RTIO engaged our team to Project Manager, Design, Install, Test and Commission the the HCO Fuel Farm facility to the Rio Tinto Cape Lambert facility. Works include, construction of the entire fuel farm, installation of 8 Diesel fuel tanks, MEP pipe reticulation, pipe bridge, oily water separator, bund installation, water treatment and tailing ponds, heavy Mechanical, Electrical, complex Electronic and Instrumentation/communications systems.
| Project Name | HCO Fuel Farm Facility Development |
| Client Company | Rio Tinto Iron Ore (RTIO) |
| Project Type | Industrial Infrastructure – Fuel Farm Construction |
| Project Value | $10.5m |
| Project Start and Finish | September 2012 – December 2013 |
| Strategic Objective | To design, construct, install, test, and commission a fully operational fuel farm facility at Rio Tinto Cape Lambert, ensuring seamless integration of mechanical, electrical, and safety systems for sustainable and reliable operations. |
| The Challenge / Need | – Develop a large-scale fuel farm facility with integrated mechanical, electrical, and instrumentation systems. – Manage complex piping networks, bund installations, and water treatment systems. – Maintain uninterrupted operations during phased construction and commissioning. – Uphold stringent safety and environmental compliance standards. |
| Our Approach | – Engineering Leadership: Led by a team of designers, engineers, and PLC/SCADA specialists. – Stakeholder Alignment: Ensured alignment across RTIO leadership and operational teams. – Safety and Compliance: Designed robust safety systems and implemented stringent monitoring processes. – Program Management: Oversaw procurement control, contractor evaluations, and adherence to delivery milestones. – Phased Execution: Managed staged construction to ensure operational continuity. |
| Solution & Key Deliverables | – Construction of Fuel Farm Infrastructure with eight diesel fuel tanks. – Installation of MEP Pipe Reticulation and Pipe Bridge Systems. – Deployment of Oily Water Separator and Water Treatment Facilities. – Construction of Bund Installation and Tailings Ponds. – Integration of Heavy Mechanical, Electrical, and Instrumentation Systems. – Comprehensive BIM-referenced documentation and integration with DCM systems. – Operational Training and Handover Documentation. |
| Risks and Challenges | – Ensuring safety compliance across 111,000 work hours. – Managing environmental and operational risks during construction phases. – Coordinating multidisciplinary teams and contractors across complex tasks. – Adhering to strict timelines while maintaining operational continuity. |
| Result / Outcome | – Delivered a fully operational fuel farm facility on time and within scope. – Achieved Zero Lost Time Injuries (LTI) across 111,000 work hours. – Successfully integrated advanced safety, instrumentation, and operational systems. – Provided comprehensive documentation and training, ensuring seamless operational handover. |
| Our Value-Added Differentiator | – Integrated Delivery: A holistic approach covering design, procurement, construction, and commissioning. – Safety Leadership: Maintained exceptional safety standards with zero LTIs. – Technical Expertise: Advanced integration of heavy mechanical, electrical, and instrumentation systems. – Client-Centric Approach: Strong engagement with stakeholders to ensure alignment across every phase. |
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TEAM
Design for the design project the team consisted of:
- 1 x Lead designer
- 3 x Engineers, 5 x Drafters
- 3 x PLC/SCADA designers
- 1 x PM
SMP Construction for the Construction project the team will consist of:
- 1 x Project Manager
- 1 x Construction Engineer
- 2 x Fabrication contractors
- 1 x Erection contractor
- 3 x functional contractors
- 1 x Electrical contractor
- 1 x Project Manager
- 1 x Quality Manager
- 1 x Construction Manager
- 1 x Safety Manager
Project was completed with 111,000 hrs with ZERO LTI and 2 x FAI.
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
