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Case Studies

Burton Downs CHPP
Client: Thiess/Peabody
Location Burton Downs CHPP, Central QLD
Pipe Size Sold: 219 ID 20 WT
Qty: 1.6km (4 lines of 300m + spare)
Connection Type: Stub flange - Table E
Date of Purchase: September 2012
Date of Install: March 2013
Process Details:
Process Type: Coal Co-Disposal Tailings
Solid Size: Max 150mm
Density / Composition: Rock, Mud, Sand stone, 1.2 SG
Flow rate / Velocity: 7.4 m/s max @ 46,000 tonne per month per line (4 lines) 5.2 m/s median. 270 TPH max, 97 TPH mean, 86 TPH median
Total Dynamic Head 6-8 bar at pump/plant
Wall Thickness Testing Testing occurred at a minimum 120 points per visit, every 3 months. WT readings were taken at the flange – where failure would normally occur. On average the lines lost 8mm WT p/a each.
Summary: Results indicate that we are outperforming the previously used PE100 4 to 1 in terms of wall thickness lost per co-disposal ton, on this site. Furthermore, as a by-product of the smoother pipe, it has been indicated that blockage frequency was greatly reduced.
Kunawarra KG1 Magnesia Ore
Client: Resource Equipment Limited - Sibelco
Location KG1, North of Rockhampton
Pipe Size Sold: 297 ID 15 WT
Qty: 250m (trial length) – Total 2.5km
Connection Type: Stub flange - Table E
Date of Purchase: March 2014
Date of Install: September 2014
Process Details:
Process Type / Service: Magnesia Tailings
Solid Size: Fine
Density / Composition: Magnesia Ore Tailing, 1.6SG, 30% w/w
Flow Rate / Velocity: 2.5 m/s
Total Dynamic Head: 6 bar at pumps
Wall Thickness Test: 1mm wear loss per month (tested fornightly) 1.5-2mm wear loss at pipe lengths joining with Steel Minimum of 28 points of testing per visit
Summary: The wear loss exhibited is half that of hardened Steel. Site was particularly pleased with how much lighter and easier the pipes were to work with, including the lack of need for gaskets and welding (all the steel is collar welded to allow for rolling, due to high wear).
Coppabella CHPP
Client: Resource Equipment Limited - Peabody
Location Coppabella CHPP, Central QLD
Pipe Size Sold: 250 ID 30 WT
Qty: ~1.5km - 2 lines
Connection Type: Stub flange - Table E
Date of Purchase: August 2014
Date of Install: October 2014
Process Details:
Process Type / Service: Coal Co-Disposal, Reject
Solid Size: 30% of solids > 50mm, up to 200mm max
Density/Composition: 50% w/w
Flow Rate / Velocity: 4.2 m/s
Total Dynamic Head: 10-14 bar at pumps
Wall Thickness Testing: 3-4 mm net wear loss per month (tested fornightly) in straight sections. 8mm net wear loss per month (tested fortnightly) in sweeps 12mm net wear loss per month (tested fortnightly) in bends Average of 1.5-2mm per line for straight sections Minimum of 450 points of testing per visit
Summary: The wear loss exhibited is similar to that of Hardened Steel. Our product being 30mm thick and the “extra strong” 250ID Steel being 12.7mm means we have a lot more wall thickness to play with prior to requiring rolling. Both being similarly priced. Should this be managed properly, the average lifespan of pipe will be 3 years (for both lines) – rather than the 1.5 years attributed to Steel. Comments: The wear rate is exacerbated greatly in areas of severe misalignment.
TBA
Placeholder
Location Burton Downs CHPP, Central QLD
Pipe Size Sold: 219 ID 20 WT
Qty: 1.6km (4 lines of 300m + spare)
Connection Type: Stub flange - Table E
Date of Purchase: September 2012
Date of Install: March 2013

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