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A part of BMT in Energy and Environment

Ports Materials Handling Capability Statement

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1 2 3 4 INTRODUCTION HEALTH & SAFETY QUALITY ASSURANCE PORTS & SHIPPING CAPABILITY
4.1 4.2 China Light & Power Audit, Design & Refurbishment India Port Developments 4.2.1 4.2.2 4.2.3 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18 Dahej Port Development Khambhat Port Development Mundra West Port Development

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TOLL Geelong Port Lascelles Wharf Lyttelton Port of Christchurch Coal Handling Facility Review PASMINCO Bulk Transfer Vessel Esperance Port Authority Shiploader OneSteel Whyalla Shiploader Life Extension CLP Grab Unloader Life Extension Project CLP Continuous Ship Unloader Project JICT Container Crane Life Extension BT Marine Spur Barge Sydney Ports Passenger Gangways Port Kembla Coal Terminal Shiploaders Redesign Crane Audit - Port Of Melbourne Crane Audit - Port Of Brisbane Crane Audit - Port Of Fremantle Crane Electrical Upgrade Port Botany Crane Spreader Modifications Port Botany

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INTRODUCTION
BMT is a leading international multi-disciplinary engineering, science and technology consultancy offering a broad range of services, particularly in the defence, energy, environment, shipping and general transportation sectors. Customers are served by a network that currently comprises 26 international subsidiary companies. Further details can be found at www.bmt.org. BMT WBM is an Australian subsidiary that was established in 1969 to provide specialist engineering and environmental consultancy services to a broad range of industries from offices in Melbourne, Brisbane, Newcastle, Sydney, Perth, Karratha, Vancouver (Canada) and Denver (USA). Our web site can be found at www.wbmpl.com.au for more detailed information. BMT WBMs team of engineers, scientists and technicians are highly qualified and collectively have vast experience in a broad range of fields. An open-minded approach enables BMT WBM to characterise root causes of problems and provide definitive solutions. The benefits of these services are improved quality, robustness, reliability and availability of machinery, greater safety, avoidance of unexpected operational problems, extended life and lower life cycle operating and maintenance costs. One of BMT WBMs particular specializations is the engineering associated with large materials handling equipment including bucketwheel excavators, stackers, reclaimers, ship loaders, ship unloaders, conveyors and conveying systems, mills, crushers, screens, draglines and mining shovels. As a highly experienced designer of this type of plant, BMT WBM has the technical expertise and experience to provide engineering services for projects involving this type of plant. Some of the services offered by BMT WBM include: Investigation services including design auditing, feasibility studies, due diligence studies, plant life extension, risk and hazard assessment. Project management for construction and overhaul, including complete refurbishment projects, Design of machinery and associated peripherals from concept through to the detailed design of individual components for manufacture. Our design engineering methodology involves finding a solution based on innovative thinking, knowledge and engineering expertise. Specialist electrical services including power reticulation design, control systems design and PLC programming, Procurement services including supply contract management, quality assurance in manufacture, etc. Technical support for projects including test and measurement services, commissioning, mine development technical services, BMT WBM has particular expertise in using specialist design tools for analysis and design, including finite element analysis, computational fluid dynamics, discrete particle modelling, fatigue analysis,

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conveyor analysis, etc. BMT WBM has experienced analysts to provide efficient and reliable analysis of problems and has developed in house software for complex state of the art analysis work in conveyor dynamics, free piston dynamics and hypersonic flows. Some of the work BMT WBM has conducted for various port clients have been briefly described in this capability statement. BMT WBM has been involved with both the industrial and commercial aspects of port equipment from shiploaders and unloaders to grab cranes and passenger gangways. Our capability not only focuses on engineering quality but also addresses aesthetics as in the case of the passenger gangways and environmental concerns with the design of spill chutes. From design to advice, BMT WBM can provide quality engineering services that would benefit day-to-day, short term and long term operations.

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HEALTH & SAFETY


BMT WBM is committed to maintaining the safety of its employees and sub-contractors and has many years of experience working in the ports and shipping industry for clients throughout Australia and abroad. BMT WBM personnel are familiar with the BMT WBM health and safety policy and are trained in the requirements of the BMT WBM Health and Safety manual. BMT WBM employs a dedicated safety officer in each office to maintain a culture of safety within BMT WBM and to ensure that procedures and documentation follow the requirements of our safety manual. The documentation includes records relating to safety equipment, safety apparel, permits, workplace safety, defect reporting, emergency procedures, first aid, etc. BMT WBM is extremely familiar with the induction requirements of various port sites and usually augments the client requirements with additional safety responsibilities for its employees and subcontractors.

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QUALITY ASSURANCE
BMT WBM has full third party Quality Assurance accreditation to AS/NZS ISO 9001:2000. Projects are executed under BMT WBMs Quality Assurance System, which is applied to ensure: Project management is organised, resource allocation is well managed and task deadlines are met; and Sub-contractors are required to adopt a compatible QA system that ensures their performance in meeting project performance, work quality and program objectives; and Technical investigations yield quality products designed and suited to meet the projects objectives. The QA system utilised by BMT WBM includes specific procedures for design, design review, project management, etc.

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PORTS & SHIPPING CAPABILITY


4.1 China Light & Power Audit, Design & Refurbishment
BMT WBM were commissioned by China Light and Power (CLP) Hong Kong, to carry out a detailed audit of the complete coal handling conveyor system. The project was broken down into several stages, including:

Detailed inspection and testing of conveyors (around 42 off) with audit report recommending actions required to extend the operating life for a further 20 years,

Detailed design of all conveyor transfers, (over 80), incorporating improved transfer, sealing, new impact arrangements, anti-corrosion materials etc, Rationalisation study for pulleys and detailed design of new pulleys for each conveyor, Selection and nomination of appropriate belt and pulley cleaning equipment, Review and design of dust suppression spray systems for conveyor transfers, Preparation of detailed technical specifications for the refurbishment of all the conveyors, transfer houses and supporting structures. Review of tenders for the refurbishment work. Staged audits of the refurbishment work, preparation of audit reports including detailed outstanding works lists. BMT WBM were commissioned by China Light and Power (CLP) to carry out two significant design and construction projects associated with their stacker reclaimer.

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The first project involved replacement of the machines main slew race and suspension ropes. The second project involved the complete refurbishment of the machine including: Design, supply and replacement of all chutes, Design, supply and erect new automatic lubrication systems, Repair of mechanical and structural damage and modification of belt profiles, Overhaul of the bucketwheel including redesign and replacement of the buckets and shaft, Design and installation of a complete new electrical and control system including new PLC and VVVF drive systems, Design, supply and installation of new travel drives, wheels and rail clamps, Overhaul of all other drives including the bucketwheel drive, Design, supply and installation of new conveyor components including idlers, pulleys, belt cleaners, pull wires, etc, Painting of the entire machine, Finite element analysis for life extension evaluation, Training of CLP Personnel. BMT WBM as prime contractor utilised local contractors in Hong Kong under the supervision of a BMT WBM site project manager to complete the project works on time and within budget.

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4.2

India Port Developments


BMT WBM in partnership with our BMT India office is participating in the development of a number of major port facilities in India. In these developments BMT WBM is providing services varying from design audit to complete engineering design of the materials handling plant. BMT India with other parts of BMT is providing detailed infrastructure design and vessel logistics investigations for the facilities.

4.2.1 Dahej Port Development


BMT WBM where engaged to completely review the conceptual and detailed design of the materials handling equipment for the Dahej Port Development. The work commenced with review of the master plan & port layout and then progressed to detailed mechanical, structural and electrical design review of the conveyor and stockpiling system, including dynamic analysis, power consumption analysis & optimisation. BMT WBMs review of the project identified a number of improvements that could be made in the plant design resulting in significant reduction in project capital cost, reduction in construction time and reduction in ongoing operation and maintenance costs. The work also included a complete

independent design review of the stacker reclaimers used for the stockpile system.

4.2.2 Khambhat Port Development


Khambhat Port is a new port being developed in India to serve the region and provide coal for the nearby Power Station. BMT WBM has provided the conceptual design of the port facilities materials handling plant which includes 6 grab unloaders, an extensive conveyor system and coal stockpiling system. The concept stage is now complete and we are now entering the engineering design stage.

4.2.3 Mundra West Port Development


BMT WBM provided a coal conveyor system concept design review. Findings have been made resulting in significant capital cost and ongoing operational and maintenance cost savings.

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4.3

TOLL Geelong Port Lascelles Wharf


A new multi-product bulk material handling and transit terminal has been built at Lascelles Wharf in Geelong for TOLL Geelong Port. The new 80,000 tonne storage facility, more than doubles the capacity of the existing terminal and consists of a storage building, feed conveyor system, automated stacker, reclaim system, and delivery conveyor system. Jordanian Sand and Nauru Rock, that are stored in the new building, are transported, via conveyor, to the adjacent PIVOT facility to be used in the production of fertiliser. BMT WBM were commissioned to assist in the preparation of the specifications and contract documents, evaluation of tenders, verification of the design, combined with construction supervision, and commissioning of this key facility. BMT WBM was seen as the logical choice, due to BMT WBMs vast design experience in electrical and mechanical aspects of materials handling projects both locally and internationally. The design of the new terminal includes strict measures to curtail the generation of airborne dust, to comply with Environmental Protection Authority requirements for emissions at the site. The new facility is totally integrated with the existing grab cranes, wharf conveyors and PIVOT fertiliser production facilities. The control and monitoring of the port side terminal is undertaken by a new CITECT SCADA system. The SCADA system interfaces with a series of SIEMENS Programmable Logic Controllers inter connected via a fibre optic network. Four new conveyors and an automated travelling stacker are the key elements of the material transport system. Retrieval of material from the storage shed is carried out by front-end loaders filling a series of purpose built hoppers that incorporate dust extraction equipment. The storage facility is equipped with National Standards Council Australia (NSCA) approved belt weighers and ultrasonic stockpile level equipment to provide a fully automated loading process.

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4.4 Lyttelton Port of Christchurch Coal Handling Facility Review


Lyttelton Port Company and Solid Energy engaged BMT WBM to provide an independent review of the coal handling system and associated plant. Coal is delivered by train and is then distributed to ships via mobile plant, a bucket wheel reclaimer, conveyors and a shiploader. Improvements were sought in the following areas: Operational efficiencies Ability to achieve required load-in and load-out rates Maximise stockpile capacity Minimise use of mobile plant, and Reduce the cost per tonne handling rate

BMT WBM provided a review which detailed equipment related inefficiencies, product handling characteristics and associated inefficiencies, and the inefficiencies in the facility layout. Recommendations to rectify the issues were provided to the client.

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4.5 PASMINCO Bulk Transfer Vessel


The Pasminco Century Zinc project has commissioned a 5,100 dwt self loading / self unloading transfer vessel, the M. V. WUNMA, to transport lead and zinc concentrates from Karumba, Queensland, to export vessels anchored in deep water in the Gulf of Carpentaria.

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BMT WBM were responsible for all of the materials handling plant design, including the mechanical, structural, electrical and controls details for 7 conveyors, a bucket wheel reclaimer, a load distribution gantry, a slewing, luffing discharge boom, the cargo hold enclosure and the ventilation and dust control systems. The mechanical and structural design was progressed in detail, producing fabrication and machine shop drawings. BMT WBM supervised the fabrication and construction of the materials handling plant in China and commissioned the plant. The controls system PLC software was written, installed and commissioned by BMT WBM personnel. BMT WBM currently is contracted to Intercontinental Ship Management (ISM) to provide on-going engineering and technical support for the plant.

Bridge Type Bucket Wheel Reclaimer

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4.6 Esperance Port Authority Shiploader


BMT WBM were retained by Esperance Port Authority (EPA) Western Australia to undertake a complete independent structural design review of a new iron ore shiploader. Areas audited included all primary and secondary structures and all critical mechanical connections effecting the strength and stability of the plant. BMT WBM has since been retained by EPA, to conduct the mandatory shiploader annual structural inspections and to act as their prime consultants regarding all technical advice for their shiploaders and other general materials handling plant.

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4.7 OneSteel Whyalla Shiploader Life Extension


BMT WBM was engaged by Thiess to provide design services for the refurbishment of the OneSteel shiploader located in Whyalla, South Australia. The existing 40 year old shiploader with inherent constraints and limitations was refurbished to achieve an operable and maintainable asset to current standards and expectations. BMT WBM provided both mechanical and electrical design services to increase performance of the plant whilst simultaneously addressing environmental issues.

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4.8 CLP Grab Unloader Life Extension Project


BMT WBM were commissioned by China Light and Power Hong Kong, to carry out a detailed audit of two grab unloaders and provide design recommendations for a twenty year life extension. The project included:

Detailed inspection and audit report recommending actions required to extend the operating life for a further 20 years,

Detailed measurement of machine structures, (no drawings available), to enable structural model to be developed,

Structural modelling of the grab unloaders using I-DEAS finite element modelling software, and fatigue analysis using in-house developed software. Design of structural repair and reinforcement procedures Detailed design and preparation of specification for new PLC control system for the grab unloaders.

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4.9 CLP Continuous Ship Unloader Project


BMT WBM were commissioned by China Light and Power Hong Kong, to carry out a detailed design review of two continuous ship unloaders.

The project included: Review of conceptual design (mechanical, structural & electrical) and specifications Review of all calculations including FEA analysis Inspection at the manufacturers works Review and finalisation of conceptual design at manufacturers premises Risk assessment Review of mechanical and structural calculations & drawings Review of electrical details

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4.10 JICT Container Crane Life Extension


JICT operate three Noell container cranes which were 12 years old and in need of some refurbishment. BMT WBM was engaged to provide refurbishment design solutions to extend the life of these machines. The scope of works included: Main hoist drum redesign by splitting the one piece drum and incorporating a centralised gear reducer Rear hoist rope sheave redesign to split the rope fleet angle Rear access maintenance rail design to achieve access to rear sheaves for maintenance purposes Boom latch design review and works proposal Boom pedestal design review and works proposal Boom hoist slack rope detection device and installation drawing Trolley drum, brake and rope tensioner review and works proposal Trim list and skew works proposal to bring the system back to an acceptable operation level

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4.11 BT Marine Spur Barge


BMT WBM was commissioned to provide concept design and detailed design services of the materials handling plant mounted atop a barge for BT Marine through PTINDOSTRAITS. The design incorporated a moving bridge structure, transfer conveyors, hoppers and a discharge boom with both slewing and luffing controls. BMT WBM provided all the mechanical, structural, electrical and controls design. Finite element analysis was conducted that assessed many different load cases provided by the barge design and its response to wave data and also for hopper design.

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4.12 Sydney Ports Passenger Gangways


Sydney Ports is now using a new passenger gangway with a unique additional safety system. The new gangway design was developed by BMT WBM Pty Ltd to meet Sydney Ports requirements for enhanced safety and performance improvements, and to provide greater flexibility in the use of a single gangway on a variety of ships.

Sydney Ports initially contracted BMT WBM to redesign the telescopic bridge sections of the existing gangways. After a review of the existing gangway systems, BMT WBM was commissioned to design a complete new gangway. The gangway bridges are hooked onto the ships coaming, and chains are attached to secure the gangway to the ship.

The unique feature of the new design is the secondary support system that provides a back up support for the gangway bridge. This new gangway design received a highly commended distinction in the category of Innovations & Inventions, Research & Development during the 2003 Sydney Engineering Excellence Awards.

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4.13 Port Kembla Coal Terminal Shiploaders Redesign


Following a skew-induced collapse, BMT WBM were commissioned to redesign the main bridge structures and all of the front equalisers and bogies of the two shiploaders at Port Kembla Coal Terminal. In addition, BMT WBM supervised the fabrication and structural rectification works.

As follow on activities, BMT WBM subsequently redesigned the complete boom hoist system, the shuttle drive system, and the long travel control systems.

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4.14 Crane Audit - Port Of Melbourne


BMT WBM engineers were engaged by CONAUST to carry out a condition audit of two 28 year old Container Cranes for at Swanson Dock in the Port of Melbourne. The audit comprised a detailed mechanical, structural and electrical inspection of the crane and then a detailed evaluation of the findings. The audit formed part of a long term strategy for the container operation and required that the two cranes be assessed, to assist them in reaching a decision to either extend the life of the cranes through refurbishment or alternatively to retire the cranes. The two cranes were originally planned for a 30 year life span. The audit included the preparation of a condition report for the cranes highlighting the areas of the crane that posed an immediate risk to operators. Priorities for immediate, short term and long term action were identified to enable CONAUST to plan refurbishment of the machines. The audit report comprised photographs and diagrams of problem areas and included detailed recommendations for remedial works.

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4.15 Crane Audit - Port Of Brisbane


The Port of Brisbane Authority engaged BMT WBM to undertake a condition audit of two of their container cranes operated by CONAUST at Fishermans Island, in Brisbane. The audit comprised a detailed mechanical, structural and electrical inspection of the crane and then a detailed review of the crane including life assessment. The audit team considered the structural, mechanical and electrical elements which would cause significant disruption to the operation of the crane in the event of a failure or malfunction. WBM also undertook to report on issues of safety. Finite Element Modelling And Fatigue Life Detailed modelling and finite element analysis was used for fatigue assessment, to determine the remnant life of the crane and recommend remedial action to extend the life. FEA analysis was validated by test and measurement of the crane during load cycles. Accelerometers and strain gauges were strategically positioned on the structure to measure the dynamic effects experienced by the crane during the lifting, travelling and lowering of containers. The model was tuned to adequately represent the mass distribution of the structure. Various loading and unloading cycles were considered. The fatigue stress range determined from the FEM model was used in conjunction with an experimentally determined loading spectrum. This enabled the best possible estimate of the remaining life of the structure to be determined, prior to the significant development of fatigue cracks.

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4.16 Crane Audit - Port Of Fremantle


Condition audits of two container cranes were undertaken by BMT WBM engineers for P&O Ports in Fremantle, Western Australia to document the current state of structural, mechanical and electrical components as part of a strategic direction study. The first crane had reached the end of its original planned 30 year life and BMT WBM were engaged to identify possible initiatives to sustain the operation of the machine in the short term and a long term plan to extend the life of the crane by a further 20 years. The condition of key components on the crane was known to be poor, particularly the electrical control systems. Close consultation with P&O during the audit was a feature of the project, ensuring that objectives for crane life, operability and maintenance were considered. The second crane had reached 18 years life. The audit on this crane concentrated on items that presented an existing unacceptable level of risk to the plant, safety of personnel or the longevity of the plant. The audit reports comprised a diagrammatic and photographic record of the crane condition and included detailed prioritised recommendations for remedial action.

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4.17 Crane Electrical Upgrade Port Botany


BMT WBM was engaged by PATRICK Corporation to carry out a comprehensive condition audit of a container cranes at Port Botany in Sydney. Findings of the audit indicated that key areas of the crane needed to be upgraded to meet the major criteria of trouble free operation for another 10 - 15 years. In conjunction with PATRICK, BMT WBM developed list of priorities for work to be performed in the planned maintenance outage program. As part of the ongoing support for the upgrade BMT WBM carried out detailed electrical and mechanical design including: A new network of Programmable Logic Controllers was established linking the driver chair consoles, the switchroom and the cable reeler. The network assists with the transfer of data, while providing an appropriate interface for visual display units and other controls initiatives. A safe and reliable suite of AC distribution Cubicles, incorporating safety vents to prevent pressure build up in the event of an internal fault. The cubicles, designed to AS 3439.1 Appendix EE incorporate a safe exit path for ionised gases, directing material away from the operator, in the case of a catastrophic fault. A new High Voltage Main Isolator Cubicle. The unit features the latest compact SF6 switchgear ensuring a high degree of operator safety, while being very compact, and easy to maintain. An upgraded cable reeler torque regulation unit. The central part of the new system is a constant torque variable speed drive unit. The new unit is not affected by temperature variations, wear of components, humidity fluctuations or spring tensions. A mounting arrangement for the new drivers cabin, including a revised cable entry point and access arrangement. The trolley on which the cabin is mounted, had to be checked to ensure that the cabin static and dynamic loads could be accommodated structure. by the existing

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4.18 Crane Spreader Modifications Port Botany


BMT WBM was engaged by P+O Ports to design a pin connection to be installed on the Bromma head beam frames in use at the Port Botany facility. This conversion was to allow the Bromma heads to be used with both spreader frame types (Bromma & Electruck) utilised on site. The work involved design, strength and fatigue analysis involved in changing the Bromma head beam frame design (specifically the Rotator, Upper Part) so that it has a suitable pin connection compatible with the Electruck Multispar spreaders, and adding lugs to the Bromma spreader frame design (specifically the main ram frame) to be similar to those supplied by Electruck.