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Bulk Materials Handling Procurement Guide
- 1. Procurement of Bulk Materials Handling Machines Richard Morgan Director
- 2. • Stackers • Reclaimers • Stacker/Reclaimers • Shiploaders • In-pit systems Equipment Types
- 7. • Custom designed • Long lead Time • High cost • Critical elements in supply chain Features
- 8. Identifying requirements • Configuration • Specification & procurement documents • Modularisation
- 14. Specification • Define design, material and quality requirements • Ensure configuration and performance can be met realistically • Good knowledge of the design standards • Industry experts should be consulted to ensure that problems are not repeated • Operators and maintainers should review
- 15. • Common practice for shiploaders • Now possible for land based machines such as stackers and reclaimers • Considerable savings in onsite labour. • Allows procurement from overseas where costs are lower than in Australia. • Include transport load cases and sea fastenings Modularisation
- 22. Type of contract • Design and Construct (EPC) - Single Contract • Design and Supply – (Installation & Commissioning Separate) • Design Contract – (Supply, Installation & Commissioning Separate)
- 23. Challenges with overseas procurement • Design – Design by Experienced OEM - Fabrication Overseas – Design by new entrant OEM - Fabrication Overseas
- 24. Challenges with overseas procurement • Standards • Materials Substitution • Fabrication – Main Structure – Access – Machining – Protective Coatings – Trial Assembly
- 25. Challenges with overseas procurement • Vendor Items • Electrical Installation • Commissioning
- 30. Overseas procurement - lessons • Detailed review of specifications pre award • Australian Standards discussed pre-award • Review of the 3D model is needed • Adequate translation resources needed • Access design considered throughout the design phase, not at the end. • Supplier design 100% prior to placing orders • Constructability review of design
- 31. Effective quality control and supervision • Design Phase – Effective Specification Key Dimensions properly thought out Interfaces Well Defined Machine Loads required by other designers – Owners Engineer Role – Design Audit
- 32. • AS 4324.1 Appendix K guidance for engagement of a design audit engineer • Engage Design audit engineer before specification for machine is finalized • Involve audit engineer in tender review Design Audit
- 33. Effective quality control and supervision • Fabrication Phase – Owners Engineer Role – Local Inspectors
- 34. Shipment, site erection and commissioning • Modular Construction • Packing • Road Transport o/s • Shipment • Road Transport in Country • Erection/Installation Phase • Cut in
- 35. Shipment, site erection and commissioning • Commissioning • Deconstruction
- 36. Shipment •
- 37. Installation
- 38. Deconstruction
- 39. THANK YOU
Editor's Notes
- We have been involved with materials handling machines at most of the major ports in Australia as well with quite a number of mining operations. These machines are large cost items and their performance is critical to the efficiency and cost effectiveness of the operation. Within the last 10 years there has been a lot of activity in new construction. Many existing machines are also at the end of their design lives and require replacement. However costs have risen dramatically and owners and engineering organisations are actively looking at more cost effective solutions.
- The specification for the machine should cover design, material and quality requirements for manufacture and installation, commissioning and hand over to operations, provision of spare parts and requirements for ongoing maintenance. The specification needs to be written to ensure that the configuration and performance parameters upon which the requirements for the machine were determined can be met realistically in practice. Specification of the design requires a good knowledge of the design standards, their limitations and interpretations of the design standards commonly used within the industry. Industry experts should be consulted to ensure that problems commonly encountered on equipment of this type are not repeated should review the specification. The operators and maintainers of the plant have a large influence on the ongoing safe performance of the machine and should also be involved in review of the specification.
- A project shipping and transport plan should include details of load-out facilities at the overseas port and should be prepared in conjunction with the shipping agent and local road transport sub-contractor. A detailing ship packing list should be prepared, including all components and equipment. The ship packing list should detail the overall dimensions and weight of each item, therefore allowing a detailed stowage plan to be developed by the freight forwarder. The design engineers need to ensure that the lifting and lashing lugs are captured in the design. Special consideration will need to be given to the packing and quarantine regulations that apply to Australia. The protocol for custom clearance needs to be coordinated with the shipping agent. It large components fabricated overseas will be unloaded and transported to site by road. Due to the restricted space available on site, the major components will often need to be stored off-site in a storage yard and transported when required for erection. Where possible it is desirable to transport the machine to site in as large components as possible. However iot may still be necessary to remove some components such as the counterweights to facilitate safe shipping.
- The construction methodology for replacement machines is normally to cordon off an end of the stockpile to allow the existing machines to operate while the new machines are being constructed and commissioned as shown
- Once the new machines have been assembled, commissioned, and put into operation, the existing machines can be moved to one end of the yard, the area cordoned off, and the machines deconstructed as shown.