BHP Iron Ore – Jimblebar Mine Fuel System Upgrade, Control & Monitoring
Client: BHPIO (BHP Iron Ore)
Location: Jimblebar Mine, Western Australia
Project Period: 2014
Project Type: Capital Project – Industrial Process & Fuel Infrastructure
System Scope: Fuel Storage, Dispensing, Control & Remote Monitoring
Role: Head Contractor – Program Director
Strategic Objective
Jimblebar is a cornerstone asset within BHP Iron Ore’s Pilbara operations, where fuel availability underpins continuous mining, haulage, and processing activity.
By 2014, the site’s fuel systems required modernisation to:
- Improve reliability and operational oversight
- Reduce exposure to downtime and environmental risk
- Enable real‑time monitoring and remote diagnostics
- Integrate seamlessly with existing mine control architecture
The strategic objective was to upgrade and optimise the site fuel system, delivering enhanced control, safety, and visibility—without interrupting live mining operations.
The Challenge / Need
Fuel systems represent a high‑consequence operational node in large‑scale mining.
The Jimblebar upgrade needed to address:
- Legacy fuel infrastructure no longer aligned with operational scale
- Limited real‑time visibility of fuel dispensing and inventory
- Integration of modern control systems into existing assets
- Strict environmental and safety compliance requirements
- Delivery within a live operating environment with zero tolerance for disruption
Any failure during installation or commissioning would have had immediate production and reputational impact.
Project Scope
The engagement encompassed end‑to‑end system leadership, including:
- Detailed audit of existing fuel infrastructure and control architecture
- Engineering design of upgraded fuel storage and dispensing systems
- Implementation of advanced control and monitoring platforms
- Integration with site SCADA and operational systems
- Installation of environmental safeguards and fail‑safe mechanisms
- Phased construction, commissioning, and operational handover
- Development of technical documentation and staff training programs
Our Approach
A risk‑led, operational‑first delivery model was applied—recognising that fuel systems must perform invisibly and reliably under continuous demand.
Key elements included:
- Whole‑System Assessment: Identification of capacity, control, and compliance gaps
- Operational Alignment: Close collaboration with BHP operations, maintenance, and safety teams
- SCADA‑Based Control Design: Deployment of real‑time monitoring, control, and diagnostics capability
- Phased Implementation: Sequencing works to protect uninterrupted site operations
- Environmental Protection by Design: Integration of spill‑prevention and overfill safeguards
- Operational Enablement: Structured training and documentation to support long‑term reliability
The focus throughout was on predictable system behaviour, not just infrastructure replacement.
Complexity & Risk
The project sat at the intersection of several high‑risk considerations:
- Live fuel systems servicing active mining operations
- Hazardous material handling with environmental exposure
- Integration of modern control systems into legacy assets
- Tight timeframes within an active production schedule
- Strict regulatory, safety, and corporate governance requirements
These risks were mitigated through disciplined planning, conservative sequencing, and continuous safety governance.
Solution & Key Deliverables
The project delivered:
- Upgraded fuel dispensing and distribution infrastructure
- Advanced SCADA‑based monitoring and control systems
- Automated inventory tracking and remote operational visibility
- Fail‑safe mechanisms to prevent spills, overflows, and losses
- Comprehensive technical handover documentation
- Operational training programs supporting long‑term site capability
All systems were validated under live operating conditions prior to final handover.
Delivery Team
Design
- 1 × Lead Solutions Engineer
- 4 × Solutions Integrators / Designers
- 1 × Process & Control Implementation Engineer
Construction
- 1 × Project Manager
- 1 × Construction Engineer
- 1 × Contracts Manager
- 1 × Quality Manager
- 1 × Safety Manager
- MEP fabrication and installation contractor
- Mechanical systems fabrication contractor
- Tanks and tanking contractor
- 7 × Functional suppliers
- Electrical contractor
Delivery & Safety Performance
The project was completed with:
- Zero Lost Time Injuries (LTI)
- One First Aid Incident (FAI)
This outcome reflected disciplined safety leadership within a high‑risk operational environment.
Outcome
The upgraded fuel system:
- Delivered enhanced operational efficiency and control
- Enabled real‑time and remote monitoring of fuel assets
- Reduced exposure to downtime and environmental risk
- Integrated seamlessly with existing site infrastructure
- Was delivered on time and within approved scope and budget
- Maintained uninterrupted mining operations throughout execution
BHPIO gained a future‑ready fuel infrastructure platform aligned with Jimblebar’s operational scale and governance expectations.
Why This Matters
This project reinforces a recurring capability across Murray’s mining portfolio:
- Ownership of high‑consequence operational systems
- Delivery within live production environments
- Automation and control applied as risk‑reduction tools
- Safety and environmental assurance embedded by design
Fuel systems are invisible when they work—and immediately disruptive when they do not.
This engagement ensured reliability, compliance, and control without operational compromise.
For more visit our affiliate Qfactor Performance Consulting
