Hydrogen Park Gladstone Site Construction

Australian Gas Infrastructure Group (AGIG) are developing the Hydrogen Park Gladstone project, for the small scale production of hydrogen and injection into the natural gas distribution network as a 10% blended mix. A 175kW NEL electrolyser is the primary hydrogen generation equipment installed, with supporting infrastructure to facilitate the generation and injection of the gas into the distribution grid.

Walz Group were engaged as Principal Contractor to lead the mechanical, electrical and civil installation scope of work for the project. This included all bulk and detailed earthworks, concrete foundations, underground service trenching, mechanical installation of electrolyser package and supporting services, electrical and instrumentation installation, hazardous area compliance inspections, and dry commissioning of all equipment.

Key highlights included:

Receipt and inspection of all free issued materials and equipment
Form and pour 55m3 of concrete foundations
Installation of 2.8km of site run power and control cabling
Connection of services to external provider networks – gas, electrical, water, and sewer
Completion of hazardous area compliance inspections.

PDM Thickener Bridge Replacement

Peak Downs Mine (PDM) identified the Coal Thickener Bridge was at its end of life and required replacing. It supports a range of services including mechanical drives, hydraulics, electrical and control services, flocculent dosing system, compressed air and coal slurry and water pipes. It also provides the suspension of the feed well and thickener raking system.

Walz Scope included:

Pre-assembly and installation of a new BMA supplied bridge and mounting stools, plus the installation of new pipes, brackets, cable trays and existing equipment;
Removal of all existing mechanical, electrical, fixture’s, pipes, feed well as required from the existing bridge structure to facilitate its safe removal;
Supply and installation of new pipes, valves, cables and fixtures that could not be re-used from the existing bridge;
Supply of scaffold and temporary support frames;
Commissioning assistance;

With the support of our subcontractors and a dedicated Walz crew, all works were completed without incident and the coal thickener bridge was back online as per the schedule.

Ironbark No. 1 Coal Mine – Installation of Stacker Structures

Fitzroy Coal Management are currently constructing a new underground coal mine, Ironbark No1, located 50km northeast of Moranbah Queensland Walz Group were engaged to complete full Structural, Mechanical and Piping Installation as well as managing an electrical subcontractor to complete the E&I installation works. These works include preassembly and installation of 9 gantry sections, drive end assembly, Pulley and drive installation and alignment, idler installation and alignment, fire water and air line installation and Electrical and instrumentation installation.

Key highlights included:

Liaising with other contractors to commence and complete works
Sequencing, Assembly and installation Trestle 7
Pre assemble G7 and G8 Gantries and install
Installation of VSL Stress Bars
CST Drive installation and alignment
Underground cable installation from Drive area to Substation

K2 Main Kiln Bag Filter Upgrade – Mechanical

Walz were engaged to complete the Structural, Mechanical and Piping construction scope for the main kiln bag filter replacement project, at Cement Australia’s Gladstone plant. The scope of works included the unloading and destuffing of all free issued materials, preassembly, and installation of 600T of structural steel and platework. Due to the short timeframe in which to complete the installation of the new bag filter during the site major shutdown, a methodology that included the preassembly of the new bag filter on temporary foundations and relocated using SPMTs was developed, to reduce the overall duration required during the shutdown to complete the installation and mechanical commissioning.

Key highlights included:

Handling and unloading of 90+ containers and flat racks
Preassembly of 8-off 30T filter casings and installation using 150T Kobelco crawler crane
Erection of 170T of structural steel
Design and installation of 30T of falseworks, to enable the SPMT relocation

SPMT relocation of the 450T new bag filter structure a distance of 60m

Installation of 3,500x 10m long filter cages and bags

YC1 Gantry Protective Coating Repairs

Complete coating patch repairs on gantry stacker girders and associated structural elements from top of rail to 1m below rail level. The work scope comprises the following:

Establish access platforms to the underside of the gantry structure
Undertake coating inspections to determine location of patch repairs
Complete corrosion repairs (pad welding)
Complete localised abrasive blasting works to remove coating defects
Apply new coating system to localised patch repairs
Relocate access platforms

Saraji Mine Optimised Stripping Workshop

To facilitate the acquisition of up to 50 additional Heavy Mining Equipment (HME), the BMA Saraji Mine (SRM) engaged Walz to build an extension to the existing workshop to include 4 additional Ultra-Class (UC) bays.

As Principal Contractor, Walz scope included:

All works associated with the relocation of existing buried services.
Demolition of existing tool store on the western side of the existing HV Workshop.
All bulk earthworks to building up the pad and hardstand for the new workshop extension (10,200m3)
Bulk excavation for the pad footings.
All concrete works for pad footings and pedestals.
Formwork and concrete for new workshop slab (720m3)
Supply, fabrication, surface treatment, erection and cladding of new workshop (65m long x 20m wide x 21m high).
Supply and installation of electrical and mechanical works, including satellite tank farm and point of lube (POL).
Testing and commissioning.

580 Area Tank Inspection & Repair Program

Walz were engaged by our client to complete necessary maintenance repairs and improvements to four 22m diameter thickener tanks, as part of their periodic API inspection requirements. The scope of work involved the replacement of corroded pipework, internal feedwells, structural repairs to the strakes, and full internal blast and paint. The work was scheduled over a 12-month period to coincide with the regular operational downtime, with Walz working with our Client to ensure that each thickener tank was returned earlier than scheduled, to minimise the overall duration of the program of work and thereby the time spent at reduced operating capacity.

 To complete the repairs of each thickener tank, Walz designed and built a full internal scaffold system that provided access for the blast and paint work and replacement work consisting of 54T of At-Pac Ringlok scaffold. This scaffold was erected to provide access to all internal surfaces of the tank, as well as a large working area for the replacement of the internal feedwells and pipework.

 Key highlights were:

Completion of 2500m2 of blast and paint
Removal and replacement of 300m of associated piping
Completion of nearly 14,000hrs injury and lost time free

Hydrate Stockpile Upgrade – Structural, Mechanical and Piping

The Rio Tinto Alcan Yarwun Refinery (RTAY) is undertaking a CAPEX project to upgrade the existing Hydrate Stockpile infrastructure in an effort to reduce contamination of the Hydrate Stockpile. The project focuses on the construction of a new stockpile pad, shed facility, transfer towers and associated conveyors to effectively convey hydrate between the plant and pad – ready for shipment via conveyor to the Fisherman’s Landing Wharf.

Scope of Work:

Erect portal frames (70.5m L x 38m W x 24m H) and install an elevated walkway with conveyors and 2 monorails.
Build structural steelwork (23m H) for the North Transfer Tower with four working levels and conveyor tie-ins.
Construct the West Transfer Tower modularly (27.5m H, 7 levels) with conveyor tie-ins and a 20t surge bin.
Install a stairway across Export Conveyor (480CV10100).
Tie into the existing 470CV10010 belt; install new plough, headchute, and head end drive.
Install a 26m gantry for Cross Conveyor (480CV10070) and align mechanical components.
Install a 20m gantry for Feed Conveyor (480CV10080) with a total length of 86m and add 3 mechanical ploughs.
Install and commission sprinkler and small-bore piping; tie in eyewashes and hose reels.

The project involves constructing 1 shed, 2 transfer towers, and tying into the existing plant, with approximately 715t of steelwork and mechanical installations completed.

Removal and Installation of R10M Conveyor GRM

BHP Mitsubishi Alliance (BMA) Goonyella Riverside Mine (GRM) replaced the rejects conveyor gantries and trestles as part of the Goonyella R10M Conveyor & Trestle Replacement project. This work was part of a planned upgrade to the existing R10M Conveyor required to rectify a series of identified deficiencies during a major 6 week outage.

Walz fabricated the new conveyor gantries and trestles under a separate job number, so our scope for the R10M Conveyor Replacement works involved removing the existing conveyor gantries, GTU and trestles scope and installing the newly fabricated conveyor gantries, GTU and trestles. The work included structural, mechanical, piping and electrical disconnections, removal, installation and reconnections. Walz provided cranes, operators, boilermakers, fitters, riggers, scaffolders and electricians as well as development of complex lift studies, a detailed methodology and commissioning assistance. We provided the following:

150t Hydraulic Crane
80t Hydraulic Crane
28t TIDD
Supervisors, Crane Operators, Riggers, Boilermakers, Fitters, Scaffolders and Electricians (24/7)

With the support of Walz equipment and a professional crew of Walz personnel and key subcontractors, the project was safely and successfully completed LTI free.

Caustic Pipeline Integrity Project

The Scope incorporates the fabrication and installation of new carbon steel pipelines (Bauxite Slurry line, Caustic line, CGW line) from the wharf to South Trees Island and from STI to the mainland via the causeway.

Key activities in this Project gravitate around the multiple shutdown works required in order to remove and replace the existing pipework infrastructure, as well as associated repairs to the structural integrity of the supporting steel frames and additional civil works for the construction of new spill containment solutions.