Nepean Conveyors Projects Capability

Innovation . Dedication . Specialisation

Nepean Conveyors Capability Statement (Jan 2014)

Nepean Conveyors is a wholly Australian owned company specialising in the design, in-house manufacture, installation and service of overland, underground and surface belt conveyor systems and bulk materials handling projects for over 25 years.

Nepean Conveyors as part of the Nepean group head office is located at Unanderra (NSW). Nepean has forged a solid reputation for robust, practical and reliable designs and quality manufactured equipment. Nepean Conveyors has become the leading technology provider for materials handling in Australia through our group organisations such as Nepean Power (formerly M.I.Power), Nepean Longwall and Nepean Asia.

Design, Engineering and Detailed Drafting

Source, Supply + In-house Manufacture (mechanical, structural, process and electrical)

Flexible engagement: e.g. Financing, D+C Contracts,

Performance Warranty: Single point accountability (all disciplines)

Installation + Commissioning

Sustainable technology: e.g. VVVF energy optimisation systems

PMBOK accredited Project managers Life Cycle Services: Audits + Optimisation

Studies + Spares + After sales service + Training


When dealing with Nepean Conveyors for conveying systems or

individual component supply you gain access to:

In-house specialist conveyor and materials handling designers

(mechanical, process, civil/structural, electrical)

OEM support for Order of Magnitude studies through Pre-

feasibility studies and Bankable studies

Modern in-house manufacturing

Full life cycle support

Global sourcing

Single point accountability for your materials handling project

Specific experience: Downhill regenerative braking conveyors Truck and Rail loading and unloading stations Feeders / Sizers / Crushing stations Transfer stations / Material Placement solutions / port infrastructure Power distribution and supply systems to 130kV Earthing / Switchgear/ protection systems Complete drift, trunk and main gate solutions Feeders / Sizers/ Crushing stations Transfer stations, Dewatering Screens and systems Splitters, Belt Winders, Clamping Stations, Belt Maintenance Stations Power distribution and supply systems Earthing / Switchgear/ protection systems Hazardous area systems e.g. hazardous area Exd solutions Functional safety systems to SIL2 and SIL3 Control system design and functional specification design Conveyor Drives - BOSS, VVVF, CST, Fluid Coupling Loop Take Up and Belt Storage Units Constant Tension Winches Eddy-Current, Hydraulic, VVVF, Electromechanical Jiffy/ Nifty/ Hefty Combination Drives Power distribution systems / Conveyor substations and controllers Class A approved workshop for Exd equipment manufacture and overhaul Extensive software design tools (Catia, X-Steel, Tekla, MicroStran, Autodesk Inventor) In-house pulley design and manufacture, deadshaft/ liveshaft various types of lagging Comprehensive mechanical design facility e.g. DEM + FEA modelling

1200+ Employees Industry leading world class LTIFR > 80,000m2 manufacturing/ fabrication facility NEPEAN operates in the USA, Canada,

Europe, Middle East, Africa, Asia, New Zealand and Australia

Strong Balance sheet backed with significant fixed assets

NEPEAN is one of Australias largest privately held Engineering Businesses


Sample Projects: (A sample of completed contracts is included on the following pages)

Atlas Iron: Port Hedland Utah Point Expansion to 15mtpa Owner: Atlas Iron Project Type: Turnkey Completion: 2013 Value: $15M Scope: Major plant expansion consisting of overland transport conveyor

Above: Atlas Iron overland conveyor magnet station

Carborough Downs: ROM Stockpile Conveyor + Underground Coal

Clearance System

Owner: AMCL (now Vale) Project Type: Design + Construct Completion: 2006 Value: $25M Scope: Design and supply entire coal clearance system on Greenfield site, including:

2500tph 1200mm Ramp conveyor / cross conveyor / eastern mains conveyor. Development phase =1600tph. Full production =2500tph

Ramp conveyor included covered gallery discharging onto 20,000m3 ROM coal stockpile. Project included civil design of footings and slabs and reduced speed conveying operation during development phase of operation.

Above: (L) Drift conveyor during construction (R) Drift conveyor with ROM stockpile


Boggabri Coal: Coal Terminal Upgrade

Owner: Idemitsu Resources Australia Project Type: Turnkey Fixed price Design and Construct Timing: 2010 Value: $20M Scope: Design and Construct 1500tph Stockpiling System including: Conveyors, radial stacker, feeders, unloading station, loadout station,

roadways, HV substation with PF correction, control system, dust control, earthworks:

Above: Overview of the BCTU site

Above: Completed BCTU works showing CV02, CV03 and CV04 stacker conveyor in operation


Ridges Iron Ore: Wyndham Barge Loading Facility Owner: Kimberly Metals Group Project Type: Design, Supply, Install, Commission Completion: 2011 Value: $15M Scope: Design, Supply, installation assistance package for greenfield 1755tph barge

loading facility site, incorporating: Jetty Overland Conveyor, Pivot Conveyor, substation and control system

Significant design criteria: The Pivot Conveyor was particularly challenging, with the head end positioned on a pontoon capable of moving significantly in all directions, loading into a rotating hopper, and accommodating an 8.5m tidal range and withstand cyclonic wind conditions.

Design of the CV01 Jetty Conveyor was also very challenging in terms of the footing design to intertidal zone land, and over water. Management of differential settlement was paramount in ensuring system performance did not erode due to environmental conditions.

Above: KMG: Aerial photo of site showing overland/over water conveyor installed over inter-tidal waters (differential settlement a key design parameter)

Above KMG: Overland/Overwater CV01 Jetty conveyor


Above KMG: (L) Jetty conveyor with over water transfer to Pivot conveyor; (R) Telestacker/ Barge loading

All ore is loaded onto barges via the Telestacker, which is mounted on the pontoon with the head end of CV02. These are then towed 1.2km to waiting ships in the Cambridge Gulf for delivery to sinter markets in China.

Kayuga Mine: KD01 Trunk Conveyor

Owner: Anglocoal Australia Project Type: Turnkey (Design + Construct) Completion: June 2004 Value: 8 Million Scope: Design and supply 4200tph 1800mm Trunk conveyor for new mine -

incorporating 500kW VVVF drives, regeneration system, 160kNm dynamic brakes, 11kV/415VAC substation starter

One of the most technically challenging conveyor design projects undertaken in Australia

Uphill/downhill configuration (inverted boomerang profile) ensures conveyor power demand varies from -800kW (ie regenerative) to +400kW when loaded on uphill sections only. Due to high risk of damage to plant and risk to safety of personnel in event of brake failure under any condition (including power-loss), multiple redundancies were designed into the operation and control of the braking systems to ensure controlled braking under any circumstance. Commissioning included deliberately flooding the conveyor under worst case load profile, then dropping power to the substation to mimic a power-loss condition under extreme loads, with one of the brakes disabled.


Narrabri Coal: Drift and Skyline Conveyor System

Owner: Whitehaven Coal Project Type: Turnkey (PFS development through to Design + Construct) Completion: 2010 Value: $20M Scope: Turnkey design and construct package for greenfield 3600tph system,

including: Drift Conveyor, Skyline Tripper Stockpile Conveyor 11kV/690V/415V Electrical Substation and Switchroom

Installation, commissioning and training packages

Above: Drift and Skyline conveyors

The Drift conveyor was designed to be functional firstly as a drift development conveyor with a sacrificial belt and installation of 2 x 1000kW VVVF drives, and once tunnelling by the roadheader is completed to the coal seam, the conveyor shall be reconfigured for production by adding a third 1000kW drive, supplying a tail take-up system and pulling on the steel cord belt.

Stockpiling of ROM coal is via a travelling tripper mounted on elevated gantry structure with 30m spans, walkways fitted both sides. Stockpile height was limited by the mine development application and approval, and thus the client sought to maximise live stockpile area provided by the conveyor system. Rail clamps provide security against unwanted movement of the travelling tripper, which discharges either side of the gantry.

Above: (L) Skyline conveyor with tripper in operation and stockpile conveyor


Above: (L) Skyline conveyor with tripper and gravity take-up and tail drive during construction

Curragh North Material Handling Project

Location: Blackwater, QLD, Australia Client: Barclay Mowlem (Laing ORourke) Contract Value: Completion: November 2005 November 2006

Project involved the design, manufacture and supply of 3 complete conveyor systems and modifications / upgrades to 7 existing conveyor systems. This contract involved providing equipment to a 20km overland conveyor, making it the longest single flight conveyor in the world. The infrastructure project earned Curragh the prestigious title of 2007 Bulk Handling Facility of the Year.

Khumani: Overland Conveyor

Owner: Mittal Steel Project Type: Turnkey Design + Construct Completion: 2008 Value: $15M Scope: Design, supply, install entire 8km overland conveyor system

Above: Khumani overland conveyor system, River crossing (wet season)


CSR: Gypsum Storage System

Owner: CSR Building Products Project Type: Design and Construct Completion: 2008 Value: $8M Scope: Turnkey design and construct package for complete wharf upgrade system

capacity to 1500tph, including: Modification to existing SC1 conveyor to create SC1A shuttle conveyor, Elevated Tripper Transfer Conveyor, Bi-directional Stockpile Conveyor, Sealed Transfer Point TT1 on Wharf, Electrical field equipment, Installation and commissioning supervision

CSR Building Products Yarraville (VIC) plant is amongst the oldest industrialised sites in Australia. The site is shared with Sugar Australia (CSR), dating back to the 19th Century, with many of the timber sugar sheds (still in use) heritage listed. A new Gyprock manufacturing plant being constructed on the site required a new 1500tph conveyor system capable of transferring gypsum from self unloading ships via the existing wharf conveyor system and stockpiling into a 40,000 tonne shed (by others).

Above: (L) GC01 and GC01A conveyors; (R) Modified wharf conveyor SC1A showing feeder

Nepean submitted an alternative tender proposal which was technically superior, and overcame many of the technical challenges faced on the congested site. Amongst these were:

Restricted load sizes into the site through the Melbourne CBD Strict environmental dust and noise limitations Conveyor galleries to be totally enclosed, minimise number of trestles/maximise span Sealed transfer points, including external cladding to support structures Wharf conveyors were over 40 years old, requiring significant modification during brief

outages between ships, requiring to remain operational at all other times Majority of site was operational, including sugar sheds, refinery and wharf Highly unionised worksite

Above: (L) Redispan gantry during installation, (R) Inside conveyor gallery


Newpac: Underground Coal Clearance System

Owner: Pacific Resources (now Glencore/Xstrata Ravensworth No. 1 Mine) Project Type: Turnkey Completion: Staged, 2006 to 2007 Value: $25M Scope: Design and supply entire coal clearance system including:

Upgrade existing 1500mm Drift conveyor from 2500tph to 3500tph 1 off 3500tph 1500mm PG01 Trunk conveyor 1 off 3500tph 1500mm PG02 Trunk conveyor 1 off 3500tph 1500mm PG03 Trunk conveyor 1 off 3500tph 1500mm Maingate Conveyor 12 off 500kW VVVF drives 6500m conveyor idlers and structure 5 off 11kV/415V Conveyor substations (M.I. Power)

Upgrade of Drift conveyor included new drive modules fitted with braking system and flywheels to ensure coasting time and transfer capacity were matched, and upgraded the gravity take-up.

PG01 trunk conveyor installed with ST2000 steelcord belt, Goodyear Sensorguard rip detection and tail gravity take-up (inbye of loadstation) to control belt tension at convex curve at tail end of conveyor.

An inline de-watering transfer station and tramp iron magnet were installed at the PG01-PG02 trunk transfer. All conveyors were optimised to provide commonality of parts such as 500kW VVVF drive modules, pulleys, idlers, belt, belt clamps and belt storage/LTU systems, guards.

Above: (L) 355kW Drift drive flywheel and brake; (R) PG01 drivehead, looking inbye

Kestrel Coal: Ti-Tree Project Owner: Rio Tinto Coal Australia Project Type: Turnkey Completion: March 2004 Value: AUD6.4 Million Scope: Design and supply new coal clearance system to increase mine capacity.

1 off 5000tph 1800mm CV007 Trunk conveyor 3 off 3500tph 1500mm Maingate Conveyor upgrades 1 off 3500tph 1500mm Maingate Tripper 11 off 500kW VVVF drives 6500m conveyor idlers and structure 4 off 11kV/415V Conveyor substations (M.I. Power)

Subsequent to the successful completion of this project, all future conveyors at the Kestrel mine have been awarded to Nepean Conveyors, including 4 x development conveyors for the Kestrel KME expansion project (via Ausenco), 2 x drift development conveyors (via Redpath Mining) and


more recently the new underground Trunk and Maingate conveyors (direct to Rio Tinto Coal Australia) representing a total additional investment with Nepean of approx.. $40M in past 4 years.

Xstrata Coal: Blakefield South Coal Clearance system Owner: Xstrata Coal Project Type: Turnkey Completion: January 2010 Value: AUD 25.0 Million Scope: Turnkey design and construct package for complete systems, including:

1800mm 4600tph CV702 Trunk, 4 x 500kW 650TPKL host drives Dewatering and magnet station on CV702 trunk 1600mm 1200tph CV420 Tailgate 1600mm 3600tph CV801 Maingate 1600mm 3600tph CV802 Maingate 11kV/690V Substation Starters for each conveyor

Full installation, commissioning and training packages

As with all projects by Nepean, future requirements of the mining operation were considered when selecting and optimising the size of the conveyor drives to ensure commonality and minimised spares holding, whilst ensuring maximum drive efficiency at stated design capacities.

The CV702 trunk conveyor is fitted with 4 x 500kW 650TPKL drives, whilst the CV801 and CV802 Maingate conveyors are designed for 3 x 500kW 650TPKL installed on the host drivehead and up to 2 x tripper drives, each rated for 2 x 500kW thus providing a total installed power of 3500kW per maingate conveyor.

Nepean provided full electrical and mechanical installation packages, with significant time spent developing specific training packages and comprehensive manufacturing data records (MDRs) and equipment manuals, design verification dossiers, risk assessment and SIL assessment records.

Appin: Loddon Area Conveyors Owner: BHP Billiton Illawarra Coal Project Type: Turnkey Completion: February 2006 Value: AUD5.2 Million Scope: Design, supply, install and commission underground trunk conveyors to

access recoverable reserves in new mining area. 1 x 3500tph Loddon trunk conveyor c/w tripper and dewatering station 1 x 3500tph South trunk conveyor 1 x 3500tph South West trunk conveyor

1 x Tramp iron magnet 3500tph ROM coal sizer and maintenance station

South/SW transfer included supply of 3500tph ROM coal sizer, which can be rolled out of service for maintenance without disruption to conveyor operation.

Nepean were subsequently awarded a further contract in 2008 to supply Appin West Douglas Mains Trunk Conveyor with an inline tripper sizer station comprising of powered tripper drivehead discharging into an inline sizer (same model for reduced spares holding) complete with retractable wheeled maintenance station and lifting/rotating equipment for handling and removal of sizer (refer below)


Above: (L) Tripper sizer station during shop mock up; (R) view from non-drive side

Matla No 2 Mine: 4 Seam Upgrade Owner: Anglo-American (South Africa) Project Type: Turnkey Completion: January 2001 Value: AUD10.5 Million Scope: Major upgrade of existing conveyor system to cope with capacity of newly

acquired longwall, and new conveyor supply to access new area of mining lease. Supply included: 1 off 4500tph 1600mm Underground Bin conveyor

1 off 4500tph 1600mm Incline Trunk conveyor 1 off 4500tph 1600mm SW Trunk conveyor 3 off 3500tph 1500mm Maingate Conveyors 1 off 3500tph 1500mm Maingate Tripper 26 off BOSS400 Platinum Transmissions 6 off 11kV/1kV Substations

Wambo Mine: Upgrade of Coal Clearance System Owner: Peabody Energy Project Type: Turnkey Completion: Contract awarded Q4 2013, currently in delivery phase Value: AUD5 Million Scope: Upgrade of existing coal clearance system with new maingate conveyor

utilising multiple 500kW VVVF drives

Moranbah North: Upgrade of Coal Clearance System Owner: AngloCoal Project Type: Turnkey Completion: Contract awarded Q1 2014, currently in delivery phase Value: AUD13 Million Scope: Upgrade of existing coal clearance system


Griffin: Overburden Conveyor System Owner: Griffin Coal Mining Co. Ltd (Lanco Resources) Project Type: Turnkey Completion: 2005 Value: $20M Scope: Design, supply, install overburden conveyor system to convey and dump

overburden to expose coal reserves in open cut coal mining operation. 1 x 2500tph Face conveyor, Trunk conveyor, dump conveyor, radial stacker,

22kV/415VAC substations

Nepean worked closely with customer to develop a shiftable conveyor system to uncover coal reserves and dispose of overburden independent of the existing truck fleet. Utilizes a dozer trap feeder and D11R dozer to load, and conveys around pit boundary to dumps (elevation increase 70m), spreading using a self slewing portable radial stacker and D11R dozer.

Above: Griffin overland overburden removal conveyor

THE ABOVE LIST IS A SAMPLE OF OUR EXPERIENCE - FURTHER PROJECT DETAILS MAYBE PROVIDED AS REQUIRED

Documents

Nepean Conveyors Projects Capability