Bechtel – SMP Installation Works on Train 2, QCLNG Curtis Island

We were proud to support our client, Bechtel, to deliver one of six LNG trains on Curtis Island as part of the largest concentration of private capital investment in Australian history. This historical program of work resulted in three plants that yield roughly 8% of the world’s total LNG production.

Walz was engaged to provide specialist teams to perform pipe installation, pipe welding, structural steel installation, structural steel removal, structural steel welding, and associated activities on the Queensland Curtis LNG (QCLNG) Project. The completed works included 250t of structural steel and 6km of class 1 piping. Our scope also included line blowing and commissioning activities.

Off the back of our successful delivery of the SMP works for Train 2, Bechtel awarded Walz Group the ongoing maintenance and warranty works for all three plants on Curtis Island.

Dedert – Wet Distillers Grain Dryer Installation

The Dalby Ethanol Plant is Australia’s first grain-to-ethanol facility. Each year the plant converts nearly 200,000 tonnes of sorghum into 76 million litres of ethanol. The product remaining after ethanol distillation — known as sillage — is separated and concentrated using centrifuge and evaporation technology to form a high energy, high protein animal feed known as wet distiller’s grain. The soluble dry matter, known as syrup, is blended with the Wet Distiller’s Grain (WDG) and sold to the local animal feed market as Wet Distiller’s Grain with Solubles (WDGS).

As part of a plant upgrade, the Dedert Corporation engaged Walz Group to construct and install a drying facility for the wet WDGS. The closed loop drying system with integrated thermal oxidizer was installed adjacent to the existing wet grain system.

Our scope incorporated all civil works, including concreting, plus the structural, mechanical and electrical installation, as well as commissioning of the drying plant. We managed specialist civil and electrical contractors who worked alongside the Walz project team to ensure a seamless delivery. The structural work included offsite fabrication in our facility in Gladstone.

After the installation of the dryer, the plant has the capacity to produce around 180,000 tonnes of WDGS a year.

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

Curragh – ROM Upgrade

Formerly owned by Wesfarmers Resources, the Curragh Coal Mine (now operated by Coronado Curragh Pty Ltd) is located in Queensland’s Bowen Basin, 30km north of Blackwater. The main product from the mine is metallurgical (coking) coal for export.

Wesfarmers identified a need to refurbish the run of mine (ROM) coal handling facility at Curragh, in order to accommodate increased production and potential future expansion requirements. They subsequently embarked upon a major upgrade of this essential infrastructure, to enable increased reliability and capacity, and extend the life of the facility.

Walz Group was engaged to supply and install structural, mechanical, piping and electrical works, including the onsite civil package and multiple tie-ins to existing plant. We provided an end-to-end solution, performing procurement, demolition and decommissioning of redundant infrastructure before delivering construction and erection/installation services for the material handling facility and associated infrastructure works. Our scope also included verification, and pre-commissioning as well as commissioning support. The works included:

Structural steel supply and installation – 650t (Structural steel, guards, pulley frames)s
Mechanical supply and installation – 200t (idlers, pulleys, drives, scrapers, belts)
Piping supply and installation – 2,000m (25NB-150NB (carbon steel / galvanised / HDPE))
Platework supply and installation – 160t (Chutes, liners)
Electrical and instrumentation (supply and installation) — managed by Walz, performed by subcontractors
Civil (support and installation) — managed by Walz, performed by subcontractors
Tie-ins to existing plant

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 Broadmeadow – MG10 & MG11 Conveyors

As BMA’s Broadmeadow longwall mine operations advanced, a need was identified to install new conveyer infrastructure to replace shuttle cars and diesel ram cars to transport coal from the face.

Walz Group was engaged by BMA to complete the structural, mechanical and pipework installation of two new conveyers — Maingate 10 (MG10) and Maingate 11 (MG11). The project was completed in two stages — one for each conveyor — to accommodate operational constraints. We undertook all installation and construction work required to complete both conveyors.

Works were conducted in a live operating environment to maximise operational efficiency. This required careful planning and sequencing to ensure the mine could continue to operate as usual, safely and with minimal impact on production.

Specifically, the works incorporated:

Coffin seals
Drive frames
Drive modules
Belt maintenance equipment
Substation shed and related interface structures
Grouting to all structures including drive areas and transfer foundations
Hand rails
Transfer towers
Gantries and trestles and their associated mechanical components

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

Ausenco – Carborough Downs Overland Conveyor

Vale’s Carborough Downs underground mine is located in Central Queensland’s Bowen Basin, 180 kilometres southwest of Mackay. Walz Group was engaged to perform the structural, mechanical, piping, and electrical installation of the 5km overland conveyor and upgrade of the coal handling and preparation plant (CHPP). This formed part of a broader brownfields expansion. In total, we constructed almost 6km of conveyor systems (drift, stockpile, reclaim, reflect, overland and surge bin conveyors) and associated componentry.

Our works included:

Structural steel installation — trestles, conveyor gantries, transfer stations
Mechanical installation — belt weighers, scrapers, drive motors, pullies, external gravity take-up
Installation of victaulic and screwed pipework
All electrical installation

John Holland – Abbot Point X50 Expansion

We worked with John Holland Group to deliver the X50 Expansion at Abbot Point Coal Terminal. This work increased the North Queensland Bulk Ports Corporation’s annual export capacity to 50 megatonnes. The facility services the export requirements of a number of mine operators, including Newlands, Collinsville, and Sonoma mines.

Our scope incorporated a range of marine works associated with the extension of the transfer tower and construction of the additional operation berth, east of the existing Berth 1. The works included installation of piles, headstocks, and rail girders, as well as steelwork modifications, installation of new equipment, and modification of existing equipment to accommodate the expansion. Walz provided all associated marine equipment and qualified operators.

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