Innovation . Dedication .

Specialisation







Nepean Conveyors Capability Statement (Jan 2014)

Nepean Conveyors is a wholly Australian owned company specialising in the design, in-house
manufacture, installation and service of overland, underground and surface belt conveyor systems
and bulk materials handling projects for over 25 years.

Nepean Conveyors as part of the Nepean group head office is located at Unanderra (NSW).
Nepean has forged a solid reputation for robust, practical and reliable designs and quality
manufactured equipment. Nepean Conveyors has become the leading technology provider for
materials handling in Australia through our group organisations such as Nepean Power (formerly
M.I.Power), Nepean Longwall and Nepean Asia.









Design, Engineering and Detailed Drafting

Source, Supply + In-house Manufacture
(mechanical, structural, process and electrical)

Flexible engagement: e.g. Financing, D+C
Contracts,

Performance Warranty: Single point
accountability (all disciplines)
Installation + Commissioning
Sustainable technology: e.g. VVVF energy
optimisation systems
PMBOK accredited Project managers
Life Cycle Services: Audits + Optimisation
Studies + Spares + After sales service +
Training
Innovation . Dedication . Specialisation

When dealing with Nepean Conveyors for conveying systems or
individual component supply you gain access to:
In-house specialist conveyor and materials handling designers
(mechanical, process, civil/structural, electrical)
OEM support for Order of Magnitude studies through Pre-
feasibility studies and Bankable studies
Modern in-house manufacturing
Full life cycle support
Global sourcing
Single point accountability for your materials handling project

Specific experience:
Downhill regenerative braking conveyors
Truck and Rail loading and unloading stations
Feeders / Sizers / Crushing stations
Transfer stations / Material Placement solutions / port infrastructure
Power distribution and supply systems to 130kV
Earthing / Switchgear/ protection systems
Complete drift, trunk and main gate solutions
Feeders / Sizers/ Crushing stations
Transfer stations, Dewatering Screens and systems
Splitters, Belt Winders, Clamping Stations, Belt Maintenance Stations
Power distribution and supply systems
Earthing / Switchgear/ protection systems
Hazardous area systems e.g. hazardous area Exd solutions
Functional safety systems to SIL2 and SIL3
Control system design and functional specification design
Conveyor Drives - BOSS, VVVF, CST, Fluid Coupling
Loop Take Up and Belt Storage Units
Constant Tension Winches Eddy-Current, Hydraulic, VVVF, Electromechanical
Jiffy/ Nifty/ Hefty Combination Drives
Power distribution systems / Conveyor substations and controllers
Class A approved workshop for Exd equipment manufacture and overhaul
Extensive software design tools (Catia, X-Steel, Tekla, MicroStran, Autodesk Inventor)
In-house pulley design and manufacture, deadshaft/ liveshaft various types of lagging
Comprehensive mechanical design facility e.g. DEM + FEA modelling




1200+ Employees
Industry leading world class LTIFR
> 80,000m2 manufacturing/ fabrication facility
NEPEAN operates in the USA, Canada,
Europe, Middle East, Africa, Asia, New
Zealand and Australia
Strong Balance sheet backed with significant
fixed assets
NEPEAN is one of Australias largest
privately held Engineering Businesses
Innovation . Dedication . Specialisation

Sample Projects: (A sample of completed contracts is included on the following pages)

Atlas Iron: Port Hedland Utah Point Expansion to 15mtpa
Owner: Atlas Iron
Project Type: Turnkey
Completion: 2013
Value: $15M
Scope: Major plant expansion consisting of overland transport conveyor


Above: Atlas Iron overland conveyor magnet station

Carborough Downs: ROM Stockpile Conveyor + Underground Coal
Clearance System
Owner: AMCL (now Vale)
Project Type: Design + Construct
Completion: 2006
Value: $25M
Scope: Design and supply entire coal clearance system on Greenfield site, including:
2500tph 1200mm Ramp conveyor / cross conveyor / eastern mains conveyor.
Development phase =1600tph. Full production =2500tph

Ramp conveyor included covered gallery discharging onto 20,000m
3
ROM coal stockpile. Project
included civil design of footings and slabs and reduced speed conveying operation during
development phase of operation.


Above: (L) Drift conveyor during construction (R) Drift conveyor with ROM stockpile

Innovation . Dedication . Specialisation

Boggabri Coal: Coal Terminal Upgrade
Owner: Idemitsu Resources Australia
Project Type: Turnkey Fixed price Design and Construct
Timing: 2010
Value: $20M
Scope: Design and Construct 1500tph Stockpiling System including:
Conveyors, radial stacker, feeders, unloading station, loadout station,
roadways, HV substation with PF correction, control system, dust control,
earthworks:


Above: Overview of the BCTU site



Above: Completed BCTU works showing CV02, CV03 and CV04 stacker conveyor in operation


Innovation . Dedication . Specialisation

Ridges Iron Ore: Wyndham Barge Loading Facility
Owner: Kimberly Metals Group
Project Type: Design, Supply, Install, Commission
Completion: 2011
Value: $15M
Scope: Design, Supply, installation assistance package for greenfield 1755tph barge
loading facility site, incorporating: Jetty Overland Conveyor, Pivot Conveyor,
substation and control system


Significant design criteria: The Pivot Conveyor was particularly challenging, with the head end
positioned on a pontoon capable of moving significantly in all directions, loading into a rotating
hopper, and accommodating an 8.5m tidal range and withstand cyclonic wind conditions.

Design of the CV01 Jetty Conveyor was also very challenging in terms of the footing design to
intertidal zone land, and over water. Management of differential settlement was paramount in
ensuring system performance did not erode due to environmental conditions.


Above: KMG: Aerial photo of site showing overland/over water conveyor installed over inter-tidal waters
(differential settlement a key design parameter)


Above KMG: Overland/Overwater CV01 Jetty conveyor

Innovation . Dedication . Specialisation


Above KMG: (L) Jetty conveyor with over water transfer to Pivot conveyor; (R) Telestacker/ Barge loading

All ore is loaded onto barges via the Telestacker, which is mounted on the pontoon with the head
end of CV02. These are then towed 1.2km to waiting ships in the Cambridge Gulf for delivery to
sinter markets in China.

Kayuga Mine: KD01 Trunk Conveyor
Owner: Anglocoal Australia
Project Type: Turnkey (Design + Construct)
Completion: June 2004
Value: 8 Million
Scope: Design and supply 4200tph 1800mm Trunk conveyor for new mine -
incorporating 500kW VVVF drives, regeneration system, 160kNm dynamic
brakes, 11kV/415VAC substation starter

One of the most technically challenging conveyor design projects undertaken in Australia

Uphill/downhill configuration (inverted boomerang profile) ensures conveyor power demand varies
from -800kW (ie regenerative) to +400kW when loaded on uphill sections only. Due to high risk of
damage to plant and risk to safety of personnel in event of brake failure under any condition
(including power-loss), multiple redundancies were designed into the operation and control of the
braking systems to ensure controlled braking under any circumstance. Commissioning included
deliberately flooding the conveyor under worst case load profile, then dropping power to the
substation to mimic a power-loss condition under extreme loads, with one of the brakes disabled.


Innovation . Dedication . Specialisation

Narrabri Coal: Drift and Skyline Conveyor System
Owner: Whitehaven Coal
Project Type: Turnkey (PFS development through to Design + Construct)
Completion: 2010
Value: $20M
Scope: Turnkey design and construct package for greenfield 3600tph system,
including: Drift Conveyor, Skyline Tripper Stockpile Conveyor
11kV/690V/415V Electrical Substation and Switchroom
Installation, commissioning and training packages


Above: Drift and Skyline conveyors

The Drift conveyor was designed to be functional firstly as a drift development conveyor with a
sacrificial belt and installation of 2 x 1000kW VVVF drives, and once tunnelling by the roadheader is
completed to the coal seam, the conveyor shall be reconfigured for production by adding a third
1000kW drive, supplying a tail take-up system and pulling on the steel cord belt.

Stockpiling of ROM coal is via a travelling tripper mounted on elevated gantry structure with 30m
spans, walkways fitted both sides. Stockpile height was limited by the mine development application
and approval, and thus the client sought to maximise live stockpile area provided by the conveyor
system. Rail clamps provide security against unwanted movement of the travelling tripper, which
discharges either side of the gantry.


Above: (L) Skyline conveyor with tripper in operation and stockpile conveyor


Innovation . Dedication . Specialisation


Above: (L) Skyline conveyor with tripper and gravity take-up and tail drive during construction

Curragh North Material Handling Project
Location: Blackwater, QLD, Australia
Client: Barclay Mowlem (Laing ORourke)
Contract Value:
Completion: November 2005 November 2006

Project involved the design, manufacture and supply of 3 complete conveyor systems and
modifications / upgrades to 7 existing conveyor systems. This contract involved providing
equipment to a 20km overland conveyor, making it the longest single flight conveyor in the
world. The infrastructure project earned Curragh the prestigious title of 2007 Bulk Handling
Facility of the Year.
Khumani: Overland Conveyor
Owner: Mittal Steel
Project Type: Turnkey Design + Construct
Completion: 2008
Value: $15M
Scope: Design, supply, install entire 8km overland conveyor system


Above: Khumani overland conveyor system, River crossing (wet season)

Innovation . Dedication . Specialisation

CSR: Gypsum Storage System
Owner: CSR Building Products
Project Type: Design and Construct
Completion: 2008
Value: $8M
Scope: Turnkey design and construct package for complete wharf upgrade system
capacity to 1500tph, including: Modification to existing SC1 conveyor to create
SC1A shuttle conveyor, Elevated Tripper Transfer Conveyor, Bi-directional
Stockpile Conveyor, Sealed Transfer Point TT1 on Wharf, Electrical field
equipment, Installation and commissioning supervision

CSR Building Products Yarraville (VIC) plant is amongst the oldest industrialised sites in Australia.
The site is shared with Sugar Australia (CSR), dating back to the 19
th
Century, with many of the
timber sugar sheds (still in use) heritage listed. A new Gyprock manufacturing plant being
constructed on the site required a new 1500tph conveyor system capable of transferring gypsum
from self unloading ships via the existing wharf conveyor system and stockpiling into a 40,000 tonne
shed (by others).


Above: (L) GC01 and GC01A conveyors; (R) Modified wharf conveyor SC1A showing feeder

Nepean submitted an alternative tender proposal which was technically superior, and overcame
many of the technical challenges faced on the congested site. Amongst these were:
Restricted load sizes into the site through the Melbourne CBD
Strict environmental dust and noise limitations
Conveyor galleries to be totally enclosed, minimise number of trestles/maximise span
Sealed transfer points, including external cladding to support structures
Wharf conveyors were over 40 years old, requiring significant modification during brief
outages between ships, requiring to remain operational at all other times
Majority of site was operational, including sugar sheds, refinery and wharf
Highly unionised worksite


Above: (L) Redispan gantry during installation, (R) Inside conveyor gallery
Innovation . Dedication . Specialisation

Newpac: Underground Coal Clearance System
Owner: Pacific Resources (now Glencore/Xstrata Ravensworth No. 1 Mine)
Project Type: Turnkey
Completion: Staged, 2006 to 2007
Value: $25M
Scope: Design and supply entire coal clearance system including:
Upgrade existing 1500mm Drift conveyor from 2500tph to 3500tph
1 off 3500tph 1500mm PG01 Trunk conveyor
1 off 3500tph 1500mm PG02 Trunk conveyor
1 off 3500tph 1500mm PG03 Trunk conveyor
1 off 3500tph 1500mm Maingate Conveyor
12 off 500kW VVVF drives
6500m conveyor idlers and structure
5 off 11kV/415V Conveyor substations (M.I. Power)

Upgrade of Drift conveyor included new drive modules fitted with braking system and flywheels to
ensure coasting time and transfer capacity were matched, and upgraded the gravity take-up.

PG01 trunk conveyor installed with ST2000 steelcord belt, Goodyear Sensorguard rip detection and
tail gravity take-up (inbye of loadstation) to control belt tension at convex curve at tail end of
conveyor.

An inline de-watering transfer station and tramp iron magnet were installed at the PG01-PG02 trunk
transfer. All conveyors were optimised to provide commonality of parts such as 500kW VVVF drive
modules, pulleys, idlers, belt, belt clamps and belt storage/LTU systems, guards.


Above: (L) 355kW Drift drive flywheel and brake; (R) PG01 drivehead, looking inbye

Kestrel Coal: Ti-Tree Project
Owner: Rio Tinto Coal Australia
Project Type: Turnkey
Completion: March 2004
Value: AUD6.4 Million
Scope: Design and supply new coal clearance system to increase mine capacity.
1 off 5000tph 1800mm CV007 Trunk conveyor
3 off 3500tph 1500mm Maingate Conveyor upgrades
1 off 3500tph 1500mm Maingate Tripper
11 off 500kW VVVF drives
6500m conveyor idlers and structure
4 off 11kV/415V Conveyor substations (M.I. Power)
Subsequent to the successful completion of this project, all future conveyors at the Kestrel mine
have been awarded to Nepean Conveyors, including 4 x development conveyors for the Kestrel
KME expansion project (via Ausenco), 2 x drift development conveyors (via Redpath Mining) and
Innovation . Dedication . Specialisation

more recently the new underground Trunk and Maingate conveyors (direct to Rio Tinto Coal
Australia) representing a total additional investment with Nepean of approx.. $40M in past 4 years.

Xstrata Coal: Blakefield South Coal Clearance system
Owner: Xstrata Coal
Project Type: Turnkey
Completion: January 2010
Value: AUD 25.0 Million
Scope: Turnkey design and construct package for complete systems, including:

1800mm 4600tph CV702 Trunk, 4 x 500kW 650TPKL host drives
Dewatering and magnet station on CV702 trunk
1600mm 1200tph CV420 Tailgate
1600mm 3600tph CV801 Maingate
1600mm 3600tph CV802 Maingate
11kV/690V Substation Starters for each conveyor
Full installation, commissioning and training packages

As with all projects by Nepean, future requirements of the mining operation were considered when
selecting and optimising the size of the conveyor drives to ensure commonality and minimised
spares holding, whilst ensuring maximum drive efficiency at stated design capacities.

The CV702 trunk conveyor is fitted with 4 x 500kW 650TPKL drives, whilst the CV801 and CV802
Maingate conveyors are designed for 3 x 500kW 650TPKL installed on the host drivehead and up to
2 x tripper drives, each rated for 2 x 500kW thus providing a total installed power of 3500kW per
maingate conveyor.

Nepean provided full electrical and mechanical installation packages, with significant time spent
developing specific training packages and comprehensive manufacturing data records (MDRs) and
equipment manuals, design verification dossiers, risk assessment and SIL assessment records.

Appin: Loddon Area Conveyors
Owner: BHP Billiton Illawarra Coal
Project Type: Turnkey
Completion: February 2006
Value: AUD5.2 Million
Scope: Design, supply, install and commission underground trunk conveyors to
access recoverable reserves in new mining area.
1 x 3500tph Loddon trunk conveyor c/w tripper and dewatering station
1 x 3500tph South trunk conveyor
1 x 3500tph South West trunk conveyor
1 x Tramp iron magnet
3500tph ROM coal sizer and maintenance station

South/SW transfer included supply of 3500tph ROM coal sizer, which can be rolled out of service for
maintenance without disruption to conveyor operation.

Nepean were subsequently awarded a further contract in 2008 to supply Appin West Douglas Mains
Trunk Conveyor with an inline tripper sizer station comprising of powered tripper drivehead
discharging into an inline sizer (same model for reduced spares holding) complete with retractable
wheeled maintenance station and lifting/rotating equipment for handling and removal of sizer (refer
below)

Innovation . Dedication . Specialisation



Above: (L) Tripper sizer station during shop mock up; (R) view from non-drive side

Matla No 2 Mine: 4 Seam Upgrade
Owner: Anglo-American (South Africa)
Project Type: Turnkey
Completion: January 2001
Value: AUD10.5 Million
Scope: Major upgrade of existing conveyor system to cope with capacity of newly
acquired longwall, and new conveyor supply to access new area of mining
lease. Supply included:
1 off 4500tph 1600mm Underground Bin conveyor
1 off 4500tph 1600mm Incline Trunk conveyor
1 off 4500tph 1600mm SW Trunk conveyor
3 off 3500tph 1500mm Maingate Conveyors
1 off 3500tph 1500mm Maingate Tripper
26 off BOSS400 Platinum Transmissions
6 off 11kV/1kV Substations

Wambo Mine: Upgrade of Coal Clearance System
Owner: Peabody Energy
Project Type: Turnkey
Completion: Contract awarded Q4 2013, currently in delivery phase
Value: AUD5 Million
Scope: Upgrade of existing coal clearance system with new maingate conveyor
utilising multiple 500kW VVVF drives

Moranbah North: Upgrade of Coal Clearance System
Owner: AngloCoal
Project Type: Turnkey
Completion: Contract awarded Q1 2014, currently in delivery phase
Value: AUD13 Million
Scope: Upgrade of existing coal clearance system









Innovation . Dedication . Specialisation

Griffin: Overburden Conveyor System
Owner: Griffin Coal Mining Co. Ltd (Lanco Resources)
Project Type: Turnkey
Completion: 2005
Value: $20M
Scope: Design, supply, install overburden conveyor system to convey and dump
overburden to expose coal reserves in open cut coal mining operation.
1 x 2500tph Face conveyor, Trunk conveyor, dump conveyor, radial stacker,
22kV/415VAC substations

Nepean worked closely with customer to develop a shiftable conveyor system to uncover coal
reserves and dispose of overburden independent of the existing truck fleet. Utilizes a dozer trap
feeder and D11R dozer to load, and conveys around pit boundary to dumps (elevation increase
70m), spreading using a self slewing portable radial stacker and D11R dozer.


Above: Griffin overland overburden removal conveyor


THE ABOVE LIST IS A SAMPLE OF OUR EXPERIENCE - FURTHER PROJECT DETAILS
MAYBE PROVIDED AS REQUIRED