BMA Goonyella – Dewatering Screens Project

Coming off the back of successfully completing the installation of the new Horizontal Belt Filter BF703, we were again engaged by BMA to assist with an upgrade of an existing dewatering screen to larger dual screens. The installation of these dual screens would assist operations with rectifying a bottleneck identified in Coal Preparation Plant 1 (CPP1), resulting in increased production rates.

These works require us to work alongside the existing CPP1 to install the new platform that will house the new dewatering screens and associated componentry. Our scope includes the supply and installation of the entire work package, including all structural steelwork, platework (chutes, underpans, feed boxes), a new gantry section and supporting trestle, pipework, handrail, grating, valves and the new conveyor componentry. We will be working alongside a number of our key subcontractors for these works who will be assisting with the civil works, electrical works, modifications to the existing conveyor belt, re-installation of an existing belt weigher and on-site installation of wear lined pipework.

Our team have become accustomed to carrying out complex on-site installations, with this project presenting its own challenges. To successfully complete this upgrade, we will be required to carry out a significant portion of the works during three plant shutdowns.

BMA Hay Point – Sustaining Shutdown Works

Continuing our working relationship with BMA at Hay Point, we were again engaged to provide marine assistance for a critical shutdown on one of their shiploaders. These works had us working alongside BMA and its nominated Head Contractor.

This project required the services of our marine equipment and specialist personnel to assist with the planned works that would be carried out during a 12 week outage. The planned works would see a range of maintenance activities completed on the shiploader to ensure it continues to operate reliably and safely.

As with all marine based works, this Project brought with it the need for our crew to continually adapt to the ever-changing weather conditions and modifications to schedule. By working closely with BMA and its Head Contractor, we were able to stay ahead of the game and address any hurdles in a safe and timely manner.

For these works, we provided the following specialist equipment together with expert operators:

  • 1 x self-elevating platform with 120t crawler crane
  • 1 x self-elevating platform with 250t crawler crane
  • 1 x flat top barge
  • 2 x tugs
  • 1 x work boat
  • 1 x crew boat

BMA Goonyella – Horizontal Belt Filter

Continuing our ongoing relationship, we were engaged by BMA to carry out the installation of Horizontal Belt Filter BF703 at its Goonyella mine in Central Queensland. It was our first time working back at the Goonyella mine in recent years and it was a great opportunity for our team to demonstrate our capabilities working alongside a new client team.

Our works for this project included the full turnkey package. We worked alongside BMA to assist with the procurement of key items such as pumps, drives, handrail, grating, valves, pipework and other miscellaneous componentry. We also looked after the fabrication of plate and structural steelwork packages, which were integral to the installation of the new Horizontal Belt Filter being supplied by BMA. This project once again gave us the opportunity to work alongside our trusted subcontractors for the civil, electrical and instrumentation works. Once commissioned, the upgrade would see an increase in the recovery of dry product through the mine.

The project was completed safely and on time, demonstrating our capabilities in this field and establishing our presence as a key contractor for further works at Goonyella moving forward.

Rio Tinto Yarwun

Situated 10km north-west of Gladstone, Yarwun alumina refinery produces 3.4Mtpa of high quality product. Similarly to the QAL facility, where Walz is also engaged, Yarwun uses the world class four stage Bayer process to refine bauxite mined in Weipa on Queensland’s western Cape York. The expanded refinery incorporates a 160Mw cogeneration facility which significantly reduces the operations’ greenhouse gas impact and feeds surplus low emission electricity back into the Queensland electricity grid.

We have been working at the Yarwun refinery for many years and have a strong relationship with the facility’s operations team. With a workforce situated at the site, we provide comprehensive maintenance and shutdown services, as well as general sustainability works. We also support ongoing operations through our piping fabrication, protective coating, and light, medium and heavy fabrication facilities.

Throughout our long standing relationship, we have also completed several major capital works projects. In the last five years, Walz Group has worked with the Rio Tinto Yarwun team to deliver more than 290 projects valued at over $32M.

Some of our major capital works projects at Yarwun have included:

Thickener Corrosion Repairs

  • Completed: 2019
  • Project Value: $1.4 million

Caustic Line Replacement

  • Completed: 2019
  • Project Value: $1.5 million

Petite Sweeting Project– Structural steel and pipe installation works

  • Completed: 2018
  • Project Value: $2 million

Oxelate Project– Structural steel and pipe installation works

  • Completed: 2018
  • Project Value: $2.2 million

Mill LiqUOr Line & Spent Liquor Pipeline replacement

  • Completed: 2017
  • Project Value: $1.9 million

Queensland Alumina Limited

Queensland Alumina Limited (QAL) was Australia’s first alumina refinery and remains one of the largest in the country. Covering an 80 hectare site on the outskirts of Gladstone, the refinery produces around 3.8Mtpa of high grade product. The bauxite that is processed to make alumina is mined in far north Queensland and shipped 2,000km to Gladstone. Alumina is produced through the continuous four state ‘Bayer’ process.

Walz Group has a longstanding relationship with QAL and we are proud to be a trusted provider of scheduled maintenance and shutdown projects, as well as ongoing sustainability works. We also provide scaffolding services for shutdown works through our specialist plant and equipment. Walz also supports the refinery through our light, medium and heavy and piping fabrication facilities and protective coating services. Our constant presence on site supports the smooth operation of the refinery through a range of ongoing works. We also perform occasional major capital works.

Over the past five years we have carried out more than 390 projects at QAL, valued in excess of $46M. The works ranged from minor sustainability such as handrail replacements, to major capital works projects like replacing a conveyor.

Some of our key projects at QAL include:

  • Caustic Tank Floor Replacement (T15Q005 + T1515)
  • Major evaporation turnaround works
  • Power steam header remediation and upgrade works
  • Conveyor replacements
  • Miscellaneous structural, mechanical and piping works as required
  • Miscellaneous shutdown works as required
  • Providing scaffolding services for all shutdown works

Curtis Island LNG

The concurrent development of three liquified natural gas (LNG) plants on Curtis Island was an unprecedented achievement. It formed a significant part of what is, to date, the largest concentration of private capital investment in Australian history. This landmark program of work resulted in three plants that now yield roughly 8% of the world’s total LNG production.

The three facilities are owned by Queensland Curtis LNG (a joint venture of QGC – now a Shell-owned business, with China National Offshore Oil Corporation, and Tokyo Gas), Australia Pacific LNG (a joint venture of ConocoPhillips, Origin and Sinopec), and Santos GLNG (a joint venture of Santos, Petronas, Total, and Kogas)

There are six LNG trains on the island. Walz Group was engaged to provide structural, mechanical, and piping services for the installation of Train 2 for the QCLNG Plant.

Following completion of the QCLNG installation works, Walz was contracted by Bechtel to perform maintenance and warranty works for all three plants on the Island.

In addition to our ongoing warranty works, Walz supports operations on the island through our fabrication workshop and protective coating facility.

Gladstone Ports Corporation

Gladstone Ports Corporation (GPC) supports the trade of Central Queensland’s major resources, including coal, LNG, alumina, and agricultural products. GPC operates the port precincts in Gladstone, Rockhampton and Bundaberg. In the 2018 financial year, GPC ports were visited by 1,911 ships and processed 120 million tonnes of product.

As Gladstone locals, Walz Group has a long standing relationship with GPC. We’ve worked with them for more than 10 years, providing a range of services including piping fabrication, protective coating, and light, medium and heavy fabrication. We also have a consistent workforce based at the Gladstone Port, supporting GPC’s operations through a range of maintenance and improvement works, and selected capital works projects. Over the last five years we have carried out more than 140 projects at the port, valued at over $21M

We are currently engaged in mechanical life extension works, and corrosion and NDT repairs for Shiploaders 1, 2, and 3.

Some of our major capital works projects at the GPC Gladstone Port have included:

Stockpile 15 to 22 – Fabrication and Installation of a new Coal transferring conveyor system

  • Completed: 2014
  • Project Value: $112 million

Supply and Installation of 3 New Coal Product Transfer Trippers

  • Completed: 2013
  • Project Value: $3 million

Stockpile 22 – Fabrication and installation of a new Coal transferring conveyor system

  • Completed: 2012
  • Project Value: $16 million

Sedgman – Sonoma High Cut / Low Cut

Located 6km south of Collinsville in Queensland’s Bowen Basin, QCoal Group’s Sonoma Mine produces up to 4Mtpa of hard coking and thermal coal products. 

Our client, Sedgman, has operated the Sonoma plant since it was constructed in 2007, and were seeking support for the detailed design, engineering, procurement, and construction of the High Cut Low Cut Brownfield Upgrade of the coal handling and preparation plant. We worked with Sedgman to provide SMP civil works and a range of fabrication and protective coating services. Steel fabrication included steelwork, grating, floor plate, handrails, girts, cladding and a range of process platework. We also managed civil works carried out by one of Walz Group’s trusted subcontractors.

Mechanical works included installation of cyclones, coarse coal centrifuges, product screens, conveyor idler replacements, jib crane, and various pumps and drives.

Additional works comprised miscellaneous concreting, demolition of existing structures, and the construction of various ground slabs, suspended slabs and equipment plinths.

Sinosteel – Rocklands Copper Processing Plant

Sinosteel engaged Walz Group to carry out the structural, mechanical and piping works for the greenfield installation of a new 3Mtpa copper processing plant at their Rocklands mine, approximately 17km west of Cloncurry, in northwest Queensland. Our scope included the installation and commissioning of all mechanical equipment, structural steelwork and piping. Upon completion, we had installed 5,900t of structural steel, 2,500t of mechanical items and 42,000m of piping. 

Our specialist team comprised some 150 personnel at the peak of construction, and included special class welders, pipe fitters, riggers, boilermakers, equipment operators, and project support staff.

Sedgman – Construction of Reflux Classifier and Supporting Structural Works

Our long term client, Sedgman, engaged Walz Group to support their major upgrade of the coal preparation plant at the BMA owned Saraji open cut mine near Dysart in the Bowen Basin. Our scope incorporated onsite installation of all structural, mechanical and piping works associated with the reflux classifier, an advanced fine particle gravity-based separator. Works included constructing the building to house the device and installation of all mechanical and piping components. We also modified the existing walkway, and installed the new pipe bridge walkway, connecting them both to the existing plant. We also performed all tie-ins to the existing services.