This project showcased D&S Resources’ capability to handle complex modifications in a critical operational context. Conditioning Tank Modifications involved modifying the conditioning tank to enhance throughput as part of the plant upgrade to 7Mtpa. Primary Cyclone Cluster Modifications aimed to improve slurry conveyance and prepared for future enhancements by increasing the size of the launder.
Conditioning tank modifications
This project aimed to boost throughput as part of a plant upgrade to 7Mtpa. The scope included:
- Removing the existing feed box and associated piping for the rougher flotation cell.
- Fabricating and installing a new overflow launder box and pipe.
- Adding a DN600 nozzle and adapter for the flotation cell.
- Modifying the existing tank to fit these new components.
- Repairing rubber linings to align with the updated configurations
Primary cyclone cluster modifications
The goal of this project was to improve slurry conveyance and prepare for future upgrades by enlarging the launder. Key modifications included:
- Replacing the DN600 to DN500 reducer spool with a DN800 to DN500 reducing spool.
- Installing a new DN800 nozzle.
- Repairing the Linatex rubber lining in the cyclone cluster launder.
Detailed design documentation, including 3D Navisworks models and mechanical and piping isometrics, guided these modifications. All designs and installations met BHP and industry standards for mechanical works, piping, structural steel, and protective coatings.
In this project, D&S Resources provided all labour, tools, equipment, and materials necessary for the project, ensuring adherence to quality and specifications. Principal-supplied items like scaffolding and crane services supported efficient execution during the shutdown period.
A meticulous schedule of works was followed, with prework activities starting in the fabrication shop and on-site before the shutdown to optimize the available shutdown window. Close collaboration with BHP ensured that materials and preparations aligned with the operational timeline and project requirements.
Scope of work
- Remove the existing rougher flotation cell feed box.
- Remove the existing pipework from the conditioning tank to the feed box.
- Fabricate, supply, and install the blank flange to the existing nozzle on the conditioning tank.
- Fabricate, supply, and install the new conditioning tank overflow launder box.
- Modify existing conditioning tank to accommodate the new overflow launder box.
- Fabricate, supply, and install the new conditioning tank overflow launder pipe.
- Fabricate, supply, and install the new DN600 nozzle to the conditioning tank.
- Fabricate, supply, and install the new DN600 adapter nozzle to the rougher float cell.
- Fabricate, supply, and install the new DN600 pipe from the new DN600 nozzle on the conditioning tank to the rougher flotation cell 3420-FLM-001.
- Fabricate, supply, and install the new steelwork and pipe supports for the new pipework.
- Modify and repair the existing rubber lining in the conditioning tank to suit the new overflow launder box and new DN600 nozzle.
Skills/services demonstrated
- Shutdown-critical execution — complex multi-system modifications delivered within a fixed outage window, with prework staged in the fabrication shop beforehand to protect the schedule
- 3D-modelled design coordination — Navisworks models and mechanical/piping isometrics used to plan modifications before cutting metal
- Custom fabrication and installation — launder boxes, nozzles, adapters, reducing spools and pipe supports fabricated and installed to fit existing infrastructure
- Process plant modification expertise — reconfiguring live conditioning tank and cyclone cluster systems to support a capacity upgrade, not new-build work
- Rubber lining repair — Linatex and general rubber lining works to protect modified surfaces from abrasive slurry
- Full self-performed scope — labour, tools, equipment and materials all provided by D&S, working alongside principal-supplied scaffolding and crane services
- Schedule discipline and client coordination — close collaboration with BHP to align material readiness and preparation with the operational shutdown timeline
