N E W S R E L E A S E from FURMANITE AUSTRALIA
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Specialist on-site expertise keeps massive dragline upgrade on-schedule
Specialist on-site machining expertise from Furmanite enabled vital work on a massive dragline at an open cut coal mine in the Bowen Basin, Queensland, to be undertaken on-site, within a minimised time window, as part of a major dragline upgrade project.
The project, undertaken at the BHP Billiton Mitsubishi Alliance (BMA) operated Blackwater mine by field maintenance alliance partner Transfield Services, involved upgrade work to the drive and hoist motors and gearboxes on a Bucyrus 2570 walking dragline, to optimise the dragline efficiency. Bucyrus walking draglines are able to reach depths of 65 metres. The 2570 model features a bucket capability of up to 138 cubic metres, with a boom length of up to 128 metres, and has a maximum working weight of 7,271 tonnes.
Furmanite, the technical services company geared to maximising asset uptime and renowned for its specialist in-situ machining expertise, was engaged by Transfield Services to machine all hoist and drag motor gearbox bases and the propel motor bases on the massive machine. These had to be precisely machined to within tight tolerances to facilitate the installation of new motors and gearbox units which are an integral part the upgrade.
Some 40 mounting pads ranging up to 7.8 metres by 1.6 metres in size had to be machined, to a demanding tolerance of +/- 0.1mm at a surface finish of Ra1.6µ. Two scanning lasers were utilised to survey all surfaces to be machined prior to machine set up, and after completion of each machining operation, and were also used during the machining operation to ensure maximum accuracy.
The complex operation was undertaken by eight Furmanite technicians working day and night shifts, and in addition to meeting the challenging machining specifications the work also required considerable re-location and re-setting up of the X-Y milling machines to mount them in different positions and locations, according to the size and level of the pad being machined, which was facilitated by two overhead cranes within the machinery room of the dragline.
“The degree of specialist machining expertise required to achieve this successfully goes beyond most companies’ capability zone,” Furmanite sales manager Graeme Berry said. “Our technicians rose to the challenge, and completed the sizeable task (in every sense) within just 15 days, successfully meeting the requirement to complete the work inside the window of opportunity within the overall shutdown – a considerable feat that helped to keep the substantial upgrade project on schedule. This is typical of the services we offer, to help our customers minimise downtime and keep assets earning."
Commenting on the project Transfield Services engineering group general manager Trevor Cohen said: “The availability and reliability of this machinery is critical to BMA’s coal production schedule, and in maintaining its position as a leader in the international coal industry. As BMA’s long-term field maintenance alliance partner, Transfield Services is committed to ensuring these major upgrades are completed efficiently and effectively, and Furmanite’s expertise is a valuable contribution in helping us make this happen.”
With the lowest material removal cost and an average operating life of 40 years, draglines are claimed to be the most productive and versatile machine in the mining industry, with walking draglines used in many surface mining operations worldwide. BMA, Australia’s largest coal producer, operates one of the world’s largest dragline fleets, with 33 draglines and eight shovels in operation in the Bowen Basin. Blackwater Mine mines coal by open-cut methods, using seven draglines and two truck/shovel fleets.
NOTES TO EDITORS
BHP Billiton Mitsubishi Alliance (BMA) is Australia’s largest coal producer and a leader in the international coal industry. BMA is a 50/50 alliance between the world’s largest diversified resources company and the world’s largest general trading company. Combined its two owners employ more than 84,000 people and have operations in more than 80 countries. BMA is distinguished by the quality of its assets, its commitment to sustainable development, and support for the communities in which it operates.
Transfield Services is a leading international provider of operations, maintenance, asset and project management services. In addition, it owns, operates and maintains major infrastructure assets. It has more than 18,000 employees working across Australia, New Zealand, South Eat Asia, Canada, the United States and the Gulf Region in 11 diverse industries including: mining and process, hydrocarbons, roads, rail and public transport, water, power, telecommunications, facilities management and defense. Transfield Services Limited is publicly listed in Australia and included in the S&P/ASX 200 with a turnover of approximately $2.0 billion.
Furmanite, the technical services company geared to maximising asset uptime, is headquartered in Dallas, USA, with offices and service centres in Australia, Asia Pacific, USA, UK, Europe, Scandinavia, Caspian and the Middle East. It offers a wide range of on-site and on-line services and technologies to help industry operators around the world keep their assets earning, minimise downtime and maximise production efficiency. Services, all delivered by highly qualified multi-disciplined technicians, include on-line pressure leak sealing, pipeline intervention (hot tapping, line plugging and pipe freezing), on-site machining, on-line valve testing and repair, Pressurized Systems Integrity Management and controlled bolting, and composite repair, among others. The company also specialises in designing and developing bespoke engineered solutions to meet specific requirements.
For further press information contact:
Sarah Manwaring-White
Keep in Touch Ltd
Tel: +44 (0)1451 844 488
Email: sarah_mw@keepintouch.co.uk