Mechanical Engineering Consultants

Detailing the installation of mechanical equipment and conveyor structures is one of the final steps for completing a maingate drive-head design. Installations designed by Orana Engineering for Glencore’s Oaky No.1 underground coal mine included detailing drive arrangements, transfer stations, take-up units, maintenance equipment and the overhead structures supporting the carry belt. Mechanical design must consider a number of factors, including meeting the required operating capabilities, allowing for unimpeded access along travel roads, and maintaining minimum belt curves. Often equipment is relocated from previous installations with minor modifications in transfer angle and number of drives. Orana Engineering has developed unique methods for completing this type of design, enabling us to keep total costs down for our clients.

Hutchinson Builders Toowoomba was contracted to deliver portions of the Water Aquifer Injection Trial at QGC’s Woleebee Creek site. Prior to construction, Hutchinson Builders engaged Orana Engineering to perform a design review of all mechanical technical documentation associated with the Pond Transfer Pump Station. The review aimed to determine whether sufficient detailed information had been provided to allow Hutchinson Builders to successfully complete construction. Orana Engineering completed and issued a design review report which detailed recommendations from the review. During construction, Hutchinson Builders also engaged Orana Engineering to perform an inspection of a buried HDPE pipeline and to assess the construction of the pipeline against requirements of engineering drawings and specifications.

At James Cook University, MBD Energy operates a research facility investigating methods of cultivating and harvesting algae. To facilitate greater control of the algae agitation sleds, Orana Engineering was engaged to design and commission mechanical, electrical and control systems that would enable agitation sled velocity and frequency of travel to be automated. The system was designed and implemented by Orana Engineering utilising Allen Bradley Powerflex VVVF drives and a Controllogix’s PLC with an RSView SCADA interface. Orana Engineering was able to help MBD Energy improve the efficiency and quality of their research results by providing technical knowledge and assistance through our control systems, electrical engineering and mechanical engineering services.

Vale at Carborough Downs Coal Mine required quantifying of current and possible future capacities of product conveyors at their coal processing plant in Central Queensland and high level recommendations to achieve increased plant tonnages. Orana Engineering completed an initial site visit to gather the necessary information for review of each of the conveyors. Engineering checks were completed to identify ‘bottle-necks’ in the conveyor design such as motor power, drive equipment, belt curves, GTU mass, belt speed, belt capacity, belt tensions and electrical supply. Orana Engineering issued a detailed report at completion of the study and provided concept level equipment modification recommendations for tonnage ranges advised by Carborough Downs Coal Mine.

Carborough Downs Coal underground mine had transitioned from a bord and pillar mining system to longwall. The result was a need to upgrade capacity of the coal clearance conveyor system. Orana Engineering was engaged to provide Client Engineering assistance to deliver underground conveyor equipment to meet the longwall production schedule. Orana Engineering monitored vendor design progress against the schedule, performed design reviews to ensure correction of errors prior to final client approval, monitored and managed fabrication and delivery schedules and managed budget and variations in line with the contract. By co-ordinating with the client’s installation group and managing the vendor in line with the client’s schedule, the conveyors were successfully installed and made available for longwall production.

The mother beam of the 40T ship loading crane at the Port of Townsville was nearing the end of its 30 year service life. Xstrata Copper engaged Orana Engineering to redesign the beam based on the existing beam and to incorporate changes in compliance with latest regulations. After fully modelling the mother beam using Autodesk Inventor, RPEQ approved shop detail drawings were produced. Electrical monitoring systems were introduced to enable crane operators to confirm when the mother beam was fully engaged with various attachments and control wiring to the beam was redesigned to include two cable drums whereas the original had three. Mechanical redesign included a failsafe back-up locking system and design improvements highlighted by feedback from maintenance personnel.

Eloise Copper Mine purchased a Metso dual deck vibrating screen to replace an existing smaller screen and a second Omnicone cone crusher to provide a secondary crushing circuit for increased production and efficiency. Orana Engineering was engaged to develop a design solution and detailed drawings for the secondary crushing circuit which utilised as much existing equipment as possible. Orana Engineering was able to provide an efficient, practical design solution while minimising the associated design costs to provide site personnel with information required to refurbish and install the conveyor equipment necessary for the crushing circuit. Orana Engineering successfully completed the design within a tight project time frame and produced in excess of 100 detailed drawings.

Carpentaria Gold identified that bunding around their Ravenswood cyanide storage tank was inadequate. Sodium Cyanide, used in the gold recovery process, is potentially lethal to humans and animals and detrimental to the environment. It is necessary to ensure it can be safely contained in an emergency. Orana Engineering provided an innovative solution comprising a smaller tank fitted inside the existing tank. The design minimised loss of storage capacity by providing a smaller tank for primary storage whilst maintaining the existing external tank to act as the bund. Utilising the existing tank as a bund, Orana Engineering delivered a design that met the client brief while re-using the majority of major tie-in points and providing improved access for maintenance.

Orana Engineering was engaged by MMG's Century Mine to review a proposed reagent dosing system within the concentrator. An investigation was conducted which included hydraulic modelling for various reagent dosing system philosophies. Results were presented for a range of design and operating conditions and three solutions were proposed meeting the client's requirements. Factoring in control system complexity and cost, Orana Engineering recommended a preferred option and a back-up option requiring only minor system modifications. The engineering review was completed within a short timeframe and a detailed report provided to MMG detailing hydraulic modelling results and required operational settings for the offered options. MMG was able to use the results to make a decision on the solution ultimately implemented.

BMA Gregory Crinum engaged Orana Engineering to perform an audit and inspection of the Crinum underground mine surface fire water system with respect to providing adequate pressure and flow for the Crinum North conveyor system and stockpile conveyor. Orana Engineering completed a site inspection and audit against the design drawings, with site-verified information then used for compliance assessment in line with Australian Standards. The audit included in-depth assessment of the fire water system to Australian, BMA and site Fire Management Standards. Hydraulic modelling of the fire system was also undertaken to validate existing pressure measurements. Orana Engineering was able to make recommendations regarding compliance and system hydraulic performance, which assisted BMA in improving system capacity.

To increase the efficiency of their concentrator, Eloise Copper Mine enlisted Orana Engineering to provide engineering and design assistance with installation of three copper concentrate scavenger cells within the existing plant. 3D models created by Orana Engineering designers were used to visually communicate solutions for new and existing equipment locations and structure arrangements. Detailing of these concept models enabled Orana Engineering to identify key tie-in locations within the plant for survey during the detailed design phase. A multidisciplinary approach during detailed design ensured improved efficiency, with brownfield engineering challenges in relocating / connecting to existing equipment successfully achieved. Upon design completion the client was provided with an installation drawing set and scope of work.

Orana Engineering was engaged to design new sampling equipment for improved sampling effectiveness at Carpentaria Gold’s Ravenswood operations. A site visit was undertaken by Orana Engineering design staff to accurately record critical data. This enabled designers to produce a detailed 3D model which was used extensively during interactions with the client and ensured a fluent understanding of the project scope by both parties throughout the design process. Orana Engineering was able to integrate new sampling equipment into the existing plant whilst minimising any impact on the operation. Various challenges were overcome with the result being successful delivery of drawings for fabrication and installation of equipment, allowing improved sampling and production reconciliation whilst minimising impact to operations.

MMG's Karumba Port Facility engaged Orana Engineering to design a heavy vehicle washdown facility to assist with management of concentrate for site vehicles and machinery. The time frame was short due to operational requirements, such that Orana Engineering worked from concept to IFC drawings in just seven days. The design needed to accommodate a number of different vehicles from fully laden container trailers to a 30 tonne forklift, whilst also ensuring ease of facility maintenance and capture of runoff for environmental compliance. Concept sketches were prepared, from which a detailed design was developed to meet client requirements. Through effective communication with the client Orana Engineering was able to deliver the design in a compressed timeline, to specification and budget.

Orana Engineering was engaged by MMG's Century Mine to design an upgrade within the concentrator for increased flow from a flotation cell to a tailings trough. Orana Engineering conducted a concept investigation of available options to increase the flow rate. Results were presented for a range of design and operating conditions, and a preferred option was selected for detailed design. Orana Engineering design staff created a 3D model of the new pipeline using Autodesk Inventor. The 3D model was used to produce fabrication drawings for pipe supports, new platform and new pipe bridge. Drawings also included isometric pipe spool drawings and revised P&ID drawings.

Carborough Downs is an underground operation utilising conveyors to transport mined coal to the surface. As new longwall headings are mined, new conveyor installations are also required. Orana Engineering was engaged to complete a drive-head chamber design, ensuring adequate sizing for installation of conveyor equipment. During initial mining of the chamber, a coal seam fault line was discovered. Carborough Downs requested that Orana Engineering develop a chamber design that maximised product mined through the fault area, while working within conveyor installation constraints. Using AutoCAD, Orana Engineering produced several design options and sketches for client approval and reference during mining processes. Orana Engineering provided final chamber excavation drawings, which were developed into mine designs and sequence plans, by site mining engineers.

Carborough Downs is an underground operation utilising conveyors to transport mined coal to the surface. As new longwall headings are mined, new conveyor installations are also required. During installation of conveyors in an underground environment it is vital that the civil design is detailed accurately as this is the basis for locating and installing conveyor equipment. Orana Engineering was engaged to complete this design and used AutoCAD to develop a civil design that met the client’s constraints and constructability requirements. From this design Orana Engineering produced a drawing set detailing civil aspects of the conveyor design, including floor / rib trimming, equipment hold-down details, configuration of concrete reinforcing and overall grade of concrete.

Carborough Downs Coal Mine is an underground operation utilising conveyors to transport mined coal to the surface for processing. As operations progress and new longwall headings are mined, new conveyor installations are also required. Carborough Downs engaged Orana Engineering to complete a mechanical arrangement design for configuration of conveyor equipment. The design had to consider several factors, including meeting required operating capabilities, ensuring unimpeded access along travel roads and maintaining minimum belt curves. Using AutoCAD, Orana Engineering developed a mechanical design that met client constraints and constructability requirements. From the design, a drawing set was produced detailing mechanical aspects of the conveyor design, including equipment configuration, and extensive details for selection and installation of conveyor structures, whilst minimising curves.

Carborough Downs Coal Mine is an underground operation utilising conveyors to transport mined coal to the surface for processing. As operations progress and new longwall headings are mined, new conveyor installations are also required. Orana Engineering was engaged to design a new longwall drive-head chamber and conveyor installation, initially providing a drawing set detailing required drive-head chamber dimensions to suit the conveyor installation. Using AutoCAD, a civil design and conveyor equipment arrangement was produced. The conveyor design had to consider several constraints, including available equipment, transfer tie-in to existing trunk conveyor, maintenance access, drainage, minimum clearances and belt curves. Upon layout approval, AutoCAD drawings were produced detailing civil and mechanical design aspects, enabling site engineers to complete installation with efficiency while ensuring regulatory compliance.

Orana Engineering was requested to complete an audit of water and wastewater services at BMA’s Blackwater Mine. The audit was to determine whether new go-line infrastructure would adversely impact the existing mine industrial area services, and whether additional infrastructure or upgrades were required. Data collected from site by Orana Engineering was used to prepare a hydraulic model for each service. Modelling results, findings and recommendations were included in a detailed report outlining the capacity and utilisation of existing services to quantify available system capacity for the proposed new buildings. Additionally, Orana Engineering’s drawing revision services were utilised to formally revise site P&IDs to As Built, incorporating mark-ups made during the site visit.

The purpose of the Reagent System Upgrade at Oaky Creek was installation of new reagent storage tanks, discharge / delivery pumping systems and automated flow control distribution manifolds for the delivery of each reagent to the nominated process connections. Orana Engineering performed mechanical, electrical and control systems design, drafting and engineering for the project. The primary deliverables included scope of works, construction drawings, functional specification, BOM, spares lists and equipment / instrument data sheets. Orana Engineering managed the onsite commissioning of the system and provided a system handover to operations for implementation. An Operation & Maintenance Manual and Hazardous Area Dossier were provided on project completion.

The IMT project team at MMG’s Century Zinc operations enlisted the assistance of Orana Engineering to produce a set of fabrication drawings for an existing gear box frame that required replacing. The frame had been in operation for some time, however there were no detailed drawings available for construction of a replacement unit. The design staff at Orana Engineering created a detailed 3D model using client-supplied photos and sketches, enabling designers to produce 2D fabrication drawings for approval. A review of the drawings was conducted by the client to confirm the layout and accurate alignment with the existing installation on site. Following minor adjustments, As-Built status drawings were reissued to the client, accurately capturing detail of the existing frame.

Orana Engineering was engaged by Oaky Creek Coal to assist in design and construction of onsite camp accommodation, including an HV substation for power and potable water supply. Our brief included mechanical, electrical and control systems design, drafting and engineering for the project. Deliverables included scope of works, construction drawings, functional specification, drawing and equipment registers, commissioning and operating spares lists and equipment and instrument data sheets. Orana Engineering provided PLC configuration and commissioning assistance for pump control, acted as Client Representative during construction, managed onsite commissioning of the system, and provided a handover to operations for implementation. Operation & Maintenance Manuals for potable water storage and the HV substation were provided upon completion.

BHP Billiton Cannington Mine, is a significant miner and exporter of silver and lead concentrate. Orana Engineering was engaged to provide workshop fabrication drawings for a replacement cover to address corrosion issues around flanges and access openings on the existing SAG mill trommel sump cover. Following a site visit to obtain measurements, photos, drawings and documentation, the Orana Engineering design drafting team created a detailed 3D model of the existing structure incorporating new components to produce a set of detailed shop fabrication drawings while also revising multiple existing drawings. These drawings were reissued for construction after receiving client approval. The new cover sections and access panels improved the safety of trommel operation while also reducing inspection and maintenance time.

At the completion of Tailings Pumping Upgrades of the Main CHPP and Module 4 CHPP at Oaky Creek Coal, Orana Engineering received As Built drawings from site and was requested to make electronic revisions for upload into the client’s Drawing Management System. Over 80 drawings had received red pen site mark-ups indicating either that the design had been constructed as per the drawings, or highlighting design changes made during the construction phase of the project. Orana Engineering reviewed these mark-ups and formally revised all drawings to As Built status, incorporating the site mark-ups. The final set of drawings was uploaded to the client’s Drawing Management System ensuring site personnel had access to the latest As Built drawings.

Carborough Downs Coal Mine is an underground operation utilising conveyors to transport raw material to the surface for processing. As operations progress new trunk conveyor extensions are required. Orana Engineering was engaged to assist with the process of extending an underground trunk conveyor. This involved using survey data of the conveyor heading and designing a suitable belt profile, utilising minimum conveyor curves identified in the conveyor power and tension analysis. Orana Engineering produced a set of drawings detailing the belt profile, conveyor structures and locations for roof bolts that the structures would be suspended from. These drawings enabled site engineers to complete the conveyor structure installation and conveyor extension with minimal risk of error and conveyor tracking problems.

The Glencore Port Operations in Townsville operate an export facility for minerals concentrate and refined copper within the Port of Townsville precinct. The concentrate in-loading rotaside tippler was identified as being at end of life and a feasibility study was commissioned to review a like-for-like replacement option for refurbishment of the tippler. To facilitate feasibility-level costing, Orana Engineering was asked to provide electrical engineering and mechanical engineering assistance with provision of a concept design for the proposed refurbishment and upgrade. By working closely with Glencore, and other consultants engaged on the project, Orana Engineering was able to contribute as part of a collective "owners engineering team" to the feasibility assessment of a significant engineering project in the Townsville Region.

When tasked with a major repair to one of their leaching tanks, personnel at Carpentaria Gold, Ravenswood enlisted the assistance of Orana Engineering to develop a solution that would allow process operations to continue whilst leaching tank TK102 was out of service. A site visit and discussions with the client suggested a bypass line be installed around TK102. By utilising site information, Orana Engineering designers were able to detail a new bypass line through the existing processing plant area. This involved minor modification of existing structural steel and addition of pipe supports for the new HDPE bypass pipeline. Bypass piping was successfully installed during normal operation with only tie-ins needing to be installed during a single shut down.

Oaky Creek Coal uses an onsite RO plant to provide treated recycled water to various site operations. An opportunity was identified to use this recycled water for supply to critical equipment such as horizontal belt filters. Improving the equipment water quality resulted in a reduction in equipment downtime and lowered maintenance requirements. Orana Engineering reviewed the performance of two existing boost pumps intended to provide high pressure treated water to a new HBF. Hydraulic modelling was performed to predict future demand and thus determine the suitability of the existing pumps for use in the new application. Orana Engineering also prepared a control philosophy for use by systems engineers to ensure safe operation of the pumps under all operating conditions.

At Glencore’s Oaky No.1 underground coal mine, transportation of vast quantities of coal over long distances requires significant power. Often drive-head power is insufficient or constrained by allowable belt tension and an additional drive/power source is required to meet operating capacity. Additional power is commonly sourced from a driven conveyor tripper installed along the conveyor with appropriate excavation for the tripper. Using the client’s existing mine plan to position the new tripper chamber, Orana Engineering design drafting personnel worked with site engineers to assess required chamber dimensions while simultaneously minimising the excavation of material. Orana Engineering used AutoCAD to produce a drawing set detailing the mining required, and an overlay showing future equipment installations within the new chamber.

Engineers at Glencore’s Oaky No. 1 underground coal mine engaged Orana Engineering to determine civil work requirements to install tripper equipment on the MG32 longwall conveyor. On completion of chamber mining, finished surfaces (rib and floor) may require modification for the installation of conveyor tripper equipment. The civil design must determine concrete grades for drainage, safe access and reinforcing for conveyor equipment, while minimising trimming and concrete required. Manipulating “as-cut” survey data using AutoCAD, Orana Engineering design staff could accurately determine where tripper equipment could be installed with minimal trimming and concreting. A drawing set was produced detailing civil aspects of the tripper design, including chamber trimming, equipment mounting locations, configuration of reinforcing and relative concrete levels for drainage.

Orana Engineering was engaged by Glencore to design and install a detailed arrangement of tripper drives, brakes, pulley frame and load station for the MG32 conveyor at its Oaky No.1 underground coal mine. Mechanical design considerations included operating capabilities, unimpeded travel road access and minimum belt curves. The design was dependent on the civil installation previously detailed by Orana Engineering. Often equipment is simply re-located from previous installations with minor modifications. Orana Engineering has developed unique methods for completing this type of design efficiently and at reduced cost to our clients. AutoCAD was used to develop a mechanical design, from which a drawing set was produced that detailed out the mechanical aspects of the tripper installation

Mining millions of tonnes of material requires significant infrastructure and planning. Orana Engineering has been engaged on multiple occasions at Glencore’s Oaky No. 1 underground coal mine, to design new conveyor drivehead chambers to install equipment for longwall mining. Using the client’s existing mine plan, Orana Engineering design drafting personnel worked in tandem with engineers to assess required chamber locations and dimensions, with consideration to the size and orientation of equipment to be installed and minimising the material to be excavated. An AutoCAD drawing set was produced detailing the extent of mining required along with an overlay showing future equipment installations, enabling the client to efficiently complete chamber mining with a design suitable for future installations and minimal rework.

Engineers at Glencore’s Oaky No. 1 underground coal mine engaged Orana Engineering to determine civil work requirements to effectively utilise drive-head equipment in newly mined chambers for conveyor installations. On completion of chamber mining, finished surfaces (rib and floor) may require modification for installation of the conveyor drive-head equipment. The civil design must determine concrete grades for drainage, safe access and reinforcing for conveyor equipment, while minimising trimming and concrete required. Manipulating “as-cut” survey data using AutoCAD, Orana Engineering design staff could accurately determine where equipment might be installed with minimal trimming and concreting. A drawing set was produced detailing civil aspects of the conveyor design, including chamber trimming, equipment mounting locations, configuration of reinforcing and relative concrete levels.

Due to expanding operations, Oaky North underground operations saw benefit in having an underground workshop and refuelling stations to reduce vehicle travel times and increase efficiencies. Orana Engineering was engaged to provide concept design and estimating assistance for project approval. From communications with our client, Orana Engineering prepared concept general arrangement drawings for consideration. Based on these concept design drawings, a project capital estimate and project schedule were prepared for Oaky North underground operations. From the information presented by Orana Engineering, Oaky North could accurately consider whether the underground workshop was feasible, and ensure that appropriate budgets and project planning was completed at the concept design phase to improve confidence in the project prior to execution.

BHP Billiton Cannington Mine is a significant underground silver and lead mining operation in Western Queensland. Following completion of ore extraction from each stope, paste backfill is used to fill the open void and stabilise the area. This is achieved by constructing a fill wall which provides stability for areas being back filled, eliminates intrusion, and allows a higher density of back fill. Wall constructions kits supplied to Cannington contained no documentation detailing the kit components. BHP Billiton engaged Orana Engineering to confirm the components in these kits. Using measurements and sketches obtained from site, Orana Engineering design drafting personnel utilised AutoCAD to create a drawing set detailing the components required and fabrication details for each construction kit.