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FullText:COPYRIGHT2008ReedBusinessInformationLtd.AllRightsReserved.JamieWadeWiththehelpofaliftingsolutionscompanyengineersatThyssenKruppreducedtheassemblytimeofbuildinganurgentlyneededbigbucketwheelreclaimer.*RodLindbladewritesIncreasingthecapacityofAustraliasbigcoalshippingportsisvital-sightingthehugequeuesofshipswaitingweeksandweekstoloadistotallyunacceptabletomanypeopleanddoesnotreflecttheabilityofinnovative,energetic,candoAustralianstogetthingsdone-ontime.However,aninterestingexampleofAustralianingenuityandgettingthingsdoneontimerecentlyemergedattheHayPointCoalTerminal,30kmsouthofMackayonthecentralQueenslandcoast.Itwasaprocedurethatreducedtheassemblytimeofanurgentlyneededbigbucketwheelreclaimerandaprocedurethatsavedsignificantconstructiontimeanddollars,saidJimCarr,generalmanagerbusinessdevelopmentandcustomersolutionsatBoomLogisticswheninitiallydiscussingtheprojectwithAustralianMining.TheengineersatThyssenKrupp,thecompanyselectedtodesignandbuildthenewreclaimer,believedabetterandfasterwaycouldbefoundtobuildthemainboom,finishitbyaddingallcomponentsandthenattachingtheboomtotheStacker/Reclaimerinthecompletedstate.Havingdevelopedarevisedwayofassemblingtheirnewmachine,ThyssenKruppengineersthencalledinBoomLogisticsHeavyHaulageDivisiontoseeiftheirideacouldbemadetowork,andifBoomhadtheuniqueequipmentrequiredforthisprocedure.Previously,withthissortofproject,thebuildingprocesswouldinvolvethe60mlongboombeingprogressivelyassembledafterattachingthebaseunitoftheboomtothemachine,explainedPeterChapmanofThyssenKrupp.ThealternativeprocessthattheThyssenKruppengineersvisualisedwasoneofbuildingtheboomofthereclaimeratgroundleveland,whenmore-or-lesscompleted,movingitclosetothemachineandthenliftingitupandintopositionforattachingtotheslewingdeck.WechosetodiscusstheprocesswiththeheavyhaulageexpertsatBoomLogistics,saidChapman.Theywereabletoconfirmthattheproposedprocesscouldbecarriedoutand,importantly,theyhadtheequipmenttodothejob,headded.Theprocesswasapush,pull,carryandliftprocess,saidDarrenJonesofMackaydepotofBoomLogisticsHeavyHaulageDivision.The205tonneboomofthereclaimerwassittingonstoolsataheight,justover2.4maboveground.Ascanbeseenintheaccompanyingphoto,welocatedourlowprofileprimemoverandfloatunderthefarendoftheboom,andwecoulddothatastheprimemover,adaptedfromaCLRMackchassisandpoweredbya210hpengine,isonly1.2minoverallheight.Then,withaliftmechanismonourfloatwewereabletoliftthereclaimersboomupoffthestandswiththe125tonneweightofthatendoftheboomthencarriedbythefloat,explainedDarren.Thecrewwerethenabletobringinthebigfullsize550hpMackTitanprimemoverwithaspeciallyengineeredfrontmounteddrawbarandconnectittothefloat.WiththeotherendofthereclaimersboomtobeliftedbyaManitowoc200tonneringercrane,allwasreadyfortheliftandshift.First,theendoftheboomtobeliftedbytheringercranewasraised12m,beingthefinalheightforattachingtotheslewdeckbeforethemovingprocesscommenced.Thecrane,withtheloadsuspended,wasinfreeslewmode,sothereclaimerboomcouldbemovedforwardtowardsthemachine.Withringercraneholdingupthereclaimersboom,aswellasslewingitsownboomandthelowprofileprimemover-aidedbythepushfromthebigMack-wewereabletomoveforward1matatime.Then,aswenearedthemachine,extremecarewasexercised.Thereclaimersboomwasinchedintopositionforattachingtothemountingpoint.Absoluteprecisionwasrequiredinordertoinsertthe180kgpinsthroughthebearingsintheboom,addedDarren.Withthisprocess,usingBoomsheavyhaulageequipmentandcrew,ThyssenKruppwereabletomakeconsiderablesavingsandmoreimportantly,reducetheriskofworkingatheight,whencomparedwiththeearliertechniqueoffittingoutthereclaimerboomwhenitwaslocatedupintheairneareritsworkingpositionandattachedtothemachine.Firstsavingwastheneedforonlyonelargecrane,inlieuoftwo.Secondsavingwaseliminatingmanyworkingatheightissues.Andthirdsavingwascompletingthejobinfarshortertime-aboutsixweeksshorter.ThattranslatestofarlesswaitingtimeforthehugefleetofcoalcarryingshipsanchoredoffHayPoint,allatahugecost.Australiansarecandopeople,ashasbeenseenmanytimesintheresourcessector.Justletthemgetonwiththejob.*WrittenbyRodLindbladeforBoomLogist