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 Hay Point – Footbridge 3 Replacement

This work involved the urgent replacement of a heavily corroded footbridge at the Hay Point Coal Terminal. The new bridge had been fabricated, but was yet to be installed, and the existing structure was quickly deteriorating after the impact of Cyclone Ului. With high structural corrosion throughout the chords and stringers, the old bridge was not capable of withstanding a significant wind or wave event.

BMA sought to greatly reduce the risk of failure of the existing bridge by installing the new, prefabricated replacement which was capable of withstanding greater wind and wave events. The new bridge also reduced the chance of downtime to the adjacent berth, as mooring operations would be rendered disabled if the bridge were to fail.

Our primary scope was to install a pre-fabricated replacement bridge in accordance with the approved design drawings. This included removing the existing footbridge, relocating it to Mackay Harbour, and fabricating and fitting the missing connection pieces required for the installation of the bridge.

The works required the mobilisation of a range of our equipment and crew from our marine fleet to enable the installation. This included:

  • Jack up barge with crane to remove and replace the footbridge
  • Landing barge with capacity to accommodate the new and existing footbridge
  • Tug boat to manoeuvre equipment

BMA Hay Point — HPX 3 Expansion Works

Hay Point Coal Terminal is one of the largest coal export ports in the world. Walz Group had previously worked directly for the owner-operator, BMA, to urgently replace a footbridge . We were subsequently engaged to support BMA to deliver the third major expansion of the facility.

As part of this contract, Walz Group provided marine equipment and specialist personnel to support the shutdown scheduled as part of the project, and remove associated temporary works. Throughout the project, we continually adapted to the ever-changing weather conditions and modifications to schedule. By working closely with our client and taking an agile approach to resourcing requirements, we were able to meet all project milestones.

In its entirety, the expansion increased capacity at the terminal from 44 million tonnes to 55 million tonnes. The work included construction of a new berth and land reclamation, as well as building and fitting out new trestles, conveyers, and ship loaders.

Specifically, our scope included the provision of the following specialist equipment together with expert operators.

  • 1 x self-elevating platform with Favco M2480D tower crane
  • 1 x self-elevating platform with 250t crawler crane
  • 1 x self-elevating platform with 100t crawler crane
  • 2 x flat top barges
  • 2 x tugs
  • 1 x work boat
  • 1 x crew boat

Connell Hatch – Dalrymple Bay Outloading Conveyor System

We performed the onshore works for the outloading conveyor system in the second phase of the Dalrymple Bay Coal Terminal 7X project. This expansion saw the terminal increase its capacity by around 50% to 85+Mtpa, making it the third largest terminal in the world. As the terminal operates 24×7 all work was completed in a live operating environment. It was essential to minimise disruption of operations and ensure the site remained safe and accessible for staff to continue operations in a business-as-usual manner.

Walz Group supplied all equipment and materials for the onshore construction of the new outloading system. These works delivered a third reclaiming stream and associated conveyor systems for the transfer of coal from the stockyard to a new surge bin and sample plant facility. Our scope included all mechanical, structural, civil and electrical work, as well as commissioning of new systems. The works included:

  • Modifications to existing conveyors including addition of new chutework
  • Installation of 3 x new conveyors
  • Installation of a new surge bin
  • Installation of a new sample plant
  • Installation of new belt feeders

BMA Hay Point – Trestle Deconstruction

Based on our successful track record on multiple projects at Hay Point terminal, we were engaged by BMA to deconstruct and remove the original trestle and the 17BP conveyor installed when the facility opened in 1971. The ageing 1.8km structure transported coal from the terminal to waiting bulk carriers for more than 40 years and was decommissioned late in 2016.

Working from jack-up barges, our crews are dismantling the trestle and conveyor in sections, and transferring approximately 6,500 tonnes of steel to Half Tide Harbour by barge. Our work at Hay Point is ensuring that aging infrastructure is safely and carefully removed in order to best protect the local environment. In March 2019, Walz Group achieved two years recordable injury free on the project.

In conjunction with the main work of dismantling the trestle, Walz Group is undertaking additional separable portions of work under the same contract. Each separable portion of work is outlined below.

Disposal of Waste Material

Once on-shore, the trestle sections are separated into steel, concrete and timber components and prepared for transport to recycling facilities.

Dewatering and Processing of Pile Water

If the water located in the piles is not inert or has the potential to cause visual pollution, Walz is responsible for processing and filtering the water prior to release off-site.

TT8 Top Deck Removal

We are removing and disposing of the existing TT8 top deck, and installing the new structure and supporting componentry.

Berth 1 to MD2 Footbridge Installation

We have been contracted to install a new footbridge (Footbridge 2), with associated structural support and access walkways. The new structure will connect Berth 1 to MD2 after the deconstruction of 17BP conveyor and roadway.

Berth 2 Shutdown Works

The current shiploader infrastructure requires upgrading and refurbishment, as well as installation of new elements. We have completed:

  • Fender maintenance and chain replacements
  • Installation of a new davit crane
  • Upgrading the ship access gangway and supporting structures
  • Removal of redundant fenders
  • Other miscellaneous works as required

Berth 1 Shutdown Works

This refurbishment work is similar in nature to that outline for Berth 2 above and incorporates:

  • Fabrication and installation of a new tripper
  • Installation of new transfer chute and upgraded pulleys
  • Repair and surface protection to conveyor structure and rail girders
  • Supply and installation of new tripper rail
  • Installation of new walkways between berthing dolphins
  • Installation of new top Davit Crane
  • Fender chain replacements

BMA Hay Point – Stacker Reclaimer SR1 & SR2 Refurbishment

When the existing stacker-reclaimer stockyard machines (SR1 and SR2) at the Hay Point coal terminal started to approach the end of their life, BMA commenced the process of replacing them. With an anticipated lead time of two years for the new equipment to be manufactured and shipped to Australia, the machines needed work to be kept operational until the replacements arrived.

Walz Group was contracted to dismantle both stacker-reclaimers down to the fixed cone to undertake structural integrity repairs. This would extend the life of both machines for the interim lead time of their replacements. The works involved removal of mast, pendants, bucket wheel boom, counterweight arm, counterweight box and slew cone.

The machines were then rebuilt with new slew cone, new counterweight assembly and refurbished bucket wheel boom. Both machines were jacked up to clear the rails to remove all bogies, which had to be refurbished and machined to suit the new rail profile.

Our fabrication workshop and protective coatings workshops Gladstone were instrumental in the repair and refurbishment of existing componentry.