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.

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

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.

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.

Cement Australia – Heat Exchanger Duct Replacement

Cement Australia’s operations in Gladstone incorporate Australia’s largest cement kiln, capable of producing more than 1.6Mtpa of cement.

Early in 2017, it was identified that the heat exchanger duct between the clinker cooler and the inlet to heat exchanger no.1 (HE1) had reached the end of its life, and was significantly impacting on plant production. Cement Australia engaged Walz Group to replace the equipment to return the kiln performance to full capacity. The project required us to remove and replace the failing heat exchanger, ductwork, inlet chamber, associated supports, and specified tubes during a time critical shutdown.

We utilised our dedicated fabrication facility to manufacture all the ductwork, inlet chamber, and the associated supports and components. We also applied protective coating as required. Prior to the shutdown for the replacement works, we reinforced the plant foundation and structure to ensure it could accommodate additional loads.

Our comprehensive plant and equipment fleet was invaluable for this project, which required craneage and scaffolding to remove and replace the existing structure.

WICET – MP2 Marine Works

With stage 1 of the Wiggins Island Coal Export Terminal (WICET) completed, commissioned and fully operational in 2015, the construction barge wharf at the site was rendered redundant. After considering removal of the wharf, WICET decided it would be more beneficial to decommission and preserve the facility. This would keep the option of using it again for any further expansion works in the future. Walz Group was engaged by WICET to decommission and preserve the construction barge wharf at the facility. The project scope also included removing hazards to the general public that may access the area.

This project showcases our marine infrastructure capability. It highlights the benefit of owning our own specialist marine equipment and expert operators. The scope included:

Decommissioning and preservation of the construction barge wharf
- Removal, preservation and storage of pontoons, gangways and landings
- Removal of attachments on piles / sheet piles then cleaning and restoration of surface protection
- Design, supply and installation of a sacrificial anode system for the piles / sheet piling
- Maintenance of existing navigational lights and installing one new light on the mooring dolphin
- Installation of a security fence and safety signage
Ancillary make-safe works
- Modification to the berthing dolphin emergency ladders x 10
- Surface protection repairs to emergency ladder piles
- Surface protection repairs to piles W11-C and W15-C
Marine equipment and personnel
- Self-elevating platform
- 250t crawler crane
- Flat top barge
- Tug boat
- Work boat
- Crew boat

Leighton – APLNG Curtis Island Workers Camp

Forming part of the six LNG trains on Curtis Island, the Australia Pacific LNG plant is Australia’s largest producer of coal seam gas (CSG). It not only supplies Queensland’s domestic gas market, but also processes CSG into liquefied natural gas to meet the demand of customers around Australia and globally. The development of the plant took some five years, shipping its first cargo in 2016.

To support the construction of the plant, Walz Group was engaged by Leighton Contractors (now known as CPB Contractors) late in 2011 to build the works accommodation camp. Our scope incorporated:

Civil Works including
- Preparation of site
- Road construction
- Building platforms
- Drainage
- Concrete works
Building installation
- 2,600 residential units
- Full commercial kitchen and dining hall to accommodate preparation of three meals a day for 2600 camp residents.
- Miscellaneous buildings including offices, gymnasiums, laundry/toilet/washroom blocks, medical facilities, lunch cribs, security huts, etc
- BBQ shelters, pavilions, walkways

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