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Engineering at Coal Mines 

Queensland has a rich and vast deposit of high-quality coal resources with over 34 billion tonnes of raw coal having been identified.  It boasts a combination of thermal coal for power generation and over 8 billion tonnes of coking coal suitable for high quality steel milling (from Dept. of Natural Resources and Mines). Coal is extracted from the ground using both open-cut and underground mining operations and is then typically subject to further processing at Coal Handling and Processing Plants (CHPP) before being transported via conveyor, truck, rail or ship (or combination of these) to the buyer.

Orana Engineering has built a strong reputation within the coal industry, offering electrical, mechanical, structural and control systems engineering support to a wide range of clients spread throughout the Bowen and Surat basins. Our Townsville and Chinchilla offices are placed to offer local support for operations based in the Bowen and Surat Basins and to support the expansion of the coal industry into the Galilee Basin. 

Our engineering services including design, project management, design drafting, revisions and drawing management are intended to support the fixed plant and surface infrastructure of mining operations including the CHPP and associated services such as onsite water treatment plants. We also support the underground coal mining operations providing conveyor installation designs and mine dewatering designs.  As the industry is governed by specific legislation including the Coal Mining Safety and Health Act and Regulation, it is important that engineering consultants are fluent with these regulations, of which Orana Engineering is.  Further information on the Act and Regulations can be found here. 

Coal Mining Safety and Health Act 1999 
Coal Mining Safety and Health Regulation 2001

Our engineering experience and expertise within the coal industry gives our personnel a first-hand understanding of the process and site practicalities.  Explore the case studies below to see the services that we have offered to our clients in the coal sector.

Orana Engineering coal minE ENGINEERING 

Reagents Lightning Protection

To ensure the CHPP reagent tank farm lighting protection systems were adequate and complied with Australian standards, Moranbah North requested Orana Engineering undertake a review and design for an upgrade of the lightning protection systems (LPS) installed for the tank farm area. more


Sewage Treatment Plant Refurbishment

To increase productivity as well as maintaining compliance with current legislative standards, Glencore Coal employed the services of Orana Engineering to design, manage and oversee the installation of the electrical portion of their sewage treatment plant upgrade. more


Structural Audit

Orana Engineering prides itself on attention to detail, not only in our engineering design and drafting services, but also in our audit and inspection services. Orana Engineering was requested by Glencore’s Oaky No. 1 Mine to perform a structural integrity audit/inspection of major assets at the mine. The audit was a non-invasive, visual inspection of major assets. This inspection was completed alongside an audit of access systems to AS 1657 to gain efficiency by completing two audits in one visit. more


Site AS 1657 Audit

Orana Engineering prides itself on attention to detail which we not only apply to our engineering design and drafting services, but also our audit and inspection services which we offer to our clients. more


UG Conveyor Installations - MG Mechanical Installation

Detailing the installation of mechanical equipment and conveyor structure is one of the final steps for completing a maingate drive-head design. Installations designed by Orana Engineering (MG32, MG33, MG33C, MG34, MG35 & MG36) for Glencore’s Oaky No.1 underground coal mine typically detail the arrangement of drives, transfer stations, take-up units, maintenance equipment and overhead structure to support the carry belt. more


UG Conveyor Installations - MG Civil Installation

The site engineers at Glencore’s Oaky No. 1 underground coal mine have requested the assistance of Orana Engineering to determine the extent of the civil work required to effectively utilise the drive-head equipment in newly mined chambers for conveyor installations for MG32, 33, 33C, 34, 35 & 36. more


Site DCS Support

Oaky Creek Coal’s (OCC) Coal Handling and Preparation Plant (CHPP) utilises a Yokogawa Distributed Control System (DCS) for control and monitoring of their operation. The system also incorporates Yokogawa’s OPC server and Exaquantum data historian. In addition, OCC utilises a number of Programmable Logic Controllers (PLC) for specific operational purposes, with a number of the PLCs interfaced back to the DCS for control and monitoring functions. more


CHPP Conveyor Capacity Audit

Vale Carborough Downs Coal Mine (CDCM) required details of the current and possible future capacities of their Module 1 & 2 product conveyors at their coal processing plant in Central Queensland. As a result, Orana Engineering was engaged by the CDCM site engineering and maintenance team to perform the necessary site visits, calculations and reporting. The study consisted of 8 plant conveyors and outlined high level recommendations of modifications required for the plant to achieve higher tonnages. more


Electrical Drawing Registration

The electrical engineering team at Collinsville Coal found that approximately 280 drawings from a recent electrical upgrade were not available to all personnel via their drawing management system. In order to maintain regulatory compliance, Orana Engineering was engaged by Collinsville Coal to register and upload these drawings into their drawing management system, which Orana Engineering had previously assisted with developing. more


Electrical Specifications

To ensure site consistency of electrical design and installation standards as well as compliance with relevant Australian standards and state legislation, Oaky Creek Coal’s Electrical Engineering Manager (EEM) engaged the services of Orana Engineering for the preparation of new site electrical specifications. more


Treated Water Boost Pumps

The Oaky Creek Coal (OCC) operation uses recycled water treated within an onsite RO plant to provide treated water for use by various operations on site. OCC recognised an opportunity to use this clean treated water for water supply to critical equipment such as Horizontal Belt Filters (HBF), improving the quality of water used for equipment reducing downtime and maintenance requirements associated with poor quality water, in-turn improving the efficiency of the operation of the equipment. more


MG07 Conveyor – Development Conveyor

Carborough Downs Coal Mine is an underground operation located in Central Queensland that utilises 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. Designing a conveyor installation involves 3 major stages: the drive-head chamber design, the civil design, and the mechanical arrangement design. more


MG07 Conveyor – Civil Design

Carborough Downs Coal Mine is an underground operation located in Central Queensland that utilises 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. Designing a conveyor installation involves 3 major stages: the drive-head chamber design, the civil design, and the mechanical arrangement design. more


MG08 Development Conveyor

Carborough Downs Coal Mine is an underground operation located in Central Queensland that utilises 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 by Carborough Downs to design a new longwall drive-head chamber and conveyor installation. more


UG Conveyor Installations - MG Chamber Design

Mining and transporting millions of tonnes of raw material every year requires significant infrastructure and planning for future works. The site engineers at Glencore’s Oaky No. 1 underground coal mine have engaged Orana Engineering on multiple occasions (MG33C & MG34) to design new conveyor drivehead excavations (chambers) to install conveyor drivehead equipment for development and longwall coal mining. more


Carborough Downs Coal Drawing Management

Orana Engineering was engaged by Carborough Downs Coal Mine (CDCM) to design and implement a complete drawing management system from registering every drawings metadata to revising and maintaining the data base moving forward to maintain regulatory compliance. more


MG07 Conveyor – Chamber Design

Carborough Downs Coal Mine is an underground operation located in Central Queensland that utilises 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. Designing a conveyor installation involves 3 major stages: the drive-head chamber design, the civil design, and the mechanical arrangement design. more


Fire System Drawings

Accurate fire services and emergency resource drawings are important to ensure that the appropriate information is available to mine site based operations and emergency personnel. Orana Engineering was engaged by Oaky Creek Coal to assist in creating a set of fire system drawings throughout the surface operations to ensure they were up to date and relevant. more


Tailings Pumping System - As-Built

At the completion of the Tailings Pumping Upgrade for both the Main CHPP and Module 4 CHPP at Oaky Creek Coal, Orana Engineering received As Built mark-up drawings and documentation by the site project manager and was requested to make electronic revisions to the drawings and upload them into the site drawing management system. more


UG Conveyor Installations – MG32 Tripper Mechanical Design

In high capacity longwall conveyor arrangements, the installation of a tripper will typical occur after the chamber has been fully developed. The installation designed by Orana Engineering for MG32 conveyor for Glencore’s Oaky No.1 underground coal mine detailed the arrangement of the tripper drives, brakes, pulley frame and load station. more


Fire System Audit

BMA Gregory Crinum requested 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 in particular the stockpile conveyor. more


Onsite Accommodation As-Built Drawings

Following construction and commissioning of the Onsite Accommodation Camp at Oaky Creek Coal Mine located in Central Queensland, Orana Engineering was provided with “As-Built” mark-ups to the complete set of construction drawings for the Water Storage Facility, HV Substation, Water Treatment Plant tie-ins and supply pipeline. These drawing mark-ups largely confirmed that construction was in accordance with the civil, electrical and mechanical design developed by Orana Engineering, with only minor changes implemented during the construction and commissioning process (confirmation of “green” pipe spool lengths, etc.). more


Onsite Accommodation Camp Services

Orana Engineering was engaged by Oaky Creek Coal Mine in Central Queensland to assist with the design and construction of an onsite accommodation camp on the mine lease, including primarily the HV substation for power supply and potable water storage & supply. more


OC1 Drawing Registration

Orana Engineering was approached by the Oaky Creek Coal No.1 Mine (OC1) to assist with drawing management assistance, to identify the latest revision of each drawing for all hard copy and electronic drawings that OC1 had onsite and ultimately create a register of the latest revision of every drawing. This register would draw a line in the sand and provide the ability to maintain all drawings within a structured document management system into the future. more


MIBC & Diesel Upgrade

The purpose of the Reagent System Upgrade project at Oaky Creek was to install new reagent storage tanks, discharge/ delivery pumping system and automated flow control distribution manifolds for the delivery of each reagent to the nominated process connections. In the event of failure of the automated flow control system, rotameters for manual reagent addition were included as a contingency. more


22M Flyover Conveyor

Oaky Creek Coal engaged Orana Engineering to perform the electrical and control system engineering design for the 22M Flyover Conveyor. The new conveyor provides an interface between two existing conveyor systems. more


UG Conveyor Installations – MG32 Tripper Civil Design

The site engineers at Glencore’s Oaky No. 1 underground coal mine have engaged Orana Engineering to determine the extent of the civil work required to install the maingate tripper equipment in MG32 longwall conveyor. more


MIA Services Audit

Orana Engineering was requested by the BMA Projects Department to assist in completing an audit of air, water and wastewater services at BMA Blackwater Mine in Central Queensland. The work was required in order to determine if the addition of new go-line infrastructure would adversely impact the existing mine industrial area services, and if additional infrastructure or infrastructure upgrades were required. more


Collinsville Coal Drawing Registration Project

Orana Engineering was contacted by Collinsville Coal to conduct a high level review of their onsite drawing storage and management systems with respect to accessibility, security and regulatory compliance. During this review areas for improvement were identified and recommendations along with cost estimates were provided to Collinsville Coal to make an informed decision as to how they would improve the management of their drawings moving forward. more


Underground Workshop Concept Design

Due to expanding operations, Oaky North underground operations considered that there could be benefit to having an underground workshop including refuelling stations to reduce vehicle travel times and increase efficiencies of vehicle movements. Orana Engineering was engaged to provide concept design and estimating assistance for internal project approvals. more


UG Conveyor Installations – MG32 Tripper Chamber

Maingate roadways mined to accommodate longwall conveyors at Glencore’s Oaky No. 1 underground coal mine can vary from a few hundred meters to over 4 kilometres in length. Transporting vast quantities of coal over long distances requires a significant amount of power. In some cases the drive-head power is insufficient or is constrained by the allowable belt tension and an additional drive/ power source is required to meet the required operating capacity. Commonly this additional power will come in the form of a driven conveyor tripper installed at a nominal point along the conveyor, which requires the appropriate excavation for the tripper installation inclusive of drives, tripper frame, braking and belt starter. more


Quantify Drawing Registration Works

Oaky Creek Coal’s Oaky North operations (OCN) requested Orana Engineering provide an accurate estimate to collate all of their existing drawings in all formats into a single register identifying the latest revision or every drawing. more


Mobile Plant Electrical Drawing Books

To improve the maintainability of plant electrical systems and personnel safety, Hail Creek Mine employed the drawing management services of Orana Engineering to create bound books of electrical drawings for Dragline 1 (DL001), Dragline 7 (DL007) and Shovel 14 (SH014). Multiple books were made for each machine (in A4 & A3 sizes). more


Conveyor Upgrade Project

The Carborough Downs Coal underground mine located in Central Queensland, transitioned from a Bord and Pillar mining system to Longwall mining and as a result required to upgrade the capacity of their coal clearance conveyor system. Orana Engineering was engaged to provide Clients Engineering assistance to deliver the final underground conveyor equipment to meet the Longwall production schedule. more


Yokogawa DCS Upgrade

Orana Engineering has since 2005 provided 24/7 support for Oaky Creek Coal’s (OCC) control systems. At the Coal Handling & Preparation Plant (CHPP) OCC uses a Yokogawa DCS as the primary control system, which was originally installed in 1998. The system is very robust and the hardware, software and its configuration has proven to be very reliable and highly cost effective. more