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Dragline drum replacement, Australia

Overview

ALE has replaced a dragline drum at the Callide Mine site in Biloela, Queensland.

 

Services Required

ALE were tasked with the removal and replacement the drag winch drum of dragline 102 (Marion 8750) at the Callide Mine site.

A substantial amount of engineering went into the design as the drum is not typically replaced using lifting and skidding techniques and hadn’t been performed on this particular model of dragline. They also needed to make contingencies for the limited space inside the dragline.

The project was undertaken in two phases, phase one involved the removal of the old drag drum and phase two involved the installation of the new drag drum.

For the lifting operations, ALE utilised the 450t Lift ‘n’ Lock hydraulic gantry system, complete with one 12m and two 17.25m header beams, as well as various rigging.

For the skidding operations ALE utilised a 200t hydraulic push/pull system complete with 24m of skate beams and various 600t heavy equipment stands.

The Lift ‘n’ Lock and skidding systems were set-up inside the dragline, with approximately 6m of skid track extending outside of the dragline and supported using 600t stands.

The drum was lifted initially as a full assembly weighing 142t, this was then supported in a frame providing the necessary clearance for splitting into four main sections ready for removal.

The first section was the bullgear and spider, weighing 36t which was lifted, sat into a frame, restrained and skidded out of the dragline where it could be crane lifted to the ground.

The second section was one half of the winch drum itself weighing 35t which was lifted sat into a frame, restrained and skidded out of the dragline where it could be lifted to the ground.

The third section was the second half of the drum, weighing 35t, which was lifted into a frame. However, unlike the first drum, half this section was too wide to fit between one of the Lift ‘n’ Lock towers and other dragline structures during the skidding operation. This meant that this had to be removed for the skidding operation; to remove this tower meant that the header beams had to be supported from the dragline roof structure prior to tower removal.

The tower had to be replaced before the removal of the fourth section, which was the other bullgear and spider, and was lifted, sat into a frame, restrained and skidded out of the dragline where it could be crane lifted to the ground.

In order to install the new drum, ALE performed the opposite sequence of operations carried out for the removal.

Each phase lasted five days.

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