Structural Engineering Consultants

Orana Engineering was contacted by Glencore for assistance in determining ground anchoring of three mobile crib huts at its Rolleston Coal Mine. The objective of Orana Engineering’s investigation was confirmation of applicable regional wind loads on each structure and requirements for external hold-downs with respect to sliding and overturning forces.

To assess anchoring options, calculation and analysis of wind forces on the mobile crib huts was performed using AS/NZS1170.2 for loading with various earth anchor types evaluated while also taking into consideration soil properties and ground compaction.

Based on structural engineering principles and calculations, and in consideration of Australian Standards and industry best practice, it was determined that all the mobile crib hut structures required anchoring to prevent sliding or overturning. Recommendations for the most appropriate type of ground anchor, along with general stipulations for application and installation of the these, was documented and presented to the client upon conclusion of Orana Engineering’s evaluation.

Glencore’s Newland Coal operation required removal of three Redispan conveyor modules at the tail end of its CV805 conveyor, leaving the head end modules in place. Assistance was sought from Orana Engineering in evaluating the stability and suitability of the head end support structure in withstanding the longitudinal loads of the conveyor.  

Orana Engineering conducted a high level inspection and provided structural engineering advice as to the optimal lifting methodology to prevent overloading of the conveyor supports and pins as well as identification and recommendation of necessary limitations such as wind considerations and applicable exclusion areas.  A review of the linkage of each remaining longitudinal brace was also undertaken to evaluate the stability of sections prior to their removal.

Upon conclusion, a letter of recommendation was presented to the client detailing outcomes of the Redispan structural review and installation, and providing engineering advice for the demolition works.

The Village Kitchen at Glencore’s Hail Creek Mine camp was scheduled for upgrade with Orana Engineering engaged to provide engineering support for electrical, civil and building works, including a new shed.  A site visit was conducted to determine the scope of the upgrade and to collect site information comprising photos, drawings, measurements and location of water and gas services.

From the information gathered, Orana Engineering provided engineering design and project management of the Village Kitchen upgrade including a new shed distribution board, concrete slab, layout and connection of services to the new shed and prepared a detailed scope of work document for tendering purposes.

Orana Engineering design drafters produced RPEQ certified GA and concrete drawings showing details of services to be relocated, a slab and loading dock drawing, a new single line diagram for the distribution board, and revisions to existing distribution board drawings.

Orana Engineering assisted Glencore's Clermont Coal with an engineering review of the structural integrity of head end support stools connected to its train load-out (TLO) bin ring beam as material build-up at the top of the bin cone had resulted in corrosion of several lower stools connected to the ring beam. Orana Engineering presented recommendations for temporary stiffening solutions and a repair methodology to restore conveyor supports to original design capacity.

Following the initial review, Clermont Coal requested that Orana Engineering undertake a further structural review of the TLO bin to analyse the effect of scaffold arrangements to be constructed on the bin and to confirm overall structural integrity with the additional applied loads.

Orana Engineering design drafters developed a concept design 3D model of proposed bracing including finite element analysis (FEA), and RPEQ certified detailed drawings for TLO column repairs were also delivered to the client.

Glencore’s Hail Creek Coal Mine engaged Orana Engineering to develop the engineering design for a stand to elevate a 1,000 litre IBC from ground level, enabling the content to gravity feed to the pump suction during a major upgrade project.

Design considerations by Orana Engineering included the process and materials relevant to the IBC location, raw material requirements and painting specifications based on site standards, positioning and fit of the IBC with existing equipment and infrastructure once elevated on the stand.  Height requirements for gravity feed to pump suction connection and allowance for differential grouting of feet to account for concrete falls were also taken into account.

Orana Engineering design drafters generated a 3D model of the proposed design using AutoCAD Advance Steel for client review before developing a Navisworks Model of the IBC stand and completing engineering checks for load. 

Final deliverables to the client included arrangement and fabrication detail drawings of the stand with RPEQ supervision.

Orana Engineering was contacted by Glencore’s Oaky Creek Coal Mine to undertake a structural review of lighting towers situated at the Tieri township sporting oval. Existing tower bases had been buried for approximately 20 years and were displaying evidence of corrosion to anchor bolts and baseplates.

Orana Engineering conducted a review of client-supplied documentation and photographs and gathered additional information to determine repair requirements.  Following the review, a letter of recommendation was provided to the client outlining repairs required for continued operation of the lighting towers, with RPEQ structural supervision.

Additional support was provided by Orana Engineering with a further review of lighting towers within the Tieri Aquatic Centre and Shopping Centre. In this instance Orana Engineering was also able to capture 3D data from light poles using its Faro 3D laser scanner. The client was presented with recommendations for tests or further analysis required.

A filter press initially planned for Glencore’s Clermont Coal Mine was relocated for installation at Collinsville Coal Mine in a trial capacity to assist in reducing the amount of tailings produced from the wash plant. 

Orana Engineering was engaged to provide engineering and drafting support for the filter press installation scope of work, to assess suitability of the Clermont detailed design for construction at Collinsville and to plan and implement arrangements for the installation.

Considerations to ensure a smooth installation at Collinsville included concrete design and a structural analysis. Calculations were also undertaken to determine design wind and earthquake loads for the site to Australian Standards AS/NZS1170.2 and AS1170.4.

Orana Engineering design drafters produced a new site plan showing set-out of the filter press slab with new and existing underground services detail incorporated, with RPEQ Supervision. 

Personnel at Origin Energy’s Darling Downs Power Station contacted Orana Engineering seeking assistance in reviewing regulatory requirements of fire protection systems (detection, alarms, hydrants, emergency exits) relevant to areas of the site not fully protected by existing systems due to distance or obstruction.

Orana Engineering’s design was required to tie into the existing potable water fire line to supply a new fire hydrant / hose reel, while meeting operational fire-fighting requirements compliant with Australian Standards

Orana Engineering completed mechanical engineering, calculations and hydraulic modelling for review by a third party Fire Systems Designer and verification by an RPEQ Fire Engineer.  Orana Engineering also undertook pipework design and drafting with RPEQ sign-off.

Deliverables to the client comprised a scope of work document, a testing / commissioning plan, budget estimate cost proposal for installation and building certification, and provision of a drawing set for the fire water extension.

Orana Engineering was consulted by Glencore’s Collinsville mine to assist with an upgrade of its CHPP washdown water distribution system.  The CHPP clarified / raw water is supplied from either an anti-pollution pond or the raw water Sunwater pipeline, with the wash water distribution network delivering water to the yard area, CHPP washdown sprays, lime / flocculant dosing or conveyors for spray bars and washdown.

Following hydraulic modelling, Orana Engineering’s mechanical engineers delivered a design with improved flow and pressure, (increasing capacity from 375 to 700 cubic meters per hour) while structural engineers produced SpaceGASS modelling of pipe supports and 3D modelling of the discharge structural steel pipe rack. Additionally, a Functional Specification or Function Description was produced for integration of the design into the plant's control system.

Project deliverables included an Equipment Register, Scope of Supply, detailed Construction and Installation Scope of Work for Tender, Functional Description and detailed design drawings.

At the request of Glencore’s Collinsville Open Cut Mine, Orana Engineering provided a concept design for upgrade of aging infrastructure associated with the sites anti-pollution pond. 

Orana Engineering provided a detailed design for installation of permanent handrail and barrier systems along the access pathway to mitigate hazards.  The walkway bridge was identified as having inadequate support structure and was included in the proposed design, along with relocation of the existing pump pontoon and level sensors.

Orana Engineering design drafters produced 3D modelling for the installation which was provided to the client along with a general arrangement drawing of the new pontoon access, a fabrication detail drawing of the steelwork support and a civil and access ramp detail drawing, with RPEQ supervision.

The CPP chain feeder at Glencore’s Clermont Coal Mine required repair and the assistance of Orana Engineering was sought with development of an appropriate methodology and associated detailed design drawings.

Steel plates had been installed to cover the chain feeding system, which over time had been degraded by the dozer feeding the system chipping away at concrete footings. This caused exposure of the steel plate edge which subsequently caught on the dozer bucket. The result was a build-up of material around the chain, causing downtime to reinstate plates and clean up material.

Orana Engineering’s basis of design was for repair of the existing reclaim feeder concrete and development of suitable protection to reduce future wear damage and deterioration from dozer contact. Existing concrete footing drawings were revised to reference new concrete and steel detail and then issued for client review prior to finalising, with RPEQ supervision.

CS Energy engaged Orana Engineering to provide engineering and drafting support in documenting the scope for onsite civil, electrical (earthing) and mechanical (shade sail and drain piping) supply and installation at its Kogan Creek Power Stations Sewage Treatment Plant.  

The basis of design was provision of detailed design engineering of a bunded concrete slab to house two 22kL aerated tanks and a 20 foot container. The slab design was to include an effluent drainage system with a new discharge pipe to be connected to the existing underground wastewater drainage network. It was planned to remove existing tanks and pumps and the design scope prepared by Orana Engineering was to include details for filling and capping the residual drainage pipes and holes.

Design drawings generated by Orana Engineering personnel to support the scope of work included a general arrangement, a detailed drawing and a revised layout drawing.

Origin Energy’s Talinga Gas Plant oily water system treats water created during the gas compression process. Effluent from the system is pumped into the water-gathering network, delivering water to the main water treatment plant.

Orana Engineering was engaged by Origin Energy to evaluate the oily water system and conducted a high level assessment of options to reduce the risk of uncontrolled release of contaminated water from the wetlands system that was controlled by interim means.

Outcomes were presented to the client summarising options to reduce or eliminate identified risks. Orana Engineering subsequently provided detailed mechanical and electrical design and drafting for the approved option.

Deliverables for the project included a basis of design document, detailed design and a revison of the Wetland Operations & Maintenance Manual. 

Glencore’s Collinsville Open Cut Mine engaged Orana Engineering for assistance with engineering design of a new concrete slab to allow for driving, loading / unloading of forklifts and delivery trucks at its warehouse building. The design accounted for tie-ins to existing slabs and a surrounding security fence with cantilevered sliding gates on western and eastern sides of the area.

Orana Engineering’s involvement comprised gathering of additional site data and drawings on existing slabs, reviewing geotechnical and ground survey data for conditions in the area, liaison with the client and plumbers etc to confirm area runoff and underground services, as well as engaging vendors of precast concrete barriers, sliding gates and mesh fencing.

Preliminary sketches for client review and discussion were produced by Orana Engineering’s design drafting personnel, followed by concrete general arrangement and detail drawings and a structural detail drawing ‘issued for construction’ with RPEQ Supervision.

CS Energy’s Kogan Creek Power Station was experiencing intermittent lateral vibration in the structural bracing of two of its boilers. The assistance of Orana Engineering was sought in conducting a structural and vibrational engineering review of the affected plant to determine the source of the issue. The review included SpaceGASS modelling of the local structure surrounding the bracing to assess loading and determine member sizing.  A modal vibration analysis was completed to determine the natural frequencies of the plant and structural bracing.

Following review, the option of installing cables for the bracing was discounted and it was recommended that new bracing for structural members be installed and connected to the midpoint on either side using a custom designed clamped fitting (to avoid welding to existing loaded brace) and installing a new cleat at the main structural member.  The design solution increased the lowest natural frequency vibration mode shape for the structures and also reduced visible deflection.

Orana Engineering deliverables for the project included a Boiler Structural Beam Plan Arrangement and detail drawing ‘issued for construction’.

Orana Engineering was invited by MFE to provide an estimate for subcontract works for the Veolia Water brine concentrator drain pump system at Kenya Water Treatment Plant. 

Brine concentrators at the plant periodically release high temperature and corrosive wastewater to floor sumps to control or monitor processes.  The PVC pipework from floor sumps had become unserviceable due to the pipeline material not being rated for high temperatures. The existing drainage pipeline needed to be replaced with a durable system capable of withstanding high temperature corrosive wastewater.

Orana Engineering’s involvement in the project encompassed provision of engineering support (hydraulic, mechanical, civil and electrical design) and drafting support including revision of existing drawings and generation of new hydraulic, mechanical, civil and structural drawings with RPEQ supervision.

Veolia’s Kenya Water Treatment Plant contacted Orana Engineering for assistance with engineering design and drafting of a manual pull-along crane utilising existing support beams and able to travel in both long and cross travel directions.  It was proposed for the fabricated cranes to be installed in each of the treatment plant’s three brine concentrator engine bays.

A member of Orana Engineering’s mechanical engineering team attended site to inspect existing infrastructure, take measurements and gather information. Upon return to Orana Engineering’s Chinchilla office the site data was reviewed, structural engineering calculations performed and information provided to the drafting office for translation to general arrangement and detailed design drawings suitable for fabrication purposes.

Orana Engineering was contacted by Sunwater to design a frame capable of supporting two hydraulic over-shot gates to be installed on the existing Culgoa Weir structure. The purpose of the gates was to allow water flow downstream when open. Hydraulics were to be driven via a power pack on the back of a utility vehicle.

Orana Engineering undertook mechanical design of the gate frame including reviews of weir flow calculations and load scenarios.  Structural design aspects involved calculations, selection of member sizes, bolting details and connections as well as modelling of the frame in SpaceGASS with applied load cases and AS4100 analysis. 

Orana Engineering designers produced a 3D model of the frame and gate arrangements and drawings suitable for handover to a fabricator for installation.

Glencore’s Newlands Open Cut Coal Mine was investigating methods to update bunding for a 2 million litre diesel storage tank and engaged Orana Engineering to assess the existing bund while also considering requirements for a future fuel farm and compliance with Australian Standards.

Orana Engineering reviewed client-provided documentation and information gathered from site including drawings and survey data of the existing earth bund and details of underground services. Assessment of suitable liner options and an evaluation of the existing earth bund for necessary repair was also conducted along with considerations for tie in of the bund liner to existing structures. Orana Engineering delivered a file note for the site Project Manager to review compliance options.

The main plant raw water boost pumps at Glencore’s Oaky Creek Coal were supplied via a starter panel which required replacement due to water inundation and for improved functionality, reliability and compliance.

At the client’s request, Orana Engineering provided a report outlining preliminary design checks completed and provided a high-level summary of installation works required to the pump starter panel for a new MCC already on site.

Multiple upgrades were required to electrical equipment as well as associated civil / structural works. A preliminary concept sketch was prepared giving an overview of proposed upgrades. An Orana Engineering Electrical Engineer was appointed to assist with onsite commissioning of the raw water boost pumps and to provide offsite assistance with DCS configuration.

Deliverables to the client included electrical engineering and design drawings to IFA/IFC, a scope of work and a bill of materials.

Veolia Water’s Kenya Water Treatment Plant contacted Orana Engineering to provide engineering and design drafting assistance in relation to installation of fall-arrest rescue anchor points to the brine concentrator stair tower. 

Orana Engineering mechanical personnel undertook a review of applicable codes and standards in order to identify key safety considerations in the use of fall arrest systems.  Calculations were performed on existing structural members locally to determine beam capacity for the addition of lugs at 6 points as identified by the client.

Deliverables for the project included an RPEQ supervised design for manufacture and installation of the lugs, revision of existing client drawings to reflect design changes and creation of a new drawing including both general and detailed information for new lug locations.

Origin Energy sought assistance from Orana Engineering in providing a concept design for shade shelters to be retro-fitted to existing GCB enclosures at its Uranquinty Power Station in southern New South Wales. The objective of the shelters was to reduce rainwater contact with GCBs and the design to be such that shelters could be lifted off for periodic maintenance of GCBs.

A third party undertook 3D scanning of the existing cover structures and provided resultant scan data for 3D modelling by our design team. SpaceGASS modelling of the structures and analysis of compliance to Australian Standards was also conducted prior to provision of the new enclosure concept to Origin Energy for review.  Upon receipt of design approval, Orana Engineering developed and issued a scope of work for supply and installation of the GCB enclosure shelters.

At the request of Glencore Collinsville Coal Mine, Orana Engineering performed engineering design and drafting for a new monorail to be installed within the CHPP secondary spirals area. Orana Engineering’s assistance with the project included SpaceGASS modelling of the area and completing initial engineering and analysis for the proposed monorail while considering any effects on the existing structure and performing calculations and structural design checks to Australian Standards AS4100, AS1170 and AS1418.18. 

Lifting vendors were consulted for monorail trolley and chain block options which ensured the most appropriate selections for the Collinsville application. 

The designers at Orana Engineering produced a 3D model which was issued to the client for review and feedback. The monorail was fabricated and installed by others to Orana Engineering detailed design drawings and then load tested with subsequent deflection results meeting the requirements of Australian Standards.

Process Engineering personnel at Glencore’s Collinsville Coal mine contacted Orana Engineering for engineering support on various projects associated with an upgrade of the piping in its ultrafine circuit. These included incorporation of tee-offs to in situ lines, and additional pipe runs. 

Orana Engineering utilised existing 3D scan data to model a new pipe route and to provide concept general arrangement drawings to the client.  With this information site personnel had sufficient data to liaise with vendors regarding new equipment selection.  

Orana Engineering’s estimate also allowed for detailed design of RPEQ supervised drawings to allow the piping to be fabricated and installed. 

Additionally, Orana Engineering conducted a structural assessment of the horizonal belt filter (HBF) to support a proposed viper roller unit.

Glencore's Collinsville Coal Mine engaged Orana Engineering to develop a deconstruction safe work methodology for demolition and deconstruction of the CBN302 reject bin, along with appropriate risk assessment documentation based on the deconstruction methodology. 

Key considerations were ensuring that the bin and structure supporting the conveyor head end were maintained in a safe and stable condition during deconstruction and that the risks of stored energy in the curved bin shell plates was managed through the steel thermal cutting process (avoiding steel plate spring-back hazards).

Orana Engineering’s basis of design determined the necessary steps to safely remove the redundant CBN302 reject bin.

Detailed design and engineering provided by Orana Engineering included 3D modelling of the reject bin and structural steelwork to assist in preparing the methodology images.

The CHPP Structural Supervisor at Glencore’s Collinsville Coal Mine requested the services of Orana Engineering in completion of a structural review and provision of a replacement methodology for the CCV101 Trestle Clevis Plates.

Orana Engineering’s consultation included a structural review of documents and existing drawings, identification of load-bearing elements and weak points, analysis of existing design and indication of necessary modifications. Additionally, the review included development of a strengthening plan and methodology utilising temporary bracing and support systems to lift the structure for trestle clevis plate replacement and avoid working under suspended loads using props.

Outcomes from the project included a letter of recommendation with instructions for the trestle clevis plates replacement works, including notes and methodology, mark-ups of site photos and drawings to illustrate the proposed replacement methodology.

Glencore Coal Collinsville sought assistance from Orana Engineering in assessing multiple monorail designs within the CHPP area. The design review was to determine compliance with Australian Standards, including analysis of the structural capacity of each monorail, taking details from design drawings, 3D scans of the plant and physical measurements. 

Fifteen monorails in total were assessed via visual and non-invasive means to determine their general state. Photos were cross-referenced with 3D scan data of the plant and existing structural drawings, with a structural assessment completed on all monorails to AS1418.18 using SpaceGASS and spreadsheet calculations.

Deliverables to the client upon conclusion of the study included a summary of design review results and recommendations for remedial action. Results from the assessment allowed updated certified as-built drawings of each monorail to be produced.

Navarre Minerals engaged Orana Engineering to perform a structural audit of major assets within the processing plant at its Mount Carlton Gold Mine. The audit was limited to non-invasive, visual inspections of major assets and targeted obvious structural issues which would normally be identified as part of a condition inspection.

A desktop risk assessment was performed by Orana Engineering with documented results including a photo of each fault, relevant equipment details and location, observations, perceived fault severity and recommended remedial actions. 

Findings from the audit were presented to Navarre within four categories ranging from ‘Monitor’ to ‘Minor’, ‘Major’ and ‘Severe’ with recommendations for follow-up via an onsite risk assessment and remedial actions as appropriate.

The layout of the Rotary Breaker Reject Facility at Glencore's Collinsville Open Cut Coal Mine required loaders to be fully articulated to access and remove material from the reject bin.  Orana Engineering provided a proposal for re-orientation of the facility 90 degrees, allowing loaders to drive directly into the bin area for removal of material.  

The aim of proposed changes was a reduction in safety risks posed by awkward positioning of the facility. The design scope included modifying the existing reject chute to reduce blockages and other operational issues.  The new design allowed for greater clearance of reject material and with the chute supported off the side wall of the facility to ensure structural integrity.

Orana Engineering designers prepared a 3D model considering limited vehicle interactions, optimising loading operations and minimising risks of structural damage.  IFC drawings and project management were provided to complete the installation through to commissioning.

At the request of Glencore’s Collinsville Open Cut Coal Mine, Orana Engineering personnel attended site to perform a visual inspection on the CCR106 Abon Crusher following failure of the gearbox-to-crusher mounting studs.  

The focus of the inspection was assessment of damage to impacted structural steel members on the crusher floor which had resulted from gearbox movement during the failure, and to troubleshoot the reason for the stud failure.

A summary of observations and supporting photos gathered during the inspection was compiled for presentation to the client. In addition, Orana Engineering provided a professional opinion regarding possible scenarios leading to failure of the mounting studs and offered recommendations for additional checks on the integrity of the crusher infrastructure.

Glencore’s Ernest Henry Mine proposed to install a skip rotator to enable periodic maintenance and refurbishment of its underground ore hoist skips. The skip rotator was to consist of a removable access platform, a two-part skip cradle, plus a pneumatic drive motor and brake assembly supplied by the compressed air system. It was envisaged the rotator would enable ore skips to be rotated without the use of a 20T mobile crane and a 32T forklift which was the established method.

Orana Engineering was requested to provide mechanical and structural design and drawings of sufficient detail to allow fabrication, installation and operation of the skip rotator. In addition, Orana Engineering mechanical design personnel generated a model of the skip rotator using Autodesk Inventor which provided the client with a 3D overview of the design.

Orana Engineering was approached by Glencore’s Oaky Creek Coal CHPP personnel to supply a cost estimate for development of modified winch systems for its CV15 and CV16 take-up towers.

The scope of work included provision of mechanical, structural and electrical engineering and design drafting for inclusion of electric take-up winches to facilitate lowering of conveyor counterweights during maintenance activities.

Structural and civil checks were conducted to account for expected force changes caused by additional sheaves and electrically driven winching effects on the structures when compared to the existing gravity take-up applications.  The installation was configured and commissioned into the DCS control system by Orana Engineering's control systems engineers.

In addition to mechanical and electrical detailed design drawings, Orana Engineering provided equipment recommendations and specifications, bill of materials and a Safety In Design Report upon finalisation of the design development cost estimate.

Orana Engineering provided client engineer and project management support for the design and installation of a new product coal sampler at Glencore's Collinsville Mine CHPP.  The scope also included civil engineering support and design drafting for the concrete footings which were out of scope for the sampler supplier.

Orana Engineering's project manager provided onsite support as required to deliver the multidisipline design and installation taking into account the requirements of site stakeholders in the brownfield site. 

Orana Engineering was called upon by Glencore's Collinsville Open Cut Coal Mine to provide engineering, drafting and project management for an upgrade to its tertiary crusher and supporting structure, involving multiple site visits to assist with on-site aspects of the construction phase.  

The basis of design included engineering and drafting to understand and develop the FEED and scope for the capital project, designing of the support structure to install the replacement tertiary crusher and provision of package management for the entirety of the project.

Some of the primary deliverables for the project included 36x IFA / IFC drawings for the tertiary crusher structure upgrades, a critical spares list (including liaison with vendor), fabrication scope of work for tendering, a Change Management document, and a Risk Assessment.

Century Mining’s zinc tailings treatment operation is situated in north-west Queensland and is the largest tailings retreatment operation in Australia. Century sought the services of Orana Engineering in providing engineering support for its PPP027 Plant Feed Upgrade Project. 

The project scope encompassed multidisipline engineering design for the upgraded plant feed pumping system including Weir Warman pumps. The client also requested a mechanical engineering review into combined use of poly lined, rubber lined and UHMWPE piping supported by Orana Engineering’s liaison with product vendors.  Electrical design and site based support was delivered by Orana Engineering to suit the requirement of the project resources and timeline. Civil and structural engineering design was completed for the underground services and concreted area and footings.

Orana Engineering was engaged by Glencore's Ernest Henry Copper Mine to complete a preliminary inspection and condition assessment according to AS13822 "Basis for Design of Structures - Assessment of Existing Structures". Outcomes from the audit were presented with a focus on facilitating optimal rectification and categorised in level of significance from high end catastrophic, through critical, high and medium, down to those items of low significance. 

Orana Engineering added additional value to the client by identifying various non-conformances of access systems, general industry standards and safeguarding.  

Monadelphous Group was contracted to deliver the Talinga Pipeline Compression Facility for Origin Energy’s APLNG project. Towards the end of plant construction, the Monadelphous team engaged Orana Engineering to complete structural inspections and provide Form 16 Building Certificates for structures ranging from small plant air shelters to entire compressor train buildings and associated platforms.

The inspections assessed construction to the requirements of AS4100: Steel Structures and AS1657: Fixed Platforms, Walkways, Stairways & Ladders - Design, Construction & Installation.

The work was completed within strict timeframes by employees from Orana Engineering’s Chinchilla Office, situated in close proximity to the site.  This allowed multiple site visits to be conducted at very short notice and with minimal travel and mobilisation costs.

Eloise Copper Mine required recommissioning of their No.2 Ball Mill. During recommissioning it was identified that a means of relocating grinding media to the feed chute needed to be designed and engineered, with RPEQ certification. Orana Engineering was contacted to assist and a monorail, complete with electric hoist and trolley, was identified as being the practical solution. 

Challenges presented themselves while locating the monorail within the existing structure, however Orana Engineering was able work within the constraints of the existing structure to meet client requirements. All elements of the structural engineering review and design of the monorail to were taken into account. 

RPEQ certified fabrication and installation drawings were produced, ensuring the upgraded structure was fit for purpose.

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.

During an upgrade to the concentrator at MMG’s Century Mine, Orana Engineering was engaged to design a lifting beam for installation of a new flotation cell. The lifting beam design was to provide adaptation between lifting points on the tank and the crane, providing stability during lifting and protecting the integrity of the tank. 

Structural considerations involved hand calculations and modelling in SPACE GASS based on client requirements and relevant Australian Standards.  Orana Engineering's design utilised available structural members on site, providing cost benefits to the client.

Orana Engineering design staff created a 3D model in Autodesk Inventor, producing a fabrication drawing for the beam which also detailed the sling configuration for use during the lifting process.

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.

The maintenance department of Eloise Copper Mine contacted Orana Engineering with a requirement for design of an access platform for their jaw crusher, including engineering certification and drafting. The client provided site measurements and a basic concept of the design they were looking for.

Being a brownfield engineering project, the design had to consider the surrounding area and existing structures to minimise modifications.  Autodesk Inventor was used to create a basic 3D model of the area.  Once the physical data was established the detailed design of the platform was able to be performed efficiently.

Orana Engineering was able to produce both detailed shop drawings for fabrication and site installation drawings, all of which were provided with structural engineering certification.

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.

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.

Melbourne Bio Diesel’s James Cook University research facility required an elevated level area for installation of fresh sea water storage tanks. Orana Engineering was requested to design a solution that increased efficiency with tank drainage and improved safety around the tanks.

A site visit was performed to gather measurements of the nominated tank farm area. This included identifying trees requiring removal and determining required tank heights and current ground levels. From the information gathered Orana Engineering used AutoCAD to model ground levels and the amount of fill required to lift tanks to a suitable level for gravity drainage. The design incorporated a conical base on each tank for drainage and the introduction of buried control valves accessible via covered pits.

Management at Carpentaria Gold’s Ravenswood Operation enlisted Orana Engineering to design a fall arrest system that could be easily removed and repositioned above multiple leach tanks, allowing for safe removal and servicing of tank agitators.

From a site visit, Orana Engineering identified the need for an arrangement that could be easily disassembled and relocated to each leach tank.  The design was challenging due to the varying nature of access structure members above tanks. 

Orana Engineering designers proposed an assembly utilising a common set of supporting columns with struts of varying lengths depending on the work location.   A full set of shop fabrication and assembly drawings were issued with the final design providing safety for personnel working above open tanks.

When tasked with a major repair to one of their leaching tanks, personnel at Carpentaria Gold's Ravenswood Operations 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 the installation of a bypass line around TK102. By utilising site information, Orana Engineering designerswere 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.

Due to expanding operations, Glencore's Oaky North underground operations saw benefit in having an underground workshop and refueling 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.

From the information presented by Orana Engineering, the client could accurately consider whether the underground workshop was feasible and ensure that appropriate budgeting and project planning was completed at the concept design phase to improve confidence in the project prior to execution.

BHP Billiton Cannington’s Port Storage Facility operates a water polishing plant for treatment of stored water. The system requires regular maintenance for replacement of plant filtration rods, however with maintenance ports inaccessible from the ground, work platforms had to be arranged. To simplify this task and improve safety, BHP Billiton Cannington identified the need for a permanent access platform.

Orana Engineering was engaged to design a platform that allowed easy access to the maintenance port, while ensuring access to existing services was not compromised.

Orana Engineering utilised AutoDesk Inventor to model a platform that would not impact on the existing structure, services or access routes while ensuring safety for maintenance workers.  Following model verification, shop detail fabrication drawings were produced.