Avoiding common pitfalls in liquid management projects

A guide to success

In large complex industrial and mining operations, the success of a liquid management project hinges on thorough planning and engineering, as well as the consideration of key environmental factors. Any missteps can result in costly delays, project inefficiencies, or performance issues.

Whether you’re constructing a floating mine pontoon or heavy-duty access walkway, or managing dam tailings, dewatering, sludge pond reclamation and dredging, the right expertise matters. At Coerco, extensive experience in the design and delivery of liquid management systems for the most challenging applications has taught us valuable lessons that can help clients avoid these common pitfalls.

The following guide ensures liquid management projects stay on track and prevent operational setbacks, while de-risking a project and achieving the best outcomes possible.

1. Site Assessments: The Foundation for Success

A common cause of failure in liquid management projects is oversight, particularly the unique requirements of a project site. From the topography and soil conditions to climate and weather patterns, an in-depth understanding of the local environment is critical to developing the right solution. This includes variable water levels, unexpected terrain challenges, and other site-specific conditions that can drastically impact a system’s performance.

That’s where comprehensive site assessments come into play. It addresses every aspect that will contribute to the design, development and delivery of a solution. This not only supports more effective planning, but ensures project implementation remains ahead of time and provides a contingency for potential specification changes or customisations.

One project that highlights the importance of this process is Coerco and Xylem’s partnership at Sydney Water’s Picton Water Resource Recovery Facility.

“When designing the required floating pontoon and access gangway, we had to take into account a range of considerations,” said Coerco Head of Projects, Warren Classen.

“Strict design requirements coupled with the unique location meant we had to evaluate the lake’s topography, submergence and fluctuations in water levels, water density, wind loading, pump dimensions, pontoon layout and assembly, and the different materials in which the fluids would pass through. The pontoon not only had to support heavy pumps, but float on water and land on a hard uneven surface when water levels dropped.”

Projects, particularly ones where solutions have not been previously developed, pose significant design challenges and carry inherent safety risks. That’s why the initial assessment, planning, and design stages are so important as they will eventually contribute to the success of a project.

2. Equipment Selection: Finding the Perfect Match

Although equipment mismatches are a frequent source of project complications, they are often overlooked. Whether you’re dealing with irrigation, water storage, or pumping systems, the design and specifications of the equipment must align with your liquid management goals. Equipment capacity, durability, and the materials used for tanks, pumps, and pontoons, must be aligned with the project scope and suitable for the environment in which they will operate.

Whether it’s a heavy-duty, lightweight poly, or modular setup, the type of pontoon used can be a real game changer in liquid management.

“Many of our clients in the mining space use heavy-duty options built to provide a stable platform for handling pump setups and heavy loads of up to 25 tonnes,” said Coerco Technical Director, Gareth Wallis.

“On the other end of the spectrum, there are lightweight and versatile poly pontoons that are ideal for tight spaces and temporary setups. These are made from high-quality polyethylene, UV-stabilised with resistance to corrosion and harmful chemicals.”

Wallis says that when selecting a pontoon, before any floatation activity commences, several critical factors must be considered, from load, buoyancy and operating water level, to durability and corrosion resistance.

“The weight of the load determines the buoyant force, the upward force exerted by the body of water on the object. Buoyant force must be calculated to determine whether the pontoon or floating platform will sink or float when fully or impartially submerged in a body of water. You also need to calculate the total weight distribution on the pontoon during a full-on operation, since industrial floating pontoons are attached with other accessories such as an access walkway and structural frames.”

From a durability perspective, infrastructure must be designed to sustain years of heavy use and harsh chemicals.

“Pontoons and floating walkways manufactured from polyethylene are ideal in mining operations,” said Wallis. “As it is UV-stabilised, this slows down the degrading impact of UV radiation, harsh weather conditions, moisture, and chemical-induced corrosion.”

3. Modular Designs: Streamlining Installation & Maintenance

Installation is one key challenge that is often underestimated. Larger projects, particularly those with remote or difficult-to-access sites, benefit from pontoons with modular designs. These not only allow for more efficient transport and installation, but also simplify maintenance and future upgrades. At Coerco, the modularisation of pontoons is common in many projects to support smoother installation, provide a cost-effective solution, and offer more flexibility when making future design adjustments.

Limitations and launch considerations play a significant role in determining the appropriate pontoon configuration.

“Modular pontoons are easier to assemble, reassemble, or take apart,” said Wallis. “In mines, modular builds offer flexibility when adding or removing pump float units. Portability is important here, so you need to be able to load pontoons onto shipping and freight containers seamlessly.”

As most mines are located in remote locations that have limited power sources and a site layout carries its own set of challenges.

Wallis added that engineers must design pontoons based on site layout and topography that factor in the preferred launch method. “This either involves using a mobile crane if a suitable launch pad in the pit exists, or manoeuvred into position using bulldozers or excavators when cranage isn’t possible.”

Take Queensland’s Kidston Hydro Project for example. Coerco designed a pontoon system capable of dewatering 30 gigalitres from an abandoned gold mine, while manoeuvring with fluctuating dam water levels at a vertical depth of 180 metres.

“Due to accessibility issues, we needed to employ different service methods,” said Coerco Head of Projects, Warren Classen.

“This included what pumps and motors to use, winching system, installation and assembly, transportability, launch method and manoeuvrability in the dam. The pontoon’s modularisation allowed it to be disassembled once it reached the bottom of the pit and then extracted via a tunnelling system.”

Maintenance is another key aspect of pontoons and walkways. Moving parts such as pins, joints, bearings, and mechanical components require lubrication, pain touch-ups, and in some cases, replacement. This is why the design stage is so important to ensure maintenance teams can access all areas of the pontoon system and connected infrastructure.

4. Regulatory Compliance: Meeting Standards at Every Stage

Aside from the physics of fluid control and the complex nature of water treatment processes, every region has its unique regulations that govern liquid management projects, from environmental compliance to safety standards. This is more important than ever when dealing with projects that pose significant design challenges and carry inherent safety risks, particularly in remote mine sites where a solution being developed has never been done before.

There are also safety considerations such as the ability to access, inspect, and maintain equipment safely. Incorporating elements like safe access points, as well as systems to manage operational risks (e.g., water surges or system overloads), can significantly de-risk a project.

The design and features of industrial floatation platforms specifically, must adhere to safety standards and regulations imposed by local authorities. This includes things like the use of anti-slip decking, which is a mandatory workplace safety requirement across Australia.

In the Sydney Water Picton project, Coerco’s floating pontoon needed to comply with industry standards, including AS 4100:2020 (steel structures), AS 4997-2005 (floating structures), and AS 1657:2018 (fixed platforms, walkways, stairways and ladders).

As an ISO9001:2015 certified company, Coerco is committed to providing the highest levels of product quality and safety. The company ensures all products and processes comply with, and are manufactured in accordance with all relevant regulatory standards. This involves engineers working closely with project partners to engineer the right pontoon solution aligned to specific site applications and regulations.

5. Collaboration: Expertise from Conception to Completion

Complex liquid management projects require collaboration and multidisciplinary expertise. From engineers to project managers, having the right team in place ensures all technical, logistical, and operational elements are covered. Working with experienced partners like Coerco, who can offer support from the discovery phase to project completion, can help mitigate issues before they arise.

Coerco utilises a carefully curated project delivery pathway designed to manage and deliver complex projects at scale. The framework identifies and solves the challenges clients face, including time pressures, conceptual design, costs, unknown risks, resource utilisation, and compliance, to name a few.

6. Customisation: The Key to Peak Performance

In liquid management, there’s no one-size-fits-all approach. The ability to customise designs to fit the precise needs of an operation can make the difference between a successful project and one plagued with operational inefficiencies and constant issues. Customisation includes everything from designing systems that fit specific environmental conditions to delivering a solution that’s compatible with other site operations.

Coerco has operated for over 30 years and now offers clients the most comprehensive solution for their diverse liquid management requirements.

“Our philosophy has always been centred around water conservation and liquid management,” said Coerco Chief Executive Officer Justin Jackson. “We understand this better than anyone and is reflected in our product design, development and delivery capability. We design and engineer solutions for individual projects aligned with customer specifications and give them total control of their liquid management.”

Every project Coerco is involved in is a truly collaborative effort. Whether it’s design, fabrication, project management, or technical know-how, you can be assured the team will deliver at every step of the process.

“At Coerco, there’s no project too complex or technical for us, and we can engineer solutions of all scales that address any total liquid management and fluid control problem,” said Jackson.

“By working with Coerco, you have a single point of contact from initial discovery to final delivery and commissioning.”

7. Testing & Feedback: Connecting the Loop

Testing equipment under operational conditions allows for the identification of potential weak points before the system is fully deployed. Additionally, maintaining feedback loops between project stakeholders (including design engineers and site managers) allows adjustments to be made as a project evolves. Businesses can therefore avoid many of the common pitfalls that derail liquid management projects.

You can be assured that when you deal with Coerco, you’ll receive a high-spec engineered solution built to solve any complex challenge. We leverage shared capabilities to achieve success in all areas of liquid containment, flotation on liquid, and liquid movement.

This is backed by dedicated poly manufacturing and steel fabrication facilities, and an in-house engineering team, that rigorously tests products and materials under site conditions. This addresses any potential design flaws or faults, while ensuring client pain points are overcome and projects are delivered without delay.

If you’re looking for a trusted partner for your next liquid management project, visit Coerco at the WA Mining Conference and Exhibition (stand E118) on October 9-10, and IMARC (stand C12) on 29-31 October 2024. You can also check out our Guide to Floating Mining Pump Pontoons for more insights.

Website: www.coerco.com.au
Email address: [email protected]
Contact Number: 1800 646 277