The pre-feasibility / definitive feasibility phases were completed by metals process and estimating specialists in Aker Solutions’ Toronto office in Canada before transitioning to the Melbourne execution office. The teams in both offices include Russian speaking technical personnel who are familiar with engineering in accordance with the Russian design compliance requirements.
Engineering for Artic environments
The Arctic is a region of severe environmental conditions. The terrain itself is composed of a deep layer of permafrost, the top layer melting each summer and re-freezing in the winter.
Locating a metallurgical plant on a bed of permafrost is an enormous challenge. Heat from the plant melts the terrain and causes significant sinking of facilities. Complex foundations are required to maintain the frozen state of the terrain. For the Mayskoye Gold Project a ‘ventilated-type’ foundation was proposed. This provides for the circulation of cold air in a series of pipes beneath the slab to balance the heat from the plant and maintain the frozen state of the terrain.
With average temperatures well below zero degrees Celsius for most of the year, it is essential that facilities are protected from the elements by building enclosures. A single building (250m long x 80m x 30m high) has been designed to enclose the majority of the plant. The plant layout has been designed to maximise efficiency: all ground space is utilised for the process plant while the top of pipe-racks is used for control rooms, substations and building amenities.
Delivering compliant engineering in Russia
In the Russian Federation, metallurgical plant design and equipment imports are heavily governed by a range of statutory requirements, regulations and approvals. Aker Solutions’ execution model for Russian and former Soviet Union projects incorporate all elements necessary to ensure construction deliverables are fully design compliant. Central to Aker Solutions’ capability is possession of an appropriate Russian Engineering License. This, together with a team of Russian speaking engineers, technically literate translators and our association with select local Design Institutes, provides assurance for compliance purposes.
China procurement and supply
Aker Solutions’ China Procurement Hub connects the global Aker Solutions business to the Chinese market. This hub facilitates access to an ever-increasing range of quality equipment and commodities delivered faster and for less cost. China offers a range of equipment and materials delivered through state-of-the-art facilities at very competitive costs.
The Mayskoye Gold Project utilised the China Procurement Hub extensively. The long-lead Sag Mill is being supplied from China on a 13 month delivery instead of the nominal delivery of 30 months. Sourcing this crucial item in China has secured delivery time as well as a notable cost benefit.
Logistics management
Logistics severely challenge this project. All deliveries to site have to go by sea, but the sea port of Pevek is frozen in from November to June. This leaves only two effective shipping windows for the project: July to October 2008 and 2009. All process equipment was planned to be delivered in the 2009 window - within 15 months of EPCM award.
During the 2008 shipping window, Aker Solutions managed, on behalf of Russdragmet, the supply of all equipment and commodities necessary for the winter construction phase. Over 800 containers were shipped from ports in China, Russia, USA and Europe. Sea freight from Europe utilised the treacherous Northern-Route shipping passage, which provided a significant saving in freight time by avoiding transport via Suez and Asia. In a first for a major project, Aker Solutions arranged for a nuclear powered ice-breaker to navigate the passage and deliver essential materials to Pevek port.
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