Pulley Design and Build

Project Description

Camco was invited to tender on Pulley design and manufacture for one of Australia’s largest mining projects. The comprehensive project included not only the largest but also some of the most structurally robust Pulleys ever constructed in Australia. The tender included a requirement for Australian Industry Participation and had significant focus on the quality of the build. The project scope for design aimed to deliver reliability and longevity of service from commissioning to full operation. The magnitude of this project and time frame for delivery required a company that had significant resources financially and assets to meet and achieve the build in a relatively short time frame. Camco was successful in winning the $26m dollar tender meeting all criteria as defined by the client.

Approach/Issues

The requirements of the weighted tenderer included:

Australian Participation (AIP)

• Camco is 100% Australian owned and operated
  • Camco suppliers are predominantly Australian companies

Training and Indigenous Engagement

• Camco operates a comprehensive apprenticeship program producing recognised skilled tradesmen
• Camco has a highly developed Indigenous Engagement Policy and is RAP endorsed

Design

• Assessment of mine site operational parameters
• Comprehensive engineering design
  • Finite Element Analysis (FEA)
• Detailed build drawings
  • Client review and adaption
• Transport frame design

Manufacture

• Comprehensive manufacture
  • Jig manufacture
  • WPS development
  • Welder qualification
  • Subcontractor review (rollings)
  • Lagging (ceramic/polyurethane)
  • Component fitting and assembly
  • Polyurea component protection
  • Testing – designed to simulate site operation
• Transport frame build and assembly (vibration isolation frames)
• Supplied with comprehensive MDR

Solution

Aspects of Innovation (supporting our successful tender)

• Proven streamlining of production – delivering high-volumes in short time frames guaranteeing continuity of supply
• Cost effectiveness through manufacturing methods
• Innovative tiling rooms that are dust and climate controlled for optimal adhesion properties of lagging products
• Inhouse hot cast polyurethane operations
• Scalable manufacturing capabilities for welding, machining and fitting inhouse allowing efficient processing of pulleys
• State of the art Pulley load test facility to bench test all pulleys to the client Vibration Analysis specification prior to dispatch
• Vibration Isolation transport frame design that ensures service life of Pulley in operation