Package 1 – Structural, Mechanical, Piping, Electrical and Instrumentation for the Roy Hill Iron Ore Mine

The Roy Hill Project is a 55 million tonne per annum (Mtpa) iron ore mining, rail and port project being developed approximately 115km north of Newman in the Pilbara region of Western Australia.

Roy Hill’s purpose built, world-class mine processing plant will utilise low risk, proven technology to process 55Mtpa (wet) of lump and fines iron ore. It will be the largest single feed processing plant in the Pilbara region. Roy Hill is on track to load its first shipment of ore for export in late 2015.

Project Overview

• conventional open pit, bulk mining operation from multiple production benches
• 55Mtpa wet processing plant
• 344km single line, heavy haul railway
• purpose built, dedicated two berth iron ore port facility at Port Hedland, capable of receiving, stockpiling, screening and exporting 55Mtpa (wet) of direct shipped iron ore as lump and fines

This project was delivered by Thiess. In 2014, CPB Contractors became the construction company of the CIMIC Group, integrating the people, expertise and projects of Thiess. As a result, the capability demonstrated in this project now sits within CPB Contractors.

Our team is completing Package 1 – Structural, Mechanical, Piping, Electrical and Instrumentation for the Roy Hill iron ore processing plant.

Scope

Structural steel – 21,130 tonnes:

• 9,240t modules range from 20t – 229t
• 5,140t flat pack and conveyors
• 2,046t stick built
• 4,700t plate work

Mechanical Equipment Installation

• three crushing plants c/w primary and secondary sizers, as well as apron feeders and vibrating screens
• crushed ore stockpile complete with stacker, five off load-out feeders and five off scrubber feed conveyors
• wet scrubbing and screening plant – five trains each with scrubber, double-deck banana wet coarse and single deck wet fines screens
• filtration and residue thickening plant
• tertiary crushing – three trains complete with gyratory cone crushers and belt feeders
• dry screening building
• stockyards – two stackers and one bucket wheel reclaimer
• train load-out

Piping Supply and Installation

• all large bore pipe supplied by Samsung > DN50
• all small bore pipe supplied by Thiess
• Electrical and Instrumentation Supply and Installation
• exclusive subcontract with EC&M
• all cable free issue
• minor supply items only in E&I subcontract
• 1,005km cable (electrical bill)
• 84km cable (instrumentation)
• 5.7km instrumentation tubing
• Commissioning – day rates (Mechanical Completion achieved at Construction Verification).

Milestones and Achievements

• work commenced May 2014
• completion and handover with First Filling of Wet Scrubbing Streams 1, 2 & 3 – 18 March 2014
• completion of pre-commissioning and handover of SUB171 & 271 (Process Plant 33kV) – 5 December 2014
• completion and handover with First Filling of Primary and Secondary Crushing 1 – 16 February 2015
• completion and handover with First Filling of work required for FOOT – 25 April 2015