Non Process Infrastructure

Solomon Workshop

SOLOMON
WORKSHOP & DIESEL FUEL FACILITIES

End Client FMG
Location Solomon Hub, Tom Price, Australia
Commodity Iron Ore
Project Value $8.7M+
Solution Provided

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The Solomon NPI facilities work consisted of three distinct projects involving a workshop and two fuel facilities.

A new three-bay workshop with 30T overhead travelling gantry crane provides additional floor space to allow the servicing of heavy haul trucks. The workshop design allows for jacking of Komatso 930e vehicles and full opening of the tray.

The Kings and Firetail fuel facilities are used for refuelling of both autonomous and manned heavy haul trucks. Fuel is stored in 110kL horizontal storage tanks with the ability to dispense filtered fuel at multiple refuelling points.

The facilities are filled via pipeline to maintain diesel supply, with all fuel metered and reporting to a Banlaw fuel management system for reconciliation purposes.

The project delivery included concept approval, detailed design, procurement, installation and commissioning. With our self-perform mentality, Primero was able to offer significant additional value to the client which resulted in facilities much greater in scope and quality than originally planned.

Innovation though constructability, process improvement and industry leading Safety in Design has resulted in a successful, turn-key multidiscipline project.



Rio Tinto Dampier Salt

RIO TINTO
DAMPIER SALT DOLPHIN REMEDIATION

End Client Rio Tinto / Dampier Salt
Location Karratha, Western Australia
Commodity Salt
Project Value $2M+
Solution Provided

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The Karratha Dampier Salt facility allows 225 mtr long ships to berth, moor and warp alongside the jetty that comprises of 7 dolphins. Dampier Salt required the dolphins to be upgraded to ensure their continual performance and longevity. Each dolphin comprises 10 piles to keep them firmly in position.

The specific scope included:
+ Clean, wrap and shield 4 out of 7 dolphins
+ Design, fabricate and install 22 fenders
+ Replace top panels of main ship fenders
+ Remove redundant ladders from all 7 dolphins
+ Design, fabricate and replace 4 hawser rails
+ Design, fabricate and install 1 rope barricade
+ Design, fabricate and fit 2 rope deflectors

The works were performed with Primero management and construction crew over an intense 9 day shutdown window; between normal ship movements. To assist the Primero construction team, marine vessel and diving subcontractors were engaged. Pile cleaning was performed using 11,000 PSI water blasters. Pile cleaning, wrapping and shielding was performed using divers and floating platforms or barges depending on the weather conditions.
Design innovation was provided with slot in handrails for each of the new Hawser rails, rope deflectors to help avoid future Hawser rail damage and fenders fitted with standard HDPE pipe as a replacement to the currently used wood.

The execution of this project was reliant on multiple challenges including wind, tides, current and swell. Daily ‘war room’ style review meetings and a close relationship with Dampier Salt were crucial to the completion of this incident free project.



LV Wash Bay

RIO TINTO / HAMERSLEY IRON
EAST INTERCOURSE ISLAND LIGHT VEHICLE WASH DOWN BAY

End Client Rio Tinto / Hamersley Iron
Location East Intercourse Island, Karratha, Western Australia
Commodity Iron Ore
Project Value $1.8M+
Solution Provided

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Primero supplied and installed a new Light Vehicle (LV) wash bay facility including associated works at
the site of an existing, insufficiently equipped LV
wash facility at Rio Tinto’s East Intercourse Island operations workshop.

Primero’s scope of work included, project management, design input to tender drawings, procurement delivery to site, site survey works, underground services, decommissioning and demolition works of existing facility, construction, commissioning and handover of all necessary earthworks, civil, structural, mechanical, electrical
and control works.

PROJECT HIGHLIGHTS:
+ Existing facility decommissioning and demolition
+ Commissioing of facility completed in line with target dates
+ Works completed in a safe and effective manner under new RTIO Safety intitative CRM (Critical Risk Management)



RIO TINTO
FUEL INFRASTRUCTURE WEST ANGELAS & BROCKMAN FUEL HUBS

End Client Rio Tinto
Location Pilbara, Australia
Commodity Diesel
Project Value $70m+
Solution Provided Fuel Infrastructure Process and Detailed Design

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The West Angelas and Brockman fuel hubs are located in the Pilbara region of Western Australia and are two important nodes in Rio Tinto iron ore’s fuel storage and distribution infrastructure.

With a strong background in hydrocarbon facilities and safety in design, Primero Group was engaged to undertake the process and detailed design of the fuel infrastructure for both sites.

The solution consisted of rail tank car unloading, three 25m diameter diesel storage tanks, road tanker loading and all associated pipework, structures and amenities.

Primero Group delivered the detailed design of civil, structural, mechanical and piping elements to meet the process design criteria, and exceed client and statutory compliance requirements.



BHP BILLITON
IRON ORE AREA C MINE FACILITIES DESIGN

End Client BHP Biliton
Location Newman, Australia
Commodity Iron Ore
Project Value $38m+
Solution Provided Detailed Engineering and Design

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The BHP Billiton Area C Mine is an operating iron ore mine located in the Pilbara region of Western Australia, 92km North-West of Newman. Opened in 2003, the Area C Mine produces 42 million tonnes per annum for export, via rail to Port Hedland.

Primero was engaged to deliver detailed engineering and design of new buildings and facilities for heavy vehicle maintenance and washdown, lube storage, tyre maintenance, water treatment, power, communications and other services.

The project required delivery of works across a full range of disciplines spanning civil, concrete and earthworks, structural, mechanical, piping, process and electrical, and including extensive 3D modelling of buildings and other facilities.

Primero also delivered multiple HSE components including HAZOPs and Safety in Design, as well as demonstrating full compliance with all BHP Billiton Iron Ore standards and specifications throughout the project.



RIO TINTO YANDI SUSTAINING PROJECT
HEAVY VEHICLE FUEL INFRASTRUCTURE

End Client Rio Tinto
Location Pilbara, Australia
Commodity Diesel
Project Value $5m+
Solution Provided Turnkey Solution

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The Yandi Sustaining Project is focussed on upgrading the existing Yandicoogina Mine located in the Central Pilbara region of Western Australia as part of Rio Tinto Iron Ore’s Pilbara expansion operations.

With a strong background in hydrocarbon facilities and Safety in Design, Primero Group was engaged to provide a full turnkey solution for the heavy vehicle refuelling infrastructure at the Mine’s Junction South West operations, including tie-in to existing infrastructure at the Mine’s Junction Central Fuel Farm.

The solution consisted of design, supply, fabrication, delivery, construction and commissioning of the facilities; including; 2x110kL self bunded diesel storage tanks, duty/standby fuel pumps, inline filters, road tanker unloading and autonomous heavy vehicle refuelling. Non-diesel infrastructure consisted of an oily water separation system, wash down hose reels and safety showers.

With the design successfully delivered ahead of schedule the project has now moved into the construction phase where Primero will be completing a turn-key for the civil, structural, mechanical, piping, electrical and instrumentation elements of the project.


HOPE DOWNS 4 NON-PROCESS INFRASTRUCTURE

RIO TINTO HOPE DOWNS 4
NON-PROCESS INFRASTRUCTURE

End Client Rio Tinto
Location Newman, Australia
Commodity Iron Ore
Project Value $100m+
Solution Provided Engineering Design & Commissioning Services

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Sino Rio Tinto’s Hope Downs 4 project is located near Newman, Western Australia. The non-process infrastructure includes diesel storage and dispensing facilities, heavy vehicle workshop and lubrication facilities and ANE storage and dispensing facilities.

Primero Group was engaged by Forge Pty Ltd to complete detailed design modifications for the diesel and ANE areas associated with the overall facilities. In addition to the design modifications, a specialist team was mobilised to site to commission the bulk lubricant area, oily water area as well as the diesel and ANE facilities.

The team was responsible for managing numerous stakeholders involved with the project (KBR, Rio Tinto, Forge, construction contractors etc.) as well as leading the commissioning activities and handover of completed areas.

PROJECT HIGHLIGHTS INCLUDE:

  • Successful detail design modification and re-design works.
  • Commissioning of bulk lube, oily water and diesel facilities.
  • Full stakeholder involvement during the commissioning works.


RIO TINTO FUEL MANAGEMENT SYSTEM NORTH WEST

RIO TINTO
FUEL MANAGEMENT SYSTEM NORTH WEST

End Client Rio Tinto
Location Pilbara, Australia
Commodity Fuels & Oils
Project Value $1m+
Solution Provided Procurement, Fabrication, Construction and Commissioning

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The scope of this project comprised of the design, supply, installation and commissioning of a diesel fuel inventory management system for all diesel storage tanks across all sites of Rio Tinto.

The system included tank gauging, outbound metering, alarming, transaction recording and reporting at Rio Tinto sites.

PROJECT WORKS INCLUDED:

  • Site visits to determine specific requirements for the successful implementation of the fuel monitoring system.
  • Detailed design and development of the total fuel monitoring system.
  • Supply of the fuel monitoring system.
  • Installation of fuel monitoring system including required instrumentation, gauging equipment and site interfacing.
  • Configuration and commissioning of the fuel monitoring system.


RIO TINTO MARANDOO DEWATERING CONTROL SKIDS

RIO TINTO MARANDOO
DEWATERING CONTROL SKIDS

End Client Rio Tinto
Location Pilbara, Australia
Commodity De-watering
Project Value $15m+
Solution Provided Turnkey Fabrication Delivery

More on Primero’s dewatering capabilities.

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The Marandoo iron ore mine is located east of Tom Price, Western Australia. The site required dewatering as mining was planned for below the water table from the last quarter of 2012.

Forging an alliance with a well-established industry leader in electrical switchboards and associated equipment, Kounis Industries, Primero Group was awarded the sub-contract for the detailing, fabrication, assembly, pre-commissioning and delivery to the Marandoo site of 27 off dewatering head work control skids.

PROJECT HIGHLIGHTS INCLUDE:

  • Completion of all fabrication, assembly and pre-commissioning works at Primero Group’s Bibra Lake Workshop without a recordable injury or incident.
  • Complete off-site testing of all skids so as client site work requirements could be minimized.
  • Safe and efficient road delivery off all skids in a sequenced delivery as per schedule and site requirements.