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Mine Dewatering in Papua New Guinea Using Flexibore® 

High-capacity flexible rising main supporting deep pit dewatering in extreme mining conditions

Power Profile

Overview:

A gold mine in Papua New Guinea required a robust dewatering solution to remove large volumes of water from a deep open pit affected by rainfall and seawater seepage. Crusader Hose supplied Flexibore®, enabling the safe suspension and operation of high-capacity submersible pumps under demanding conditions.

Customer:

Gold Mine Operator

Location:

Papua New Guinea

Industry:

Mining

Application:

Bore Pumping

Gold Mine Operator

Challenge:

The mine required continuous dewatering to enable expansion within a geothermally active volcanic caldera, where water accumulation was caused by:

  • Heavy rainfall
  • Seawater seepage into the pit

 

Key challenges included:

  • Installing pumps at 175 m depth inside an angled casing
  • Managing high loads from large submersible pumps (350 kW units)
  • Operating in harsh and unstable conditions
  • Ensuring safe suspension and lowering of pumps
  • Maintaining high flow rates for effective dewatering

 

Traditional rigid systems would have added complexity, weight, and risk in such an environment.

Solution:

Crusader Hose provided Flexibore® (8”) as the flexible rising main to support and operate the dewatering system.

The system design included:

  • 3 × 350 kW stainless steel submersible pumps
  • Pumps suspended using Flexibore® as a load-bearing system
  • 175 m installation depth within angled poly-pipe casing
  • Power cables integrated with the hose
  • Diesel generators supplying power to each pump

 

Key advantages of Flexibore®:

  • High tensile strength, capable of supporting loads up to 16 tonnes
  • Continuous hose length, simplifying installation
  • Flexible design, allowing smooth lowering into angled casings
  • High burst pressure ensuring safe operation
  • Ease of handling, reducing installation complexity

 

The hose acted both as a fluid transfer system and structural support, enabling safe and efficient pump deployment.

Results:

The Flexibore® system delivered strong operational performance:

  • Safe installation of pumps at 175 m depth
  • Flow rate per pump: 168 litres per second
  • Reliable operation under extreme environmental conditions
  • Efficient installation process, reducing complexity
  • Stable and secure suspension of heavy pumps

 

Customer feedback:

“I was impressed at how efficiently the system worked. Our company will look for more opportunities to partner with such a reputable supplier as Crusader Hose.”
— Gabriel Hoascar, Taranis Power

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