Project Report - 2018
Client:
Cockburn Cement Limited (Kwinana Beach) Project: Replace a cement bagging line Challenges:
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The team:
Cockburn Cement Limited (client, project management and supervision) Haver & Boecker (Bagger System supplier) Beumer (Palletiser System supplier) RSA Consulting Engineers (structural design oversight and certification) D.A.K. Systems (duties below) Henry & Hymas (shop detailing) Statewide Industrial Maintenance (Fabrication & erection) D.A.K. Systems’ Tasks: Design the support structure for the replacement process line and resolve the associated existing plant process flow interfaces. I was also onsite for the construction period, for support and supervision. |
Outcomes:
The new bagger system line was in place, ready for MCC connections, in 8 days from the decommissioning of the old line. Wet commissioning of the replacement process line commenced 5 weeks after the decommissioning of the old line.
How we did it:
It was decided that main loaded structure be pre-assembled in four modules. The first two modules would position side by side at floor level. The third and fourth modules would stack on top of the second module. The third module was partially clad where it extended beyond the existing roof level. The fourth module was fully clad. Each module had two landings, and all of the mechanical plant was accurately installed as each module was built.
The fourth module roof level was 29m above floor level and 16m above the existing factory nominal roof level. The heaviest module was 51T.
This module pre-assembly took place over 3 months in a shelter at the rear of the site.
Coupled self-propelled modular transporters were used to transport the modules 600m from the pre-assembly location to the crane pick-up point. The state’s biggest slewing crane (750T) lifted the modules up 20m and then down through a tailored hole in the factory’s roof.
With the exception of some slinging re-arrangement and a minor clash between some mechanical plant and the adjacent mechanical plant’s guarding, all lifts were completed with one take, and the modules splice connections were made good as intended.
Minor ancillary platforms around the modules were erected in situ whist the electrical and mechanical services were connected.
Each team member did a great job, enabling the project to be erected with excellent efficiency.
Further reading & pics: Global Cement's write-up on the project
The new bagger system line was in place, ready for MCC connections, in 8 days from the decommissioning of the old line. Wet commissioning of the replacement process line commenced 5 weeks after the decommissioning of the old line.
How we did it:
It was decided that main loaded structure be pre-assembled in four modules. The first two modules would position side by side at floor level. The third and fourth modules would stack on top of the second module. The third module was partially clad where it extended beyond the existing roof level. The fourth module was fully clad. Each module had two landings, and all of the mechanical plant was accurately installed as each module was built.
The fourth module roof level was 29m above floor level and 16m above the existing factory nominal roof level. The heaviest module was 51T.
This module pre-assembly took place over 3 months in a shelter at the rear of the site.
Coupled self-propelled modular transporters were used to transport the modules 600m from the pre-assembly location to the crane pick-up point. The state’s biggest slewing crane (750T) lifted the modules up 20m and then down through a tailored hole in the factory’s roof.
With the exception of some slinging re-arrangement and a minor clash between some mechanical plant and the adjacent mechanical plant’s guarding, all lifts were completed with one take, and the modules splice connections were made good as intended.
Minor ancillary platforms around the modules were erected in situ whist the electrical and mechanical services were connected.
Each team member did a great job, enabling the project to be erected with excellent efficiency.
Further reading & pics: Global Cement's write-up on the project