Engineering Australia Excellence Award - Port Hedland Port Authority


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Winning Engineering Australia Excellence Award 2012 submission copywriting and design services provided to Port Hedland Port Authority and PinC Group.

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Engineering Australia Excellence Award - Port Hedland Port Authority

  1. 1. Utah Point Multi-User Bulk Export FacilityPort HedlandServicing Australia’s future trade growth2011 WA Engineering Excellence AwardsResource Development Category
  2. 2. ContentsContentsProject Overview 1Categorisation Statement 4Mandatory Criteria 6Optional Criteria 21AppendiCES 30Acknowledgements 46
  3. 3. Project OverviewProject Overview Project Overview The Utah Point Multi-User Bulk Export Facility A number of sustainable technology initiatives (Utah Facility) addresses the resource industry’s and innovative engineering practices were need for expanded port facilities to meet current adopted and significant studies and consultation and future growth in global demand for Western undertaken as part of a full Public Environmental Australian mineral resources and to facilitate Review. This process addressed the complexities export for emerging mineral producers in the associated with designing and constructing Port Hedland region. a port facility to transport, store and export a multitude of minerals with potentially adverse The Utah Facility was constructed on Finucane environmental and community impacts. Island opposite the existing public berths and within the narrow neck of the Port Hedland Innovations were introduced to achieve harbour. The Utah Facility development concept operation efficiency and to mitigate health risks consisted of a new dredged berth pocket and and other community concerns including: a 270 metre long concrete wharf, travelling ship 45,000m3 water recirculation and stormwater loader, 24 hectare stockyard and associated harvesting system; bentonite geosynthetic lined materials handling infrastructure, administration stockyard floor with plastic reinforced seawall and controls facility, and a 10 kilometre dedicated embankments; custom designed automatic access road. vessel mooring system; real time vibration monitoring of the BHPBIO tunnel; quad road train Originally designed for a maximum export wash facilities; unique mobile hopper train ore capacity of 12 to 15 million tonnes per annum, reclaim system and a commitment to a mangrove increased industry demand resulted in design propagation farm. modifications to accommodate an export volume of up to 21 million tonnes per annum. Expanded The Utah Facility performed beyond expectation capacity was achieved by increasing the dredged in achieving nameplate capacity within 6 months depth of the berth pocket, introduction of an of operation and has proved capable of delivering innovative new automatic mooring system to 9 million tonnes of trucked ore per annum berth larger vessels and increasing the materials throughout representing estimated export sales handling system peak loading rate from 5,000 of $1.5 billion per annum. to 7,500 tonnes per hour. These innovations Future increases in industry demand can allow the current facility and stage one of the be accommodated within the Utah Facility stockyards to reach up to 14Mtpa prior to the with provision made for receiving product via construction of future stockpiling. alternative ore transport modes such as rail Using an integrated client team approach, the or slurry pipeline. Additional land has been Port Hedland Port Authority (PHPA) worked allocated adjacent to Utah Point to increase collaboratively with project management opportunities for new and emerging mining consultants, Pinc Group Pty Ltd (Pinc) to deliver companies that would otherwise be denied the project. Project planning commenced in access to export markets. September 2006 and first ore on ship was achieved within 4 years on 17 September 2010 after a 20 month construction phase. 2
  4. 4. Utah Point Multi-User Bulk Export Facility Port Hedland Servicing Australia’s future trade growth About Port Hedland Port Authority Categorisation StatemenT The Port Hedland Port Authority PHPA’s major functions are the control of all (PHPA) is a statutory authority shipping, and maximising the loaded capacity owned by the Western Australian of ships through the use of world leading Government. The Port Authority technology that allows the Authority to maintain has a charter to operate along minimum safe under keel clearances. The Port commercial lines with a primary Authority also has a responsibility to plan for and purpose to facilitate trade manage new developments whilst protecting the through the port. environment of the port. About Pinc Group Pty LtD Established in 2005, Pinc is an emerging provider of choice for specialist project management and project services to the resource sector. Pinc’s unique PMC management processes and integrated software and systems are designed to support clients to successfully develop major capital works. Previous clients of Pinc include: • Boddington Gold Mine • Fortescue Metals Group Ltd. • Abesque Engineering Ltd. • Karara Mining Ltd. • Extension Hill Pty. Ltd. • Atlantic Ltd. • Midwest Vanadium Pty Ltd. • Atlas Iron Ltd. • Newcrest Mining Ltd. • Ausenco Ltd. • Rio Tinto Ltd. • BHPB Petroleum • Worley Parsons Ltd.3
  5. 5. Utah Point Multi-User Bulk Export Facility Port Hedland Servicing Australia’s future trade growth CATegorisation statement Mandatory Criteria The Utah Facility addresses the resource industry Implementation of sustainability initiatives need for expanded port facilities to meet current and innovative engineering practices and and future growth in global demand for Western technologies have not only improved operational Australian mineral resources. efficiency across the port, but reduced environmental and health risks to Port Hedland Construction of a new multi-user bulk export residents, whilst improving amenity for all. facility on the west side of the harbour at Utah Point, with a capacity to receive small cape Within the 2010/11 financial year, the Utah size ships up to 120,000 tonnes deadweight, Facility is expected to increase export tonnage resolves current pressure placed on existing port over the PHPA operated berths by 360% from facilities within Port Hedland, and allows Western the previous year achieving the facility’s designed Australia’s junior mining companies to export nameplate capacity of nine million tonnes per their products to a resource hungry annum with an estimated total export value of global market. $1.5 billion.5
  6. 6. Utah Point Multi-User Bulk Export Facility Port Hedland Servicing Australia’s future trade growth Mandatory criteria Mandatory Criterion 1 - Occupational Health & Safety As the first major construction project undertaken “The Utah Facility is committed to by PHPA, the Utah Facility presented a number ensuring the highest possible standards of occupational health and safety (OH&S) of occupational health and safety, the challenges for the project management team and minimisation and control of all risks, and contractors given the absence of established to zero harm.” safety management policies and procedures, Excerpt from the Utah Facility’s Safety and minimum safety standards for construction. Management Plan. This situation was further complicated by Safety management initiatives targeted a contracting strategy that required the training, risk assessment and problem solving in construction management team to control high risk areas. It was recognised early that the Seawall construction using concrete impregnated miracell the interfaces between multiple independent most impact could be achieved by focusing on contractors occupying the same work spaces, improving behaviour and attitudes of front line along with Port Hedland’s difficult environmental workers and supervision to improve the overall An example of an effective safety initiative is working conditions where dust exposure and safety awareness and culture. evident in the implementation of safety controls Key OH&S initiatives employed across the high ambient temperatures and humidity pose over the dredging and piling operations over the project included: Backed by a high visibility, supportive and BHPBIO tunnel as detailed in Appendix A. significant health and safety risk. • igh weighting to safety performance and H positive leadership culture in which the entire Real-time vibration monitoring with direct systems in the evaluation of tenders. A carefully crafted project management strategy project management team and contractor contractor communication was established to was established to ensure safe design and personnel were genuinely engaged in predict when dredging and piling operations • azard Identification Analysis (HAZID) and H construction outcomes. The project’s OHS decisions affecting workforce safety, the might exceed pre-determined safe vibration formal risk assessments undertaken regularly. Plan set minimum standards and procedures project management team led work planning limits. This allowed the extent of further work to • Early identification of unacceptable risks that based on industry standards and statutory and communication through daily Tool Box be forecast and quickly agreed upon to ensure could lead to unsafe outcomes. requirements. Outlining site specific requirements meetings and weekly contract meetings with the work undertaken by third parties within the tunnel • Empowering all personnel to stop work where for entering and working on site, the Plan relied Construction Manager that focused primarily could continue safely and without disruption. unsafe practices or risks were observed. heavily on the contractors own quality and safety on safety and environmental issues. Despite the difficult environmental conditions, • Daily, unobtrusive observation of work management systems and procedures. The need relative remoteness of the site and high risk practices with positive feedback for safe work. for cooperation, trust, individual responsibility nature of the construction work, the safety • voidance of safety clichés or rules for which A and accountability were adopted as a basic management strategy delivered a Lost Time the rationale could not be justified. undertaking by all parties. Injury Frequency Rate (LTI FR) of 1.4 resulting • Elimination of unnecessary paper work, from one lost day through injury from a total especially for workers and supervisors. 850,000 site manhours. • genuine no blame system and no penalties A This LTI FR represents only 10% of the WA for lapses or mistakes. construction industry’s average of 13.9 and • Early and comprehensive incident/near only surpassed by the best performing miss reporting. industry sector, that of the finance and insurance industry1. 1 Work Related Lost Time Injuries and Diseases in WA 2006-07 to 2008-09,Worksafe WA.7 8
  7. 7. Utah Point Multi-User Bulk Export Facility Port Hedland Servicing Australia’s future trade growth Mandatory criteria Mandatory Criterion 2 – Sound Engineering Practices Principles A fresh approach to project management the award of construction contracts in line with the availability of funds. Successful delivery of the Utah Facility can be attributed to the selection of contract and The financial benefit of adopting a fresh approach procurement strategies matched to project and to contracting was evident in the supply and commercial risks and the implementation of an installation of the site’s high voltage electrical effective client integrated team. feeder. A risk loaded fixed price offer presented by the service authority was renegotiated to a Flexible contracting strategy matched to risk reimbursable contract (cost plus fixed fee) that A significant element of the project’s success netted a 57% cost saving for the augmentation of lay in the careful selection of contract strategies power to the site. to minimise scope, cost and time risks. When An integrated team approach to project and the project was assessed as requiring a full construction management Public Environmental Review (PER), the planned fixed lump sum design and construction model Following completion of the concept had unacceptable prolongation risk and was development phase, PHPA commissioned the therefore replaced with a client integrated project services of Pinc Group Pty. Ltd. (Pinc) to work and construction management team. collaboratively as project manager in a genuine integrated team approach where Pinc was This allowed close management of project empowered to think and behave like the client approvals and funding requirements, with Sample of 3D Computer Model Used in Designing the Utah Facility preliminary engineering and procurement During design and procurement, Pinc provided undertaken whilst the scope continued to be the flexibility required, with part-time and full-time developed during the PER process. This strategy multi-disciplined staff allocated according to the led to PHPA taking responsibility for long lead changing needs of project implementation Pinc was able to provide PHPA with the approach provided a more efficient and cost item procurement, managing engineering at a Refer Appendix B for Utah Facility resources, procedures and systems required to effective project management solution. pace consistent with PER outcomes and to stage Organisational Chart. effectively manage project planning, scheduling, Total engineering, procurement and construction procurement, contract management, project management (EPMC) services from concept controls and reporting. This service was development (excluding the PER and associated simplified by the adoption of Pinc’s innovative studies) through to commission and handover proprietary Integrated Project Management were delivered for a minimal 10.2% of total Software (PincSys) which continues to be utilised project capital (as summarised below) in an by PHPA in its ongoing operations. industry where the costs of EPMC services are The client integrated team approach typically in the range of 15-25%. required a high degree of trust to foster close • roject Management P communication, eliminate duplication of and Procurement 1.76 % management and encourage fast decision making. With PHPA’s limited experience in • Engineering 4.30 % the development of major capital assets, this • Construction Management 4.11 % Utah Facility Construction team Photo9 10
  8. 8. Utah Point Multi-User Bulk Export Facility Port Hedland Servicing Australia’s future trade growth Mandatory criteria Mandatory Criterion 3 - Originality Ingenuity Utah Facility Stockyard Design Flexibility The Utah Facility has a 24 hectare (1030m As selection of facility clients and their products x 235m) multi-user bulk materials stockyard were indeterminate during the design phase and designed to receive nine million tonnes per expected to change over time, the stockyard annum of ore delivered by road train. This facility layout, loading and stacking infrastructure, is the first of its size and purpose in the world materials handling and electrical systems were and is truly unique in the design and construction designed to manage a range of minerals, loading methods used in its creation. rates, material properties and ore sizes ranging from 120mm abrasive chromite lump to superfine Size mineral concentrate. Designed for 20 hour operation (allowing a 4 hour traffic curfew for evening peak hour), this facility is the only one in the world capable of receiving one quad road train transporting up to 106 tonnes of multiple ore products every 5 minutes in a continuous operation. Workers rolling out Geogrid layer to marine mud stockyard floor Construction selected as the preferred lining material given its chemical stability, self-sealing properties and The stockyard was constructed over potential ability to adjust to differential movement in the acid sulphate marine mud to depths up to 2.5 stockyard floor. metres. Too environmentally unstable to expose to oxygen and expensive to treat, the stockyard Each of the 13 stockpiles housed in the was designed to “float” on the mud. To minimise stockyard are capable of exerting a pressure earthwork haulage costs, the stockyard floor was equivalent to a 30 storey building. Two Securgrid restricted to a depth of 2 metres, which required 400/40 geogrid layers with tensile strength of strengthening of the fill to avoid overturning slip 400KN were chosen as the preferred method failure from the weight of stockpiled ores. of reinforcing the stockyard base given their superior strength and environmental stability. The stockyard base contains a bentonite barrier Stockpile height restrictions were imposed on layer and groundwater collection system installed initial stacking operations to allow consolidated 0.9 metres below the stockyard surface to marine mud to develop strength. Fill settlement prevent ore residues and dissolved solids from of up to 20cm was forecast and the stockyard contaminating the groundwater. Bentonite was design accommodated this predicted movement. Preparing marine mud for geogrid layer11 12
  9. 9. Utah Point Multi-User Bulk Export Facility Port Hedland Servicing Australia’s future trade growth Mandatory criteria A safer, more efficient way to moor vessels Catovec’s MoorMaster Automatic Mooring System uses new technology to improve safety, time and operational costs associated with berthing large ships and significantly increase the port’s throughput. Innovative 200MM units designed to withstand Port Hedland’s extreme tidal, heat and dust conditions have not only improved safety Quad Road Train Adjacent to Stockyard Dump Pocket compared to traditional rope mooring, but reduced vessel capture, moor and release times by approximately 2.5 hours per vessel. Operations Refer Appendix C - Utah Facility General More information on the innovative application Arrangement Plan and Process Flowsheet for of Cavotec technology is found in Mandatory Given the volume of trucks and variety of more further information. Criteria 8. ores being transported to multiple stockpiles within the facility, customised transport, truck Significant cost savings were achieved by management and communications systems were replacing the traditional fixed hoppers with two designed to manage stockyard efficiency. originally designed hopper trains. These rail trains were designed to operate over the central A two lane elevated perimeter road allows trucks reclaim load-out conveyor with trailing power and to circulate, pull out safely and right side dump water cables. The six hoppers and two motor into hoppers capable of automatically identifying control centres required for this solution achieved the truck and its contents before unloading. A considerable capital cost and operating savings. CCTV system linked to a central control room at the entrance was also constructed to ensure Refer Appendix D - Mobile Hopper Train General efficient facility management and security. Arrangements 1 and 2 for further information. 3D model view of stockyard Mobile Hopper Train Schematic13 14
  10. 10. Utah Point Multi-User Bulk Export Facility Port Hedland Servicing Australia’s future trade growth Mandatory criteria Mandatory Criterion 4 - Economic Contribution Provision was also made for ship loading rates of up to 7,500 tonnes per hour, well in excess of the rate required to service the stockyard. When “This was a development that needed coupled with the increased operating efficiency to happen… it is necessary to meet the provided by the Cavotec Automatic Mooring significant growth that has come through system, the Utah Facility can increase throughput the port but also facilitate iron ore juniors to capacity well beyond the current 9 million tonnes get their products out.”1 per annum. Andre Bush, CEO, Future expansion of the facility has also been Port Hedland Port Authority. considered in its establishment. Additional land has been assigned for the construction of a second stockyard capable of receiving mineral products through a variety of alternative transport modes such as rail, overland conveyor or slurry pipeline. Existing facility capability and Increasing Port Hedland’s export capacity existing public berth infrastructure to increase access road design will permit these options to inner harbour capacity without reducing the be pursued without modification to the current The development of the Utah Facility has had a export capacity of other port users. The BHPBIO materials handling system. fundamental impact on Western Australia’s future under harbour tunnel that crosses at shallow export potential and economic activity. depth under the Utah Wharf constrained the The Utah Facility signals a vital opportunity depth of the Facility berth pocket such that it for new and emerging miners to export their was only suitable for Panamax and Small Cape products to international markets. Commencing vessels with low drafts capable of accessing the the export chain through affordable trucking harbour during low tide when larger ore carriers options is expected to provide a starting point cannot operate. for the generation of valuable cash-flow to new Custom built to manage between 85,000 and market entrants, which will in turn provide future 100,000 road trains per year, the Utah Facility opportunities for expansion through capital stockyard delivers a diverse range of ores from development and encourage investment in mines within a 550 kilometre radius of Port minerals mining well into the future. Hedland. Within the first year of operation, the PHPA’s strategic plan to expand the Port’s inner Utah Facility has achieved nameplate export harbour capacity from 200 million tonnes to 495 capacity of 9 million tonnes of trucked ore per million tonnes per annum cannot be achieved annum worth an estimated $1.5 billion in export without the Utah Facility. Through clever design sales and facilitated a 360% increase in annual and use of technology, the facility accommodates export tonnage for PHPA public berths. Ore being conveyed onto ore carrier docked at Utah Point berth15 16
  11. 11. Utah Point Multi-User Bulk Export Facility Port Hedland Servicing Australia’s future trade growth Mandatory criteria Mandatory Criterion 5 – Community Benefit Development of the Utah Facility and Strengthening community links relocation of chromite and manganese exports The Utah Facility initiated the establishment of from Port Hedland’s west end to Utah Point the Port Collaboration and Heritage Agreement has resolved a number of significant between PHPA and the local Marapikurrinya environmental issues affecting the local community, the original custodians of the land community. In addition to the significant occupied by the Utah Facility. This agreement environmental and health improvements outlined initiated a number of benefits for the community in Optional Criteria 16, the following have also that were not in place prior to the project, contributed to a significantly improved amenity including a commitment to the provision of for the Port Hedland community. employment, ongoing business development Increasing employment opportunities in assistance, development of a Cultural Heritage the region Masterplan and provision of assistance with cultural heritage training and awareness by The number of employees working for the PHPA the PHPA. increased from 25 to 90 with a diverse range of skill sets, following completion of the project. Traditional land owners also secured JV These personnel were either sourced from the partnerships with three of the major contractors local community or new residents following during construction which resulted in direct a commitment made from staff to live in Port employment, traineeships and dry-hire of Hedland. Given Port Hedland’s typically transient equipment. The project also employed a heritage population, PHPA has made a significant monitor to oversee all construction activities. contribution to strengthening Port Hedland’s Improved traffic flow and road safety permanent employment base. The project improved traffic safety by removing Many local contractors and services were utilised road train traffic from Port Hedland’s suburban during the construction phase. Upon completion and feeder roads. Trucks now enter the Utah site of the facility, three of the four major contractors via a new dedicated 10 kilometre sealed access employed have made long term commitments road, and significant improvements have been to working in the local community and have made to address safety issues associated with set up local offices and established permanent road train and light vehicle interaction on the accommodation arrangements. Great Northern Highway network. Further benefits included the mandated requirement to cover all truck loads to prevent dust and contaminants affecting suburban areas. Utah wharf construction17 18
  12. 12. Utah Point Multi-User Bulk Export Facility Port Hedland Servicing Australia’s future trade growth Mandatory criteria Mandatory Criterion 6 - Sustainable Development Water conservation and mangrove preservation metre high perimeter seawalls. This allowed the were significant drivers for the development embankment to be steepened and prevented the of sustainable engineering solutions for the loss of 1.2 hectares of mangroves at the seawall Utah Facility. toe at a cost of $0.63m (investment of $52 per square metre of mangroves preserved). Preserving Port Hedland mangroves Refer Appendix E for Stockyard Embankment Twenty four hectares were required to establish Road Details. a stockyard capable of stockpiling trucked Seawall construction using concrete impregnated miracell ores with a nine million tonne per annum Care was also taken to ensure that export potential. mangroves outside of the construction footprint were not disturbed. At the conclusion of Water Quality and Conservation A 45,000m3 lined recirculation water pond and Consistent with the requirements of EPA construction activities, mangroves were thriving controlled discharge pipe system and three Guidance Statements No. 1 (Tropical Arid Zone The potential adverse eco-toxicological effect of at the toe of the seawall as a result of careful 1,000m3 storage tanks were installed to enable Mangroves; EPA 2001) and No. 29 (BPPH chromite and manganese on mangrove construction practices. fire and dust suppression, and management protection; EPA 2004c) to minimise mangrove and marine systems was studied by PHPA loss and in particular, to protect valuable closed In total, 18 hectares of mangroves were of potable water across the site to deliver the during the PER and led to a requirement to canopy mangroves, the stockyard footprint was removed during construction of the stockyard abovementioned water conservation outcomes. prevent ores containing chromite and manganese minimised and re-oriented. and access road. A commitment has been from contaminating groundwater systems and Contaminated stockyard stormwater harvested given by PHPA to the Environmental Protection the harbour. through a ring main pipe system to the A partially disturbed calcarenite (limestone) Authority and local community to meet the recirculation water pond will provide an estimated outcrop at Stanley Point was selected as the The project team developed the following Guidance Statement target of 10% historic 6 weeks reprieve per year from the need most appropriate stockyard location given its initiatives to prevent mineral contamination of loss of mangrove environments since European for expensive scheme water representing a low ecological value as a result of being ground and harbour waters: settlement through the establishment of a considerable cost saving. previously disturbed and consisting mostly of mangrove offset project. This work will further • hysical separation of iron ore from other P sandy saline flats with low open shrubs. generate local jobs in its construction and will contaminating ores in the stockyard. Multiple layers of plastic geogrid (Securgrid support ongoing eco-tourism and aboriginal • Installation of a bentonite barrier layer with 120/20) were also installed within the six to eight heritage opportunities. sub-surface drainage collection system. • Installation of sealed internal roads. • onstruction of an automatically operated C quad road train truck wash station installed with water recirculation system. • Materials handling system designed for wash down and collection of contaminants between shipments for treatment and recirculation. • On site collection and treatment of stormwater that is harvested for dust suppression. • Installation of two Stormceptor units to operate in conjunction with the wharf wash down Stormceptor adjacent to wharf to settle Closed canopy mangroves system to settle out contaminants from the wharf wash down contaminants wharf wash down.19 20
  13. 13. Optional criteriaOptional Criteria Optional Criterion 8 - Simplicity of the Engineering Solution Cavotec Automatic Mooring System Utah Point is located in the narrow neck of Port Hedland Harbour where passing vessels (up to Striving for world’s best practice and simple 270KT bulk carriers) exert significant hydrodynamic low cost options for maximising the throughput interaction forces that act to suck vessels from capacity of the Utah Point berth, PHPA made a their moorings. Port Hedland experiences large decision to replace the centuries old practice of tides (7.5 metres) that produce in excess of 2 knot mooring vessels using ropes with an innovative currents, design wind speeds of 23 m/s (45 knots), and simple new technology. fine iron ore dust issues and extreme heat (+45 Cavotec’s MoorMaster Automatic Mooring System degrees Celsius) conditions. uses simple design concepts involving large As Cavotec had not previously designed units manoeuvrable suction cups held under vacuum to withstand these conditions, PHPA contracted to safely capture, berth and release vessels in Cavotec to design and test 14 completely new considerably less time than traditional mooring 200MM units capable of handling the large tidal methods. The time saved in mooring and releasing ranges experienced at Port Hedland. The revised vessels using the MoorMaster technology and design replaced the previous top mounted winch its ability to maintain continuous safe loading mechanism with a rail mounted travelling bus operations has improved vessel turn around (motor) to provide a robust structure capable efficiency in Port Hedland by up to 2.5 hours. of withstanding forces equivalent to 20 tonnes perpendicular (280 tonnes total) and 10 tonnes parallel to the berth face. Cavotec units mounted vertically on wharf rails Cavotec wharf mounting close up 22
  14. 14. Utah Point Multi-User Bulk Export Facility Port Hedland Servicing Australia’s future trade growth Optional criteria Since the implications of system failure or under- Post-installation, the initial hydrodynamic design were significant, PHPA commissioned interaction force concerns did not eventuate OMC-International to modify the existing as the MoorMaster units perform much better Port Hedland hydrodynamic harbour mooring in dampening the impacts of wind, current and model to simulate ropes as stiff springs. This passing vessel forces than during simulation. conservative assessment of MoorMaster system The technology has proved itself to be a more capabilities predicted that the impact of passing than effective and simple replacement of vessels would potentially exceed the capacity traditional rope technology. of the design specifications on the end units. PHPA challenged long established practices and Revised bollard designs for secondary rope put their faith in new and conceptually simply protection were implemented as a precaution technology with the MoorMaster Automatic and options for piggy backing the two end units Mooring System. This decision may drive a were explored. revolutionary change in ship berthing practices around the world with significant potential to improve safety, time and operational costs in the future. Aerial view of Utah Point berth showing 14 equidistant Cavotec units Key Benefits Through simplicity of operation and design concepts, the MoorMaster system delivers the following significant benefits to PHPA and facility proponents: • Improved safety of mooring operations. • Improved Utah Point Berth throughput capacity and berth efficiency with maximum • Greater port export efficiency through vessel size increased to a length overall (LOA) elimination of vessel creep, lost time due to of 270 metres compared to 225 metres using passing vessel interactions and reduction in traditional rope mooring methods. the time required to capture, moor and release individual vessels which combined provide an • Reduced port operating costs for tug boats estimated time saving per vessel of 2.5 hours. and personnel involved with stevedoring and corresponding reduction in fuel emissions. • Eradication of the need to construct large and expensive Mooring Dolphins. Refer Port Strategy May 2007 article in Appendix G for more information on the 200MM unit factory acceptance testing in France Cavotec Automatic Mooring System.23 24
  15. 15. Utah Point Multi-User Bulk Export Facility Port Hedland Servicing Australia’s future trade growth Optional criteria OPTIONAL CRITERION 13 - LEVEL OF IMPORT REPLACEMENT Utah Point Travelling Ship Loader and Tripper Conveyor In accordance with the project’s stated objective and tendering criteria whereby preference was given to locally manufactured products, PHPA rejected the cheapest tender offer from a reputable Chinese manufacturer in favour of project managing the design and manufacture of the ship loader using a range of local contractors and suppliers. Perth based Delta Engineering were awarded the contract to design the ship loader and manufacture associated mechanical and electrical components Ship loader main frame erection, January 2010 for delivery to the Australian Marine Complex (AMC) Ship loader transfer to Common User Facility at Henderson, south of Perth. Henderson Wharf, May 2010 Upon completion, the 600 tonne ship loader and Table 1: Local contract partners for construction of the Utah Point ship loader 80 tonne boom were transferred to a heavy lift ship Contractor/Location Description of Service Contract Type for transport to Port Hedland where it was placed Pinc Group (Perth) Project Managers for all Utah Point Henderson Schedule of rates directly onto the rails of the Utah Point wharf. scope of work Delta Engineering (Malaga) Overall design supply of structural Fixed lump sum Erection of the superstructure using multiple mechanical components contractors who had not previously collaborated on United Industries Manufacture of the steel superstructure components Sub-contract to Delta such a complex, schedule critical project required (Henderson) Engineering tight management of technical, schedule and scope IE Systems (Perth) Electrical and control system engineer Sub-contract to Delta Engineering risks to ensure the structure was delivered on time. Engineering Dynamics Design Auditor certification to Australian Standards Schedule of rates A list of contractors employed on the ship loader (Perth) construction is outlined in Table 1. Engineering Dynamics Designer of heavy lift ship fatigue Schedule of rates (Perth) transportation requirements PHPA were successful in providing new ProMet Engineers (Perth) Lead Engineer for the design management of Schedule of rates opportunities for local contractors to increase Delta Engineering their competitiveness in the manufacture of United Industries Erection of ship loader super structure at Henderson Fixed lump sum major capital equipment and ensured the use of (Henderson) locally manufactured steel in construction of the ProMet Engineers (Perth) Erection construction management consultants Schedule of rates (Henderson) ship loader. The all inclusive cost of the Western AMC (Henderson) Facility Manager at Henderson Facility lease agreement Australian designed and manufactured ship loader BigLift (Always Shipping) Heavy lift ship transport from Henderson to Port Hedland Fixed lump sum and was $16.9m which is in line with standard industry schedule penalties costs per tonne for comparative equipment. GECM (Perth) Structural, mechanical electrical Outfitting Cost reimbursement (Utah Henderson) with incentives Transferring ship loader from Pinc Group (Perth) Utah Point construction and commissioning managers Schedule of rates IE Systems (Perth) Utah electrical control system commissioning/ramp-up Schedule of rates heavy lift ship to Utah wharf25 26
  16. 16. Utah Point Multi-User Bulk Export Facility Port Hedland Servicing Australia’s future trade growth Optional criteria Optional Criterion 16 - Environmental Implications From inception, the Utah Facility project was negative impacts on town amenity, community motivated by the need to solve a number of health and the environment. The Utah Facility significant environmental and health issues project addressed these issues to improve overall affecting the Port Hedland community as a conditions for Port Hedland residents. consequence of bulk ore exports (in particular Reduced dust emissions chromite and manganese) from Port Hedland’s west end. Dust is a major environmental and health issue in Port Hedland. Moving the export of chromite Transporting and loading large volumes of and manganese from the west end to Utah Point mineral ores by road train and front end loader to enabled a reduction in dust levels to built up poorly designed stockpile and materials handling areas as is evident in PER Dust Contour Charts systems have previously produced significant (refer to Appendix F). Bentonite geosynthetic clay lining being applied to stockyard floor This was achieved through: • roviding concrete dump pockets to feed ore P directly into automatic stackers with • Transferring road trains from the west end dust suppression. of Port Hedland to a dedicated 10 kilometre • torage of ore in a custom built stockyard S long private access road located outside with elevated perimeter road and dust the township. suppression cannons throughout. • Mandating covered loads from mine to port. • rovision of efficient materials handling P • tockpiling ores at Finucane Island’s Utah S infrastructure to limit dust emissions and Point to move dust emissions away from to enable wash down between shipments. populated areas. • Covered tripper conveyor at the back of wharf. • tilising a single and efficient stack and reclaim U • Introduction of truck wash facilities to operation to dispense with the need to double remove dust residue from transport handle materials. vehicles post delivery. • rovision of bulk mineral controls over the P • rovision of chutes to reduce product P receipt of properly conditioned ores at the gate. degradation and direct ore into ship holds Lined 45,000m3 recirculation pond27 28
  17. 17. Utah Point Multi-User Bulk Export Facility Port Hedland Servicing Australia’s future trade growth Reduced noise emissions Groundwater collection discharge and stormwater AppendiCES Moving the export operations to the Utah Facility is pumped to a 45,000m3 recirculation water pond shifted quad and triple road trains and front from where it is settled and harvested for dust end loader operations away from the township, suppression.This recirculated water will provide up thereby considerably reducing noise emissions at to 6 weeks reprieve from the need for expensive Port Hedland’s west end. scheme water representing a considerable cost saving to exporters and conserving water. Covered drives and transfer stations and efficient mechanical and electrical infrastructure has also Long term environmental risks have also been reduced operating noise levels at the Utah Facility. mitigated in the construction of the stockyard, with a 6-8 metre high perimeter sea wall built to Reduced groundwater and harbour prevent inundation of stockpiled ores by seawater contamination risks in cyclone surge tides. Operations at the Utah Facility have implemented The size of the stockyard and recirculation measures to prevent potentially dangerous levels water pond ensures this facility successfully of manganese and chromite contaminating local contains contaminated stormwater in a 1 in groundwater or the harbour. 100 year flood event to prevent contaminated All current and future potentially contaminating run off into the harbour. ores are now environmentally contained within Protection of native flora the stockyard by a bentonite barrier layer and groundwater collection system that prevent ore Carefully orienting the stockyard position and residue and dissolved solids from contaminating minimising its footprint by steepening the seawall the groundwater and harbour. Bentonite was embankment prevented the loss of 1.2 hectares of selected as the preferred lining material given mangroves at a total cost of $0.63 million ($52 per its chemical stability, self-sealing properties and square metre of mangroves preserved). ability to adjust to differential movement in the Further details on the PHPA’s commitment to stockyard floor. protecting native flora at Utah Point can be found in Mandatory Criterion 6. Perimeter Seawall Protecting Stockyard Workers installing Geogrid to from Cyclone Surge Tides seawall embankment29
  18. 18. AppendiCESContentsAppendix A 33BHPBIO tunnel raking pile General ArrangementAPPENDIX B 34Utah Facility Organisational ChartAppendix C 35Utah Facility General Arrangement PlanProcess FlowsheetAppendix D 37Mobile Hopper Train General Arrangement (page 1/2)Mobile Hopper Train General Arrangement (page 2/2)Appendix E 39Stockyard Embankment Road DetailsAppendix F 40Public Environmental Review Dust Contour ChartsAppendix G 41Australian Port Survey, July/August 2010Port Strategy, May 2007WA Business News, October 2007North West Telegraph, October 2007The West Australian, October 2007 32
  19. 19. AppendiX A: BHPBIO tunnel raking pile general arrangement 33
  20. 20. AppendiX B: UTAH facility organisational chart CEO PHPALEGENDPinc Group ResourcesPHPA Resources Port DevelopmentExternal Consultants Manager Project Manager Administration Site Construction Administration Manager Executive Secretary Senior Receptionist Assistant Project Planner / Scheduler Manager Procurement Deputy Commercial Manager Construction Port Engineer Manager Manager Project Controls Contracts OHSE Engineering Commissioning Site Engineer Manager Manager Manager Lead Engineer Commissioning Promet Engineers Manager Senior Cost Contracts Environmental Site Sintendents Detailed Designer Mechanical Comm. Controller Clerk Office Engineer Civil/ Concrete Van Der Meer Site Mechanical Stockyard Infrasture Safety Maintenance Manager SuperIntendent Services POAGS (Stevedore) Project Cordinator Accountant Site Electrical Process Electrical Control SuperIntendent IE Systems Accounts Payable Senior Site HV Electrical Switching Eng. Officer 34
  21. 21. AppendiX C: Utah Facility General Arrangement Plan 35
  22. 22. AppendiX C: Process flowsheet 36
  23. 23. AppendiX D: Mobile Hopper Train General Arrangement (page 1) 37
  24. 24. AppendiX D: Mobile Hopper Train General Arrangement (page 2) 38
  25. 25. AppendiX E: Stockyard Embankment Road – General Arrangement 39
  26. 26. AppendiX F: Public environmental review dust contour charts Australia Port Survey – Port G: australian(World Port Development July/August 2010) AppendiX Hedland Extract port survey, july/august 2010 10 24 hour average with no Utah Point from PHPA Public Berth Graphic 1: PM10 24 Hour Dust Concentrations – Exportsdevelopment Predicted Graphic 2: PM1010 24 Hour Dust Concentrations – Exports from the Utah Facility Predicted PM 24 hour average with Utah Point development40 41