Site-Based Mechanical Engineering for Heavy Industry, Mining and Power Generation

Hamilton By Design provides mechanical engineering support for industrial plants across Newcastle, the Hunter Valley and surrounding regions.

We support sites involved in steel making, smelting, coal handling and preparation plants, coal washing, power generation, bulk materials handling and heavy industrial maintenance.

The Hunter region has a long history in coal, power generation and steel-related industry, with coal mining, CHPP operations, power stations and export infrastructure continuing to play a major role in the region’s industrial base.

Mechanical Engineering Support for Operating Plants

Industrial sites require practical mechanical engineering that understands plant availability, shutdown windows, maintenance constraints and the reality of working around existing equipment.

Hamilton By Design can assist with:

• Site-based mechanical engineering support
• Mechanical plant inspections
• Pump calculations and pump system reviews
• Like-for-like replacement of mechanical components
• Structural and mechanical component replacement
• Conveyor, chute and transfer point reviews
• CHPP and coal washing plant mechanical support
• Smelting and steel plant mechanical support
• Power station mechanical and structural support
• Reverse engineering of worn or obsolete parts
• Engineering drawings for fabrication and replacement
• 3D laser scanning for existing plant and brownfield works

Mechanical Engineering for CHPP and Coal Washing Plants

Coal Handling and Preparation Plants operate under demanding conditions. Pumps, pipework, screens, launders, conveyors, chutes, guards and structural supports are exposed to wear, vibration, corrosion and material build-up.

Hamilton By Design can assist with inspection, measurement, design and documentation for:

• Slurry pumps and process water systems
• Pump baseplates and drive arrangements
• Pipe supports and replacement pipework
• Chutes, launders and transfer points
• Conveyor structures and guarding
• Access platforms, walkways and maintenance areas
• Wear plate replacement and component redesign
• Like-for-like replacement where production risk must be controlled

Where components are worn, damaged or no longer supported by the original supplier, we can use site measurement, 3D laser scanning and reverse engineering to develop fabrication drawings and replacement geometry.

Mechanical Engineering for Steel Making and Smelting Plants

Steel making, smelting and high-temperature processing plants require mechanical engineering that considers heat, wear, access, material selection and maintenance practicality.

Hamilton By Design can support mechanical and structural works around:

• Furnace and smelting support equipment
• Ducting, hoppers, bins and chutes
• Cooling water and process pipework
• Platforms, access steel and maintenance structures
• Pump skids and mechanical drive systems
• Heavy fabrication replacement items
• Site inspection and defect reporting
• Drafting and engineering documentation for fabrication

Our approach is practical and site-focused. We understand that industrial drawings need to be useful for fabrication, installation and maintenance — not just theoretical design.

Mechanical Engineering for Power Generation Sites

Power generation sites across the Hunter region continue to require engineering support for maintenance, transition works, decommissioning, replacement equipment and brownfield upgrades. The region includes long-standing coal-fired power infrastructure, with Bayswater continuing to operate and Liddell now retired.

Hamilton By Design can assist with:

• Mechanical inspection of existing plant
• Pump and pipework calculations
• Cooling water and process systems
• Replacement steelwork and mechanical supports
• Access platforms and maintenance structures
• Brownfield scanning and as-built modelling
• Fabrication drawings for replacement components
• Shutdown planning support and site verification

Pump Calculations and Mechanical Reviews

Pumps are critical across CHPPs, smelters, steel plants and power generation sites. Incorrect pump selection, worn components or poor pipework arrangements can lead to reliability issues, cavitation, vibration and reduced plant availability.

Hamilton By Design can assist with:

• Pump duty review
• Flow and head calculations
• Pipework pressure loss checks
• Pump baseplate and support review
• Like-for-like replacement checks
• Reverse engineering of pump components
• Wear assessment and replacement drawings
• Arrangement drawings for maintenance and installation

Plant Inspection and Like-for-Like Replacement

Many industrial sites require replacement of existing structural or mechanical components without changing the function of the plant. In these cases, accuracy and practical site understanding are critical.

We can attend site to inspect, measure and document existing components, then develop drawings for:

• Replacement frames
• Platforms and access steel
• Guards and brackets
• Pump skids and bases
• Chutes and liners
• Pipe supports
• Structural and mechanical interfaces
• Worn or obsolete machine components

Where required, 3D laser scanning can be used to capture existing conditions and reduce the risk of fabrication or installation errors.

Why Hamilton By Design

Hamilton By Design is engineer-led. We combine mechanical engineering, drafting, 3D laser scanning, reverse engineering and fabrication-aware design.

This means we can support clients from site inspection through to practical engineering drawings suitable for review, fabrication and installation.

For Newcastle and Hunter Valley industrial sites, we provide mechanical engineering support that understands heavy industry, maintenance realities, shutdown risk and the need for clear, accurate deliverables.

Contact Hamilton By Design

If your site requires mechanical engineering support for a CHPP, coal washing plant, smelter, steel plant, power generation facility or heavy industrial operation, Hamilton By Design can assist with site inspection, calculations, scanning, drafting and replacement component design.

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