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Bhp Billiton's Jimblebar Project

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Bhp Billiton's Jimblebar Project CELEBRATING THE COMPLETED EXPANSION OF MINING AND PROCESSING CAPACITY AT BHP BILLITON’S JIMBLEBAR PROJECT THE PILBARA, WESTERN AUSTRALIA TO COMMEMORATE THE SUCCESSFUL JOINT VENTURE WITH SEDGMAN FOR CIVIL; STRUCTURAL, MECHANICAL AND PIPING; AND ELECTRICAL AND COMMISSIONING WORKS AT THE JIMBLEBAR MINE OCTOBER 2016 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 1 CIVMEC IS PROUD TO HAVE SUPPORTED BHP BILLITON ON THE JIMBLEBAR PROJECT IN THE PILBARA, WESTERN AUSTRALIA. Congratulations and thank you to everyone involved in the project. The Jimblebar Expansion (JBX) Project The Jimblebar Expansion Project saw the expansion of mining and processing capacity of the existing Jimblebar operations, located in the Pilbara region of Western Australia, four kilometres east of the town of Newman. The mine is fully owned and operated by BHP Billiton, and is one of • Overland Conveyor CV002: 6.2km long conveyor consisting of a • Batch plant for concrete 60m3. seven iron ore mines the company operates in the Pilbara. The company 12,695mm wide Fenner Dunlop belt powered by two 2.5mW • Distance tolerance between two stackers - approximately 100mm. also operates two port facilities at Port Hedland (Nelson Point and motors. The conveyor fed onto an existing stockpile and was tied Finucane Island), and also rail in the Pilbara. into an existing stacker conveyor sitting at 90 degrees to the SCJV managed the collection, transportation, storage, care, custody CV002 conveyor. and control of all materials ordered or supplied free issue by BHPBIO for Civmec, in a joint venture with Sedgman (SCJV), was contracted to the project, from point and time of receipt until the date of handover to carry out the expansion works. This was an engineering, procurement, • New turkey’s nest and heavy vehicle water cart filling station (with BHPBIO’s Jimblebar Operations. construction and commissioning (EPCC) works contract, comprising of the provision for a new transfer pump station), complete with electrical installation of a new primary crusher and additional conveying capacity. services (sized for future capacity of future mine dewatering The Joint Venture also carried out the shipping of heavy modules from network). China. Key management reviewed materials overseas with BHP. The JBX project scope of works to enable handover of a fully functional expansion of the Jimblebar site included design verification • 4,000T of structural steel and 600T of mechanical items. Innovation and value adding was a trademark of this project, with and validation of existing design; procurement; logistics; the supply Civmec proposing a trestle footing design which reduced a lengthy • 10,500 linear metres of piping and 100,000 linear metres of HV/LV and manufacture of fabrication; construction; erection; no-load shutdown, otherwise required for the works. This reduced cost and control and communications cable. commissioning earthworks; civil works; structural, mechanical and made works safer. Installation of a temporary retaining wall around the piping; and electrical, control and communications. • Civil and underground services for a future communications hub to ore stockpile allowed operations to continue whilst construction was service the new operational area, including 6,200m3 concrete. being carried out. In this case, the trestle footings were also raised and installed on piles which reduced large quantities of excavation and • Design, supply and installation of the overhead line and ancillary The scope of major work areas required for the JBX project included: backfill. services. • Conveyor 041: 300m long conveyor consisting of a 2,400mm wide Civmec also built a portion of the conveyor which was managed by • 1,300,000m3 bulk earthworks, including reinforced earth ROM wall. continental belt powered by a 1,000kW drive. The conveyor fed into a surge two shutdowns, with temporary work completed to keep the conveyor bin and was discharged onto a 2,400mm wide hydraulic apron feeder. • Tie-ins to the existing operation plant. running. CONTENTS BULK EARTHWORKS 08 CONCRETE AND SITE CIVIL WORKS 10 FABRICATION 14 TRANSPORTATION 16 SITE STRUCTURAL, MECHANICAL AND PIPING INSTALLATION 18 SITE ELECTRICAL, INSTRUMENTATION AND CONTROL 24 SHUTDOWN AND TIE-INS 28 HIGHLIGHTS 30 6 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 7 LEFT: Civmec, as part of the SCJV with Sedgman, utilising Civmec’s suite of plant and equipment. The bulk earthworks for the construction of the 26 metre high reinforced ROM wall comprised of 70,000m3 of select fill and 494,000m3 of bulk earthworks. BELOW: 1,300,000m3 of bulk earthworks were carried out at the Jimblebar mine in WA. BULK EARTHWORKS OCTOBER 2016 THE JIMBLEBAR PROJECT CIVMEC 9 PHOTO: Primary crushing building support pedestals and concrete slab at the JBX expansion project. CONCRETE AND SITE CIVIL WORKS PHOTO: Civil and underground services for a future communications hub to service the new operational area, including 6,200m3 of concrete. 10 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 11 Progress shots of concrete and civil works between December 2015 and February 2016 ABOVE: Concrete precast sleepers for the installation of the 6.2km long overland conveyor. LEFT AND BELOW: Concrete footings installation for the chutes, extending over 6 kilometres. 12 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 13 LEFT AND BELOW: Fabrication of over `4,000T of structural steel and 600T of mechanical items ws undertaken at Civmec’s Henderson facility between December 2015 and March 2016. These modules formed part of the overall mine processing facility. FABRICATION 14 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 15 LEFT: One of the 40 metre long modules, each weighing 40 tonnes, leaving Civmec’s heavy engineering facility in Henderson, WA. BELOW: A module beginning its 1,215 kilometre journey from Henderson to the Jimblebar mine, east of Newman, WA. TRANSPORTATION 16 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 17 LEFT: Civmec’s 275 tonne crawler crane was on site to assist with the Structural, Mechanical and Piping (SMP) installation. BELOW: SMP installation underway in March 2016. SITE STRUCTURAL, MECHANICAL AND PIPING INSTALLATION 18 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 19 PHOTO: Erection of steel and piping took place throughout the mine from March 2016 to July 2016. PHOTO: View of the conveyor from the upper platform. 20 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 21 ABOVE: Looking down towards the reinforced earth ROM wall which was built parallel with the bulk earthworks for the ROM pad. RIGHT: Structural steel erected for the overland conveyor transfer station module. OPPOSITE: Installation of all platforms and handrails throughout the site. 22 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 23 LEFT AND BELOW: Civmec installed approximately 100,000 linear metres of HV/LV control and communications cable throughout the Jimblebar mine site. SITE ELECTRICAL, INSTRUMENTATION AND CONTROL 24 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 25 Progress shots of electrical, instrumentation and control carried out by the Sedgman Civmec Joint Venture (SCJV) at the Jimblebar mine, WA. LEFT: ABOVE: 26 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 27 LEFT AND BELOW: Civmec built a portion of the conveyor which was kept in control by two shutdowns to do temporary works to keep the conveyor running. SHUTDOWN AND TIE-INS 28 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 29 LEFT: Civmec changed this ROM wall covering from Riprap to revetment mattress. This change was so successful, BHP now intends to make this the BHP standard. BELOW: Conveyor belts installed in July 2016. HIGHLIGHTS 30 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 31 ABOVE: Civmec carried out the installation of the overhead line and ancillary services. RIGHT: Modules arrive on site and are prepared for installation. OPPOSITE: Structural, mechanical and electrical items in place - September 2016. 32 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 33 Progress shots of expansion works across the Jimblebar project 34 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016 35 civmec.com.au 36 CIVMEC: THE JIMBLEBAR PROJECT | OCTOBER 2016.
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