To engineer and deliver a robust and reliable integrated solution for the iron ore slurry pipeline’s pump stations at Dabuna and Sagasahi, operating under high-pressure, abrasive, and continuous service conditions — while also providing on-site commissioning and technical supervision.
SOLUTION:
AMPO POYAM VALVES supplied a complete Integrated Smart Solution (ISS) to AM/NS India for its iron concentrate slurry pipeline, consisting of 2 Hydraulic Power Units (HPUs) and 65 severe service metal-seated ball valves (manual and hydraulic-operated) up to 20” and 600 lbs, which were rated as highly critical equipment. These zero-leakage floating design and metal seated valves were specifically designed to withstand the highly abrasive and corrosive conditions typical of iron ore slurry transport. AMPO’s zero-leakage valves stand out in the industry for their metal-seated design, a not common achievement in such demanding applications AMPO’s R&D team played a key role in customizing both the valves and HPUs. In addition to engineering and manufacturing, AMPO provided on-site supervision and commissioning services. The equipment was installed at pump stations in Dabuna and Sagasahi, and AMPO will also participate in the Performance Guarantee Test phase, reinforcing its commitment to long-term performance. This project further consolidates AMPO’s leadership in high-performance systems for the mining sector.
The development of an Emergency shutdown integrated system for Queensland Alumina Limited. (Turnkey project)
SOLUTION:
AMPO POYAM VALVES supplied in 2023 an emergency shutdown integrated system for Queensland Alumina Limited (QAL), one of the largest alumina refineries in Australia. The system was tailored designed by our in-house Ph.D level “INTEGRATED SMART SOLUTIONS (ISS)” experts in tight collaboration with our AMPO SERVICE team, who takes care of aftermarket and develops custom made engineered solutions for worldwide end users/operators of the mining and energy sectors. The system consisted of six 20” 600 lbs slurry angle valves, six Hydraulic Power Units (HPU) and Programmable Logic Controllers (PLC) as well as six oil accumulators.
Located in Gladstone, Queensland, the East coast of Australia, this SIL1 rated emergency shutdown integrated system will be shortly installed in the flash tank area of the alumina refinery, after the digestion unit. This smart system assures valve closure in case a command is received from the plant Emergency Shutdown System (ESD). Hydraulic accumulators guarantee valve closure even if electric power is down. This control system has maximum priority and overrides any other order.
The dual control system also has a Programmable Logic Controller (PLC) for valve positioning. DCS (Distributed Control System) controls the valve position using an optical fibre communication system and can be controlled in 1% increments.
The emergency shutdown system also includes a condition monitoring system to monitor critical parameters such as oil level, temperature, pressure and valve position, which are transmitted to the plant DCS (Distributed Control System) using the beforementioned optical fibre communication system. Electrical enclosure also includes vortex coolers to assure long service life under high temperature conditions. The enclosure is moreover IP65, keeping system isolated from outside contamination.
These ISS systems have already been delivered and will be shortly installed in Queensland Alumina refinery, where we will work hand in hand with the customer during the set-up process, referring our valve and ISS specialists from AMPO to Australia.
With the achievement of this new milestone, AMPO strengths its INTEGRATED SMART SOLUTIONS (ISS) development services, offering more than just valves. AMPO POYAM VALVES’ technology expertise and integration capabilities allow AMPO to design and develop complete bespoke integrated systems, both free standing or skid modular solutions.
