Engineering Design Capability Statement

YOUR ENGINEERING PARTNER

www.brightwater.co.nz
Minimise risk and ensure your project’s
success by selecting an experienced
team utilising the latest technology to
deliver fit for purpose design solutions.

The foundation of every design project we undertake is Multi-Disciplined Engineering Design

our commitment to deliver fit for purpose engineering
that reduces design time and accelerates our client’s We offer professional in-house design across all
project development through to the completed result. facets of engineering including Mechanical, Electrical,
We achieve this through close collaboration with our Control & Automation, Civil and Structural. This
clients and stringent design processes that produce complete service produces efficiencies through
high quality, cost effective professional engineering a seamless integrated design resulting in a more
design services from initial concept through to shop cost effective package for our clients. Our qualified
drawings. engineers and designers have an array of expertise
delivering proven results from design software and
tools including:
Collaboration
Mechanical
Whether it’s a large greenfield project or upgrading an • Solidworks Premium 3D Design
existing plant or process, our collaborative approach • AutoCAD 2D Design
ensures all our clients are included in the decision
making process at every stage of the project. This Electrical
close partnership produces the best design solution • Accredited Rockwell Automation PLC software
and leads to faster implementation of technology system integrator
solutions at an optimal cost. Other benefits of this • Schneider Electrical Alliance Partner
approach include: • SCADA software

• Clear and precise scope boundaries by Industry Sectors

quantifying and justifying the investment
Our professional engineering design experience and
required for a given benefit
expertise covers a wide range of industry sectors
• Fewer scope changes and more fluid
including:
management of change
• Identification of project risks early in the design • Mining & Minerals
phase so actions can be taken to mitigate their • Bulk Materials Handing
impact • Quarry & Aggregates
• Port Installations
• Wood Processing
• Water Treatment
• Energy & Fuel Handling
QA System & Checks About Brightwater
All engineering design undertaken by Brightwater Brightwater is proudly named after the regional Nelson
is assured by utilising well defined and town where we have been located since our inception
documented processes throughout the design in 1979. From the very beginning our core purpose
phase including: has been to truly understand our client’s requirements
and through a collaborative partnership provide fit for
• Documenting Basis of Design (BOD) with purpose industrial engineering solutions.
client input and verification
• Defining and verifying design input Specialising in industrial bulk materials handling, our
requirements and output specifications in-house capability allows us to provide a complete
through fit for purpose documentation such range of services from engineering & design through
as; scopes of work, equipment to fabrication, site maintenance and installation.
specifications, and equipment data sheets Our multi-disciplined projects team has delivered
• Regular design reviews throughout the significant brownfield upgrades and greenfield
design development stage projects throughout Australasia in the Mining, Quarry,
• Engineering & shop fabrication drawings Resources, Water Treatment, Dairy and Wood
adhering to a defined drafting standard Processing sectors.
• Rigorous drawing check procedures
followed to ensure the quality of finished With large workshops in Nelson and Greymouth,
product we have a significant trade workforce that provides
a full range of fabrication services as well as onsite
installation, repairs and maintenance work.
Our Approach to Safety
Zero Harm is a core value of Brightwater’s and the
Health & Safety of our staff is paramount. Having
significant experience in undertaking large and
small scale projects has given Brightwater the
internal structure, processes and support staff in
order to create a strong Health & Safety culture and
performance.

All work carried out by Brightwater is done in

accordance with our stringent H&S policies and
monitored by our Health & Safety Advisor. Our safety
record translates into lower insurance and liability
rates, therefore reduced costs and risks to our clients.

ZEROHARM
ALL ACCIDENTS ARE PREVENTABLE
Engineering Design Process
The engineering design process is flexible and adapted to meet client’s individual requirements and the
size or complexity of any given project, however the following process is an example of a typical design
process that may be followed for a significant project:

Concept Development

• Process Optimization Cost Analysis

• Plant layout Options • 3D Project /Design
• Process Flow Diagrams Visualisations
• Indicative Capital Cost • Environmental/
Estimates Resource Consent
• Capital vs. Operational Implications

Feasibility Studies

• Engineering & Process Design Analy- • Control & Automation Options

sis • Site Geotech Analysis
• Plant Layout General Arrangements • Detailed Economic Analysis
(2D & 3D) • Captial Budget Estimating
• High Level Engineering Design • Resource Consent Application Sup-
• Engineering drawings port
• Proprietary Equipment Selection
• Equipment Lists
• Power Supply Requirements
• Civil, Structural & Service Require-
ments
• Functional Descriptions

Brightwater Engineering Design Flow

Concept Feasibility Detailed Manufacturing Finalise

Development Studies Design and Documentation
Installation
Detailed Design

• Basis of Design Created & Approved • Specifications for, and Evaluation of,
• Lead Engineer & Design Team Selected Proprietary Equipment for Procurement.
• Finalise General Arrangements, Process • Electrical Supply & Service Reticulation
Flow Diagrams & Piping/Instrument Design
Diagrams • Mechanical equipment Modeling &
• Create an Interactive Project Model Design Review
• Define all Design Elements • Manufacturing Drawings & Bills of
• Engineering Calculations and Analysis Materials
• Design Development Specifying Scope • Civil Drawings for Foundations, Concrete
for all Design Elements Works, Buildings, Infrastructure,
• Design Process Controls, Automation & Drainage & Roading etc.
SCADA • Hazard & Operability Studies (HAZOP)
• Create Lists/Schedules for Equipment, • Statutory Certification & Producer
Piping, Instruments, Cables, and Motors Statements
etc. • Document Management & Control

Manufacturing and Installation Finalise Documentation

• Operations Manuals
• Engineering Advise for Manufacturing
• Maintenance Manuals
• Engineering Supervision
• As Built Drawings
• Installation Drawings & Methodology
• Document Archiving
• Installation Bills of Materials
• Lifting Plans
• Electrical Testing & Certification
• Structural Certification
• Safety & Hazard Audits
 Project Examples
Higgins Meremere Plant Upgrade

Overview:
Higgins Aggregates supplies over two million tonnes of aggregates per year throughout New Zealand. Located near Te Kauwhata in the Waikato, Higgins
Meremere Quarry supplies high PSV aggregates to the road construction industry. In an initiative by the company to drive greater efficiencies, the Meremere
Quarry was required to undergo a transformation from diesel powered mobile equipment to a new fully electric fixed plant.

Solution:
Brightwater was contracted to design, manufacture and install a purpose built fully electric plant that utilised existing tracked mobile equipment on site to
help reduce costs. The Design was a joint collaboration between Brightwater and Higgins. Brightwater completed a high level concept sketch and used three
dimensional modelling to capture and communicate the most efficient solution given the challenging topography of the quarry site.
The result of this design lead to a modular plant where mobile equipment was fixed into position, extra conveyors were added along with larger more efficient
screening plant. The design increased production from approximately 60 tonne per hour up to 180 tonne per hour capacity.

A new elevated feed bin was also designed to allow 30 tonne dump trucks to provide continuous feed material into the plant at a set rate.
The entire process from design concept to site installation and commissioning was completed within an eight month time frame.



           

 
 



 





 







  

 


 


 
 


 







  





 







  




        
     

 

    
   



    
      
 

       
      
 

NPIL Line 1 Outfeed Deck

             
            
         
  

     
   
           


Overview:
Nelson Pine Industries Ltd engaged Brightwater to design and supply a new outfeed stacking deck for their Line 1 MDF press to handle larger pack sizes. The
MDF press produces a range of MDF products in different thicknesses and sizes and the finished sheets must be stacked, squared and fed out without any
slowing or stopping of the press.

Solution:
Due to space constraints and the requirement to handle the larger pack size, the stacking deck design had to be completely different to the existing stacking
deck. The new stacking deck that was designed included automated variable side alignment rams to allow for board sizes ranging from 3m to 5.1m. Quick
acting lifting deck driven off a single hydraulic ram able to raise and lower the deck within 6 seconds and driven outfeed decks capable of feeding out a
complete pack within 10 seconds.

The brief was to design a new stacking deck capable of handling board packs up to 1.35m thick which would reduce forklift movements on site. Brightwater
achieved this with the design but also managed to produce a stacking deck significantly simpler in operation to the existing with fewer moving parts and which
took up a smaller footprint on site. The quality of design meant the both the fabrication and installation went together smoothly with zero rework required on
site.
Project Examples
Stockton Coal Handling & Processing Plant

Overview:
Solid Energy New Zealand operates an open-cast coal mine on the Stockton Plateau, 35km north of Westport, on the West Coast of the South Island, New
Zealand. The Stockton mine produces high-quality coal for export to the steelmaking industry. In 2008 Solid Energy New Zealand engaged Brightwater as the
head contractor to design, procure, and manage fabrication and construction of the green-fields Coal Handling and Processing Plant project, all within a fast-
track schedule.

Solution:
Brightwater’s Design team’s contribution was the design of the Coal Handling Plant (CHP) to support the Coal Preparation Plant (CPP) in-feed and product
out-feed. This comprised of a ROM station with rotary breaker, two feed conveyors, a surge bin, thickener (for CPP), and four product stockpile conveyors.

A key design challenge was the high wind speeds at the Stockton site which would result in high loadings on conveyor truss sections of rectangular profile.
Brightwater designed totally enclosed circular cross-section conveyors, with a resultant drag force coefficient 40% lower than those of the rectangular type.
The site layout also called for long conveyor spans; traditionally square gallery style conveyors would be specified but the required size and leg spacing proved
costly. Brightwater’s innovation was the introduction of tubular gallery sections for the CPP feed conveyors, which offered significant cost savings to the client.
A new elevated feed bin was also designed to allow 30 tonne dump trucks to provide continuous feed material into the plant at a set rate.
The entire process from design concept to site installation and commissioning was completed within an eight month time frame.

Tekapo Canal Gravel Feeder

Overview:
Fulton Hogan (FH) were awarded a contract to repair and reline the Tekapo Canal. This project required a new replacement liner to be placed through a seven
kilometre section of canal that had been leaking water. As a part of replacing the liner, FH’s scope of work required 20-200mm river run rock (AP 200-20 MM0)
to be placed on top of a 10mm thick geotextile mat that directly covered the 2.5 mm thick geo-composite PVC membrane liner. This placement of the rock acts
as ballast to keep the liner firmly located on the base and inverts of the canal.

The challenge for Fulton Hogan was to deliver this ballast material from the top section of the invert, which was several metres higher than the canal floor
and the deliver the ballast 25 metres out into the centre of the canal floor. This had to be accomplished whilst ensuring the newly laid PVC canal floor was not
damaged in the process.

Solution:
The Brightwater Design team worked closely with Fulton Hogan’s operational staff to develop several engineered solutions before settling on a combination of
newly applied technologies and proven mobile plant technologies. The process created was a Gravel Feeder mobile machine that accepted 30 tonne payloads
from articulated dump trucks into a specifically designed steel constructed mobile bin. The product was then retrieved from the bin via a 20 tonne excavator
and delivered into a hopper located on a specifically designed trailer mounted hopper. The hopper then fed the product directly onto a belt feeder conveyor in
turn delivering the product onto a declining conveyor down to the centre of the canal floor. The process created a delivery rate of 2000 tonnes per day.
Nelson Greymouth Auckland
Physical Address: 7 Spencer Place Brightwater, Nelson, 7022 Physical Address: 69 Jacks Road, Greymouth, 7805 Physical Address: 6 George Bourke Drive, Mt Wellington, Auckland 1060
Postal Address: PO Box 43, Brightwater, Nelson 7051 Postal Address: PO Box 138, Greymouth 7840 Postal Address: PO Box 132 072, Sylvia Park, Auckland 1644
Phone: +64 (3) 768 5374 Phone: +64 (9) 480 8409
Phone: +64 (3) 543 5300
Fax: +64 (3) 768 5379 Fax: +64 (9) 480 8109
Fax: +64 (3) 543 5301
Email: [email protected] Email: [email protected]
Email: [email protected]
Website: www.brightwater.co.nz Website: www.brightwater.co.nz
Website: www.brightwater.co.nz