RTIO engaged our team to Project Manager, Design, Install, Test and Commission the the Locomotive Trip Services and refuelling facility to the Rio Tinto Cape Lambert facility. Works include, construction of Locomotive shed, installation of 8 Diesel fuel tanks, MEP pipe reticulation, pipe bridge, oily water separator, water treatment and tailing ponds, heavy Mechancial, Electrical, complex Electronic and Instrumentation/communications systems.
| Project Name | Locomotive Trip Services and Refuelling Facility Development |
| Client Company | Rio Tinto (RTIO) |
| Project Type | Industrial Fit-Out – Critical Infrastructure |
| Project Value | $12m |
| Project Start and Finish | June 2012 – July 2013 |
| Strategic Objective | To design, construct, test, and commission a state-of-the-art locomotive trip services and refuelling facility, ensuring seamless integration of tanking systems, mechanical, electrical, fire and safety systems while maintaining operational excellence. |
| The Challenge / Need | – Develop a locomotive refuelling facility with complex mechanical and electrical systems. – Seamlessly integrate advanced instrumentation and communication systems. – Ensure zero disruption to ongoing operational activities. – Achieve stringent safety and compliance standards. |
| Our Approach | – Engineering Design: Led by a team of lead designers, engineers, drafters, and PLC/SCADA designers. – Construction Management: Oversaw on-site management, involving contractors for fabrication, erection, and installation. – Safety Management: Implemented advanced safety protocols and monitoring systems. – Program Oversight: Managed procurement control, contractor evaluations, and project execution compliance. – Stakeholder Alignment: Maintained regular communication with client leadership to ensure alignment with strategic objectives. |
| Solution & Key Deliverables | – Construction of Locomotive Shed. – Installation of 8 10,000ltr Diesel Fuel Tanks. – Deployment of MEP Pipe Reticulation and Pipe Bridge. – Integration of Oily Water Separator and Water Treatment Systems. – Construction on Bunding – Deployment of Heavy Mechanical, Electrical, and Instrumentation Systems. – Full handover documentation, referencing BIM and integrated into DCM. – Comprehensive operational training and handover. |
| Risks and Challenges | – Coordinating multidisciplinary teams across structural, mechanical, and electrical disciplines. – Managing safety risks across 91,000 work hours. – Ensuring compliance with operational and environmental regulations. – Balancing phased construction with active operations on-site. |
| Result / Outcome | – Successfully delivered the refuelling facility on time and within budget. – Achieved Zero Lost Time Injuries (LTI) over 191,000 work hours. – Minimal operational disruptions during construction. – Fully commissioned and operational facility, meeting all client specifications and safety standards. |
| Our Value-Added Differentiator | – Comprehensive Expertise: Delivered an end-to-end solution covering design, installation, testing, and commissioning. – Safety Excellence: Maintained zero LTIs and ensured proactive risk mitigation. – Integration Mastery: Seamlessly integrated mechanical, electrical, and communication systems. – Client Alignment: Consistently engaged with stakeholders to meet project milestones and strategic goals. |
Broader Program Integration
As the project existed within a broader Portfolio and Program of works, our team worked with all other aligned stakeholder groups, including Client side Portfolio Managers, Engineering Directors, Cost Engineers to ensure compliance of the Project across the board:
- Engineering and Project Management of: the design and implementation of all functional disciplines
- Engineering Level decisions for Structural, Mechanical, Piping, Electrical Supply, Distribution, Instrumentation.
- Management of the Project/Program Office, further redevelopment of the Project Management system in application, execution conformance/monitoring.
- Engineering design process review and execution conformance/monitoring
- Regional Board level client control
- Responsible for all aspects of Engineering design, Construction at site, Risk, Legal, Finance, SHRM, Quality.
- Leading the Procurement control process, Contractor evaluations, and Contractor Contract negotiations.
- Safety system development and execution conformance
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