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D&C Jimblebar Stretch Assist Project - BHP

BGC Contracting are committed to project delivery with minimal disruption to our clients operations. The upgrade design supplied by BGC Contracting for this project was critical to the standardisation and commonality between existing and new facilities.

PROJECT DETAILS

Located 40km East of Newman, WA BGC Contracting was awarded the design and construction services on BHP's Jimblebar Iron Ore operation for upgrades to the Mobile Maintenance Facility. The upgrades include expansion of existing operation facilities both by deconstruction and reconstruction processes, as well as new construction works in and around the existing facilities. The upgrade design supplied by BGC Contracting was critical to the standardisation and commonality between existing and new facilities on site in terms of operating procedures, sharing philosophy and shutdown management.

DESIGN & CONSTRUCT

  • Full design, construction, fit out and commissioning of a new standalone two bay boiler making workshop Assembly, installation and commissioning of a 50t overhead gantry crane
  • Structural deconstruction works to refurbish the existing boiler bay 5A/5B (MEM Workshop), including installation of new racks and accompanying electrical works
  • Design, construction, fit out and commissioning of a single storey structural steel tool locker store facility connected to the MEM Workshop
  • Construction of a new structural steel ablution building adjacent to the tool locker for BHP use
  • Installation of above ground and below ground service lines (potable water, raw water, oxygen and acetylene, compressed air, and sewer), and installation of new communication system and fire detection system
  • Site clearing, pad formation and earthworks for 3 of new buildings, plus all associated concrete and drainage works

Works undertaken within the MLO (outside of HV precinct) include:

  • Design and construct refurbishment works of existing MLO toolbox storage area, which includes structural steel and electrical fitout works
  • Full design, construction, fit out and commissioning of new mezzanine office, complete with meeting facility and kitchen/utilities room
  • Deconstruction and relocation of the MLO mine & tool store
  • Expansion of the LV workshop which includes new structural works, electrical installation and servicing equipment

There were significant challenges to deliver works alongside BHP’s ongoing maintenance operations and to ensure minimal disruption with the reconfiguration of “in use” buildings and BGC Contracting’s team were in constant contact with BHP. Including works for the procurement, installation and commissioning of two new distribution boards as part of the boiler making workshop involved termination into the existing kiosk and the routing, termination and testing of more than 80 new electrical circuits servicing the new facility. Electrical works associated required substantial coordination with BHP Operations and supervisors to manage all DB isolations and safe relocation and termination of electrical cables while maintaining minimal disruptions to operations. Further BGC Contracting streamlined work programmes whilst ensuring excellent safety and quality results with a positive results against budget and KPIs. From day one, the BGC Contracting team adopted BHP’s online commissioning platform to capture project QA/QC documentation and to provide excellent client support in this streamlined facility ready for handover.

KEY CHALLENGES

  • As the site required reconfiguration of “in use” buildings, the BGC team were in constant contact with BHP
  • The procurement, installation and commissioning of two new distribution boards as part of the boiler making workshop involved termination into the existing kiosk and the routing, termination and testing of more than 80 new electrical circuits servicing the new facility
  • Electrical works associated required substantial coordination with BHP Operations and supervisors to manage all DB isolations and safe relocation and termination of electrical cables while maintaining minimal disruptions to operations.

PROJECT OUTCOMES

Through the reengagement of structural and fitout subcontractors from previously completed BGC projects we were able to minimise site SIMOPS clashes and rework, resulting in more streamlined site management, excellent safety and quality results, plus positive results against budget and program KPI’s. From day one, the BGC team adopted BHP’s online commissioning platform Completions and Commissioning Management System (CCMS) to capture project QA/QC documentation and allow for seamless handover of the various facilities to operations. This resulted in our ability to respond to client queries and simplify the facility handover process.

Client: BHP

Duration:
March 2018 – May 2019
Status:
Completed
Location:
Western Australia
Value:
$10-$50m
Capabilities: