Project Requirements
Under a collaborative commercial agreement with Downer NZ, this project involved replacing the existing thermal drying facility with a single‑train rotary drum dryer. The DIALOG Fitzroy scope included fabrication and installation of new end‑product silos, fabrication and installation of piping, installation of pumps and valves, and connection to the existing biofilter ducting. DIALOG Fitzroy managed the mechanical components of the project, while Downer managed the civil and electrical aspects.
Scope of Work
DIALOG Fitzroy managed the mechanical aspects of the project, including:
- Design, fabrication, and installation of piping and pipe support systems
- Installation of the dryer plant and ancillaries
- Fabrication and installation of the raw materials and end‑product silos
- Installation of valves and dampers
- Procurement and installation of pumps, pump stations, and valves
- Installation of the dewatered sludge transfer systems, including the conveyor and pipeline to the raw material silo
Execution Strategy
- Early Planning & Design Integration: Initial planning included reviewing IFC design drawings, supplier documentation, technical specifications, and battery‑limit definitions to fully understand all mechanical scope boundaries.
- Fabrication: DIALOG Fitzroy fabricated the stainless‑steel pipe spools, structural frames, supports, and silos.
- Site Management: Prior to installation, mechanical, civil, and electrical works were integrated into an overall site management plan, ensuring safe access, effective interdisciplinary coordination, and compliance with environmental and safety requirements
- Mechanical Installation: Mechanical installation followed an ordered sequence, beginning with pipe supports and structural steel required for plant mounting. This progressed to installation of cooling water pumps, foul‑air fans, sludge transfer systems, conveyors, valves, foul‑water pump station equipment, ducting, and service pipework to each battery limit. Haarslev dryer components were installed in coordination with their supervisors, with strict adherence to alignment, anchoring, seismic restraints, torque requirements, and lifting procedures.
- Commissioning and Handover: Following installation, the mechanical team executed a structured pre‑commissioning programme, including:
- Rotational checks of pumps, fans, and motors
- Verification of alignment, vibration, noise levels, lubrication, and hydraulic systems
- Pipeline pressure testing, leak checks, and inspection of coatings
- Functional testing of valves and mechanical equipment
- Confirmation that all plant was installed in accordance with manufacturer requirements
- Supplier representatives supervised or reviewed pre‑commissioning of dryer‑specific equipment to ensure readiness for system commissioning.
