Engineering & design | Data collection & analysis
In 2023, Koniambo Nickel, a major nickel mining operation in New Caledonia, was experiencing major slewing abnormalities with its wet ore stacker, which were creating production losses and safety concerns on a machine critical to processing operations. When the problems were not easily explained through conventional stacker maintenance practices and other Australian companies were quoting over $700k for the job, Koniambo Nickel engaged FIELD Engineers for specialist investigation and to develop a strategy to safely return the machine to service.
FIELD recognised that the problem required expertise typically applied to draglines, shovels and excavators in Queensland mining operations, and deployed a team with specialist knowledge of how slew bearings, structural loading and machine dynamics interact.
The team conducted a site inspection and, within 24 hours, identified the slew bearing had exceeded its service life and was binding due to internal degradation. Further assessment found that the machine’s centre of gravity was significantly further forward than expected, creating excessive front section loading and accelerating wear.
Building on this diagnosis, FIELD developed a complete engineering solution for replacing the slew bearing, designing purpose-built support structures, detailed jacking studies, installation methodologies and inspection and test plans for the shutdown. High-accuracy laser scanning was used to capture site data and underpin engineering design, and the FIELD engineers supported the construction teams on site through planning and execution.
By applying our expertise earned in Queensland coal mining equipment, FIELD Engineers was able to diagnose a complex problem in an international nickel operation, engineer a replacement methodology and lead the safe execution of a critical shutdown, all for 5 times less cost than other Australian company quotes. The project successfully restored the stacker to operational service, eliminating the underlying cause of the slew system issues, and is expected to result in reduced downtime and improved long-term reliability. This project demonstrates how specialist skills developed supporting Queensland dragline fleets are successfully transferred to other industries and equipment, delivering measurable value beyond their traditional applications.
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