Peabody Energy Australia have engaged Dowdens Pumping & Water Treatment's [Mackay] Engineering Department & Fabrication Workshop to deliver a Specialised Pontoon Pumping System for use at their Moorvale Coal Mine, located 156 kilometres South West of Mackay, QLD. This project presented a number of challenges for the Dowdens Mackay engineering and fabrication staff, including but not limited to an extremely tight delivery timeline of only 8 weeks!
Peabody Energy's Moorvale Mine is an open-cut coal mine that produces low-volatile pulverized coal injection (PCI) coal, coking coal and thermal coal for export markets. The Moorvale Coal Mine is particularly challenging for its operators due to the coal seam being quite narrow with a number of fault lines. This requires excavators often having to work in confined areas. The three piles that make up the Moorvale coal seams are mined independently of each other.
Dowdens Specialised Pontoon Pumping System was needed to provide Peabody Energy more reliable access to good quality Raw Water from an on-site dam. This raw dam water was then to be pumped directly to the onsite Coal Handling & Preparation Plant (CHPP). The existing supply water was limited and of poor quality. Dowdens new pontoon pumping system allowed for an increased volume of water to be pumped from a dam containing higher quality raw water. Subsequently the Specialised Pontoon Pumping System that Dowdens supplied has helped facilitate an improvement in the CHPP's daily operations.
"This particular project had a tight lead & build delivery timeline (approximately 8 weeks). During this time Dowdens were in regular contact with us, the project coordination and regular contact I received from Dowdens Engineers enabled me to better plan for the delivery and installation of the gangway and pontoon, which required a 100 tonne crane to be booked and ready onsite for the unloading and installation.
Dowdens Engineering Department was prompt and professional in helping resolve revisions in the project scope. The design and the way the pontoon was packaged and delivered added to the "Zero Incidents" achievement during the installation of the Pontoon on site. I was satisfied with the product, price and customer service provided by Dowdens Pumping & Water Treatment - Mackay"
This project required both Dowdens Engineering Dept. & Fabrication Teams to deliver an innovative solution not previously attempted in-house. It was the first time Dowdens had manufactured 12m length gangways or a pontoon with a total weight of over 6 tonne. The total pontoon weight includes all steel work, flooring, pumps, piping etc. and is displaced using HDPE (high density polyethylene) Floats. The longest gangway Dowdens had supplied previously measured 8m in length, with the largest pontoon previously fabricated weighing in at 4.5 tonnes.
The new system meant Dowdens existing in-house designs had to be modified / improved with new floats being selected in order to safely carry the increased platform weight. Additional weight saving measures were implemented by Dowdens Engineers such as the use of light weight / high strength aluminium mesh flooring.
The timeline to design this pontoon pumping solution, manufacture the components and have them delivered to site was extremely tight. Engineering - Concept Design - Drawings & In-House Fabrication of the unique Pontoon Pumping System was completed & delivered to Moorvale Mine within their specified 8 week time frame!
No other pumping / manufacturing / engineering firm in Queensland are able to deliver such an all-encompassing product solution within the above mentioned time-frame.
Dowdens design philosophy for this project was: Fast Turnaround - Cost Effectiveness - Ease of Installation - Simple Plant Operation - Plant Reliability & Reduced Maintenance.
Key Project Features: