17

10 Material Handling TURNKEY CASE STUDY RGP6 Jimblebar mine project in Port Hedland, Australia ALE is a full solutions provider and the turnkey service includes full engineering assessment and design of any bespoke lifting equipment. Our extensive equipment fleet and experiences means we are a one-stop-shop and have the capabilities to execute projects from start to finish, from barging and handling modules at the port, and the transportation to site, to the on-site manoeuvres and installation. OVERVIEW: ALE were tasked with the receiving, storage, and land transportation of 230 modules, with weights ranging between 5t and 240t. SERVICES REQUIRED: The 230 over-sized and over-mass modules were used to construct the RGP6 Jimblebar Iron Ore project. Fabricated in China, these modules were shipped from Tianjin to Port Hedland, Western Australia. The 230 modules were received in over 11 shipments, with the first received in June 2012 and the last modules were delivered to site in Newman by late February The modules were received on SPMTs at Port Hedland Port Authority (PHPA), before being transported within the PHPA grounds and set on stools to await ground transportation on conventional trailers. Configurations of both SPMTs and conventional trailers was dependent on each modules dimensions and weight the latter to accommodate for Western Australia s axle-loading restrictions. The largest module was 42.5m long, 13.5m wide, 14.5m high and 227t in weight and the largest trailer configuration comprised of a 4 file 28 row (6.3m wide, 42m long). Transportation from Port Hedland to the Jimblebar Mine site (totalling 450km) was split into four segments, each requiring one night of travel time. The first of which saw the modules (one per trailer) travel in convoy from Port Hedland to Boodarie a staging area located 25km outside of Port Hedland. From here convoys to the Jimblebar site are formed, with the highest priority items given precedence in earlier convoys to site. As public roads were utilised for ground transportation, and Western Australia law states that cargo over 8.5m wide cannot travel during daylight hours, ALE organised and conducted night-time convoys within a rolling road-block under the guidance of Police Traffic Escorts. ALE faced the challenge of reserving and obstructing public roads and required the cooperation of multiple public stakeholders and external bodies. ALE had to work alongside various transport companies to determine suitable transport dates and road- access into and out of the world s largest bulk export harbour every night a convoy took place on the road. The route also had to negotiate multiple railway crossings of various mining companies in a prompt manner as to not cause delay to their deliveries. ALE had a dedicated SPMT crew located at the Jimblebar site on a full-time basis, equipped with 40 axle lines of SPMT trailers and 12 axle line of compatible spacer decks. As modules were placed on stools upon arrival at Jimblebar, SPMTs then transported the modules to various site locations sometimes up to 5km in distance. 18 Together, we are Smarter, Safer, Stronger 19

11 FRONT END ENGINEERING & DESIGN (FEED) With a pedigree in innovative engineering and an active R&D facility, ALE has always been known for developing new solutions to meet future needs. In other market sectors ALE is actively involved in the FEED process. Over the years we ve added to our world-class engineering skills-base through the acquisition of several successful specialist companies, and now we have more than 200 highly qualified engineers working at locations across the globe. This experience means we re well equipped to support the full FEED process, working through complex technical and logistical issues at an early stage to eliminate expensive changes later on. Our FEED capabilities form a crucial part of the service we offer. ALE has contributed to many high profile projects that have been right at the forefront of global trends in their sector. We are able to adapt to ever-changing industry requirements, evolving safety standards and scope changes as the project gathers definition during the design process, while at the same time providing solutions which are as cost-effective and safe as possible. As a result, we re able to work closely with our clients from an early stage to establish what s required and provide practical engineering advice. This advice can lead to savings later, either in time or cost, as the changes are included in the design phase, instead of modifications later. Some of our FEED services typically include, but are not limited to, the items below: Physical route surveys to determine maximum practical equipment weight and dimension information Investigation of environmental conditions affecting the heavy lifting and transport discipline Road layout and route improvement studies Advice on local regulatory issues relating to the movement of large and indivisible loads to the job site Equipment lifting and installation studies to determine the most cost and schedule effective methods of sizing and placing equipment Design of rigging and lifting equipment Outline design of new build site construction jetties Selection of optimum shipping methods and identification of suitable vessels or barges Logistical studies to ensure that transportation and installation scope support the project schedule Design and input to design of transportation support steel and lifting and lashing/securing points Assistance in modularisation studies to determine the maximum practical extent man hours can be removed from the job site 20 Together, we are Smarter, Safer, Stronger 21 21

12 RISK MANAGEMENT IN ALE THROUGH HSQE We recognise that the industries and sectors that we operate in present challenges in terms of managing risk. Our passion is fuelled by our history and foundation in protecting our people, environments and assets all over the globe. ALE is cemented in a context of over 30 years of evolving Risk Management though maturing legislation, international standards and client requirements. We as ALE see the value in a safer working environment for all and we want to capitalise on our history and better mitigate industry risks. By investing in our constantly evolving internal infrastructure, we are able to maintain our competitive advantage with industry leading initiatives that allow us to implement and use breakthrough tools to identify, assess and act upon all levels of risk to our people, environments and assets. This has given us the ability to identify areas that require attention as well as nominate single areas of concern to target resources. ALE are committed to lead the industry and influence all of our clients and subcontractors in a united approach to achieving an incident and injury-free mindset. In order to achieve this, we have developed and adopted many of the leading systems and processes that are seen as industry best practice and available techniques. We have ensured that our core systems which shape the way we operate are certified and proven to comply with ISO 9001 and , as well as OHSAS ALE know that it is imperative to not only attain the certification but to also have a robust assurance process in place to ensure that the standards are met and maintained. At ALE, we realise that this journey is not to be taken in isolation, therefore we stand by the fact that together we are safer. 22 Together, we are Smarter, Safer, Stronger 23 23

13 SECTORS SERVICES CIVIL MINERALS & METALS NUCLEAR BALLASTING CRANE LIFTING ENGINEERING JACKING OFFSHORE OIL, GAS & PETROCHEMICAL PORTS LIFTING SYSTEMS LOAD-IN & LOAD-OUT LOGISTICS MARINE ENGINEERING POWER GENERATION RENEWABLES SHIPYARDS OFFSHORE INSTALLATION SKIDDING TRANSPORTATION TURNKEY OPERATIONS WEIGHING 24 Together, we are Smarter, Safer, Stronger 25

14 EQUIPMENT INNOVATION SERIES CRANES SKID SYSTEMS WEIGHING SYSTEMS SPECIALIST CRAWLER MOBILE TRANSPORTATION BALLAST SYSTEMS JACKING SYSTEMS MEGA JACK AL.SK CRANES ALL TERRAIN TRANSPORTERS GIRDER FRAME MODULAR TRAILERS BARGES AUXILIARY, ANCILLARY & ACCESS EQUIPMENT SPMT SPT HYDRO DECK MEGA JACK 800 LIFTING SYSTEMS 26 Together, we are Smarter, Safer, Stronger 27

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