UGL’s industrials and resources east team has successfully executed asset maintenance at Dyno Nobel’s Moranbah Plant, located in Queensland.
In the lead up to the project, our recruitment and mobilisation team assembled a workforce of more than 230 skilled white- and blue-collar personnel, including a 19% female and 6.39% Aboriginal and Torres Strait Islander participation rate.
UGL’s team was comprised of personnel with expertise across a number of disciplines — including special class welders, pipe fitters, riggers, trade assistants, and painters. The team performed key vessel replacements in the M17 boiler, with the welders showcasing exemplary welding skills.
Outage preparations included our scaffolding team erecting more than 728 tonnes of scaffolding. Once the turnaround began, the focus moved to major works and balance of plant services of the ammonia plant, the nitric acid plant and the ammonium nitrate plant.
A key portion of the works involved UGL successfully executing the replacements of several critical assets in the ammonia plant, a process which required a strategic approach with particular focus on safety and quality outcomes.
“Executing this turnaround at Moranbah was a true team effort,” said Aaron Orchard, UGL Operations Manager. “From early planning to final handover, our focus was clear—safety, quality, and collaboration. I’m incredibly proud of the team who brought their skills, commitment, and discipline to every stage of the project.”
UGL has a long-standing relationship with Dyno Nobel, having previously served as the primary engineering group for the dismantling of an ammonia plant in the USA, its relocation to Queensland, and the subsequent engineering and construction of the ammonium nitrate production facility.
Despite the challenges posed by the compounds and simultaneous operations, our industry-leading safety protocols shone through, earning Dyno Nobel's adoption of a number of our processes across its facilities.
The turnaround was completed in March with 95,000 manhours and no recordable injuries.