A proven winner

A recent trial of the Hamersley system for rapid in-pit dewatering at a sizeable mine in the Pilbara proved to be a “game-changer”.

Crusader Hose’s Hamersley system has proven itself to be an innovative, efficient and user-friendly method for rapid in-pit dewatering.

This was borne out during a recent trail at an iron ore mine in the Pilbara region of Western Australia, where, according to the company, the installation of the 500m flexible layflat pipeline was completed within a fraction of the time in comparison to a rigid pipeline of poly pipe.

The trial came about when Crusader Hose, a leading Australian manufacturer of flexible layflat hose and reel systems for the resources sector, was keen to introduce its Hamersley system to another mine.

Crusader approached a large operator in the Pilbara to consider its solution to an age-old problem – mine dewatering. After months of negotiations, the mine dewatering manager agreed to the proposed trial.

The 500m of Waterlord layflat hose wound on three reels, suitable couplings and the Hamersley reel drive unit was dispatched from Melbourne and delivered within five days of the agreement being reached.

Two technical experts from Crusader Hose flew out to the site to conduct the training and oversee the system’s installation. The team assembled in the pit to learn about flexible layflat pipelines and the handling features of the Hamersley reel drive unit (RDU).

The robust Waterlord hose is capable of withstanding pumping at 2800 kilopascal (kPa). Its flange couplings quickly connect lengths with bolts, allowing pipelines to be constructed swiftly. The RDU, with its couplers, gets its power from a supplied plant. 

With the push of a button, the Hamersley takes the effort out of handling the pipeline.

A minimum of two operators is required: one to drive the plant and the other to give clear instructions to the driver, to guide the hose, and to fit and connect the couplings.

The brief for the project was a typical in-pit dewatering scenario: lay a temporary pipeline between the pump and the poly pipe outlet.

After the mobile pump was driven to the deepest part of the pit on a 4WD ute and put into position, the plan was to connect the RDU, fit the reel and deploy the hose.

The Hamersley RDU was connected to the front-end loader via the forklift tynes and hydraulic hoses. The first reel of 200m of eight-inch high-pressure Waterlord hose was deployed in just under 20 minutes.

The second reel soon followed with equal efficiency, as did 100m of the third reel. A utility knife was all that was needed to cut the hose to the required length.

The flanges were quickly fitted and the Emu clamps bolted together, all of which took place within an hour.

One end of the hose was connected to the pump via a six-inch Flexiline hose, the other to the poly line. Once the pump was started, the layflat pipeline was brought to life and proceeded to drain the pit – to much applause.

Fitting a reel onto the Hamersley and deploying the hose was done with a minimum workforce, and the speed and ease with which the hose was laid surprised many present.

The flexible pipeline easily took to the contours of the terrain and comfortably went around the buckets that were left alongside the track.

From the bottom of the pit to the poly line, the team installed the 500m pipeline in roughly two hours. No heavy lifting, welding or digging was required, nor was the need to build supports.

Never having experienced flexible layflat hose solutions, one of the operators at the site was excited by the possibilities.

“We have many more such situations, and we’ll be looking to source more layflat hose,” the operator said.

Crusader Hose managing director Francois Steverlynck said introducing mines to the Hamersley system has been something of a challenge, as many dewatering engineers are reluctant to make a paradigm shift from poly pipe to flexible layflat.

“We’ve been knocking on the door of the mining industry for many years, knowing we have the technology and systems to make their job easier and more efficient,” Steverlynck said.

“We’ve worked successfully with those who listen and are willing to take a chance. Once they experience the benefits of a layflat hose solution, they can’t believe they’ve waited so long.

“Our most recent successful installation is yet another attestation of our engineering and manufacturing success.”

One of the mining managers who agreed to the most recent trial was impressed.

“There is an expectation to seek more efficient and safe mining practices, and this engineered system from Crusader Hose is a case in point,” the mine manager said.

Steverlynck understands some initial reluctance, but feels people who take the chance and try Crusader Hose’s flexible pipelines will be happy with the results.

“Any new system takes time to master; however, all we ask is that if you ever run into a glitch, talk to us,” he said.

“We can either troubleshoot through a phone consultation or come out to your mine and offer expert advice.”

This feature appeared in the September 2023 issue of Australian Mining.

Australian Mining.

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