Project Description
Euler Engineering was engaged to provide detailed engineering design and drafting support for the safe removal, lifting, transport, storage, and reinstallation of a 9020 Dragline drum gear. The scope required multiple purpose-built lifting and handling solutions designed in accordance with Australian Standards and suitable for repeated use across mine sites.
The project was delivered across four distinct stages, each involving concept design, engineering verification, fabrication documentation, and certification.
Stage 1 – Jacking Frame for Gear Removal from Shaft
Objective
Design a jacking frame that could be welded to the existing gear and interface with a supplied hydraulic cylinder to safely jack the gear off the shaft.
Scope & Deliverables
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Site visit and measurements to define constraints and removal methodology
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Concept design developed and issued for client approval
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Detailed frame design to suit supplied hydraulic cylinder
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Finite Element Analysis (FEA) completed with engineering certification
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Fabrication drawings produced, including full Bill of Materials (BOM)
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2D DXF files supplied for plasma cutting
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Stainless steel compliance label supplied and specified in accordance with Australian Standards
Stage 2 – Lifting Hook for Gear Removal from Dragline
Objective
Design a lifting hook to allow the existing gear to be safely lifted using overhead cranes and removed from the dragline structure.
Scope & Deliverables
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3D modelling of the existing gear to develop an accurate lifting hook interface
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Concept lifting hook design issued for client sign-off
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Engineering verification via FEA with certification
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Hook plates cut specifically for physical proof testing
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Proof load testing conducted on a load bed by a certified tester
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Proof test certification supplied
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Fabrication drawings issued to site
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2D DXF files supplied for plasma cutting
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Stainless steel compliance label supplied to Australian Standards
Stage 3 – Transport & Storage Frame
Objective
Design a transport and storage frame to safely store the jacking frame and lifting hook, allowing the equipment to be reused across multiple mine sites.
Scope & Deliverables
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Design of a dedicated storage frame including lifting points and tie-down points
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Concept design issued for client approval
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Engineering verification via FEA with certification
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Fabrication drawings and full BOM provided
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2D DXF files supplied for plasma / laser cutting
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Stainless steel compliance label specified and supplied
Stage 4 – Installation of New Gear
Objective
Design lifting solutions to safely install the new drum gear back into the dragline and onto the shaft
Scope & Deliverables
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3D modelling of the new gear
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Designated lifting points incorporated into the gear model to simplify installation
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Design of a bolt-on lifting jig suitable for crane lifting
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Concept design issued for client sign-off
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Engineering verification via FEA with certification
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Fabrication drawings and full BOM provided
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2D DXF files supplied for plasma cutting
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Stainless steel compliance label supplied to Australian Standards
Outcome & Value
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Delivered fully engineered, certified lifting and handling solutions for critical mining equipment
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Enabled safe removal, handling, transport, and reinstallation of heavy rotating equipment
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Reduced on-site risk through engineered lifting systems and proof-tested components
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Provided reusable assets suitable for deployment across multiple mine sites
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Ensured full compliance with Australian Standards and site safety requirements
Key Benefit
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By combining detailed 3D modelling, engineering analysis, and fabrication-ready documentation, the project enabled complex dragline maintenance activities to be executed safely, efficiently, and with minimal operational risk.