Winning Engineering Australia Excellence Award 2012 submission copywriting and design services provided to Port Hedland Port Authority and PinC Group.

1. Utah Point Multi-User Bulk Export Facility
Port Hedland
Servicing Australia’s future trade growth
2011 WA Engineering Excellence Awards
Resource Development Category

2. Contents
Contents
Project Overview 1
Categorisation Statement 4
Mandatory Criteria 6
Optional Criteria 21
AppendiCES 30
Acknowledgements 46

3. Project Overview
Project Overview Project Overview
The Utah Point Multi-User Bulk Export Facility A number of sustainable technology initiatives
(Utah Facility) addresses the resource industry’s and innovative engineering practices were
need for expanded port facilities to meet current adopted and significant studies and consultation
and future growth in global demand for Western undertaken as part of a full Public Environmental
Australian mineral resources and to facilitate Review. This process addressed the complexities
export for emerging mineral producers in the associated with designing and constructing
Port Hedland region. a port facility to transport, store and export a
multitude of minerals with potentially adverse
The Utah Facility was constructed on Finucane
environmental and community impacts.
Island opposite the existing public berths and
within the narrow neck of the Port Hedland Innovations were introduced to achieve
harbour. The Utah Facility development concept operation efficiency and to mitigate health risks
consisted of a new dredged berth pocket and and other community concerns including: a
270 metre long concrete wharf, travelling ship 45,000m3 water recirculation and stormwater
loader, 24 hectare stockyard and associated harvesting system; bentonite geosynthetic lined
materials handling infrastructure, administration stockyard floor with plastic reinforced seawall
and controls facility, and a 10 kilometre dedicated embankments; custom designed automatic
access road. vessel mooring system; real time vibration
monitoring of the BHPBIO tunnel; quad road train
Originally designed for a maximum export
wash facilities; unique mobile hopper train ore
capacity of 12 to 15 million tonnes per annum,
reclaim system and a commitment to a mangrove
increased industry demand resulted in design
propagation farm.
modifications to accommodate an export volume
of up to 21 million tonnes per annum. Expanded The Utah Facility performed beyond expectation
capacity was achieved by increasing the dredged in achieving nameplate capacity within 6 months
depth of the berth pocket, introduction of an of operation and has proved capable of delivering
innovative new automatic mooring system to 9 million tonnes of trucked ore per annum
berth larger vessels and increasing the materials throughout representing estimated export sales
handling system peak loading rate from 5,000 of $1.5 billion per annum.
to 7,500 tonnes per hour. These innovations
Future increases in industry demand can
allow the current facility and stage one of the
be accommodated within the Utah Facility
stockyards to reach up to 14Mtpa prior to the
with provision made for receiving product via
construction of future stockpiling.
alternative ore transport modes such as rail
Using an integrated client team approach, the or slurry pipeline. Additional land has been
Port Hedland Port Authority (PHPA) worked allocated adjacent to Utah Point to increase
collaboratively with project management opportunities for new and emerging mining
consultants, Pinc Group Pty Ltd (Pinc) to deliver companies that would otherwise be denied
the project. Project planning commenced in access to export markets.
September 2006 and first ore on ship was
achieved within 4 years on 17 September 2010
after a 20 month construction phase.
2

4. Utah Point Multi-User Bulk Export Facility Port Hedland
Servicing Australia’s future trade growth
About Port Hedland Port Authority
Categorisation StatemenT
The Port Hedland Port Authority PHPA’s major functions are the control of all
(PHPA) is a statutory authority shipping, and maximising the loaded capacity
owned by the Western Australian of ships through the use of world leading
Government. The Port Authority technology that allows the Authority to maintain
has a charter to operate along minimum safe under keel clearances. The Port
commercial lines with a primary Authority also has a responsibility to plan for and
purpose to facilitate trade manage new developments whilst protecting the
through the port. environment of the port.
About Pinc Group Pty LtD
Established in 2005, Pinc is an emerging provider of choice for specialist
project management and project services to the resource sector. Pinc’s
unique PMC management processes and integrated software and systems
are designed to support clients to successfully develop major capital works.
Previous clients of Pinc include: • Boddington Gold Mine
• Fortescue Metals Group Ltd.
• Abesque Engineering Ltd.
• Karara Mining Ltd.
• Extension Hill Pty. Ltd.
• Atlantic Ltd. • Midwest Vanadium Pty Ltd.
• Atlas Iron Ltd. • Newcrest Mining Ltd.
• Ausenco Ltd. • Rio Tinto Ltd.
• BHPB Petroleum • Worley Parsons Ltd.
3

5. Utah Point Multi-User Bulk Export Facility Port Hedland
Servicing Australia’s future trade growth
CATegorisation statement
Mandatory Criteria
The Utah Facility addresses the resource industry Implementation of sustainability initiatives
need for expanded port facilities to meet current and innovative engineering practices and
and future growth in global demand for Western technologies have not only improved operational
Australian mineral resources. efficiency across the port, but reduced
environmental and health risks to Port Hedland
Construction of a new multi-user bulk export
residents, whilst improving amenity for all.
facility on the west side of the harbour at Utah
Point, with a capacity to receive small cape Within the 2010/11 financial year, the Utah
size ships up to 120,000 tonnes deadweight, Facility is expected to increase export tonnage
resolves current pressure placed on existing port over the PHPA operated berths by 360% from
facilities within Port Hedland, and allows Western the previous year achieving the facility’s designed
Australia’s junior mining companies to export nameplate capacity of nine million tonnes per
their products to a resource hungry annum with an estimated total export value of
global market. $1.5 billion.
5

6. Utah Point Multi-User Bulk Export Facility Port Hedland
Servicing Australia’s future trade growth Mandatory criteria
Mandatory Criterion 1 - Occupational Health & Safety
As the first major construction project undertaken “The Utah Facility is committed to
by PHPA, the Utah Facility presented a number ensuring the highest possible standards
of occupational health and safety (OH&S) of occupational health and safety, the
challenges for the project management team and minimisation and control of all risks, and
contractors given the absence of established to zero harm.”
safety management policies and procedures, Excerpt from the Utah Facility’s Safety
and minimum safety standards for construction. Management Plan.
This situation was further complicated by Safety management initiatives targeted
a contracting strategy that required the training, risk assessment and problem solving in
construction management team to control high risk areas. It was recognised early that the Seawall construction using concrete impregnated miracell
the interfaces between multiple independent most impact could be achieved by focusing on
contractors occupying the same work spaces, improving behaviour and attitudes of front line
along with Port Hedland’s difficult environmental workers and supervision to improve the overall An example of an effective safety initiative is
working conditions where dust exposure and safety awareness and culture. evident in the implementation of safety controls Key OH&S initiatives employed across the
high ambient temperatures and humidity pose over the dredging and piling operations over the project included:
Backed by a high visibility, supportive and BHPBIO tunnel as detailed in Appendix A.
significant health and safety risk. • igh weighting to safety performance and
H
positive leadership culture in which the entire Real-time vibration monitoring with direct
systems in the evaluation of tenders.
A carefully crafted project management strategy project management team and contractor contractor communication was established to
was established to ensure safe design and personnel were genuinely engaged in predict when dredging and piling operations • azard Identification Analysis (HAZID) and
H
construction outcomes. The project’s OHS decisions affecting workforce safety, the might exceed pre-determined safe vibration formal risk assessments undertaken regularly.
Plan set minimum standards and procedures project management team led work planning limits. This allowed the extent of further work to • Early identification of unacceptable risks that
based on industry standards and statutory and communication through daily Tool Box be forecast and quickly agreed upon to ensure could lead to unsafe outcomes.
requirements. Outlining site specific requirements meetings and weekly contract meetings with the work undertaken by third parties within the tunnel • Empowering all personnel to stop work where
for entering and working on site, the Plan relied Construction Manager that focused primarily could continue safely and without disruption. unsafe practices or risks were observed.
heavily on the contractors own quality and safety on safety and environmental issues.
Despite the difficult environmental conditions, • Daily, unobtrusive observation of work
management systems and procedures. The need
relative remoteness of the site and high risk practices with positive feedback for safe work.
for cooperation, trust, individual responsibility nature of the construction work, the safety • voidance of safety clichés or rules for which
A
and accountability were adopted as a basic management strategy delivered a Lost Time the rationale could not be justified.
undertaking by all parties. Injury Frequency Rate (LTI FR) of 1.4 resulting
• Elimination of unnecessary paper work,
from one lost day through injury from a total
especially for workers and supervisors.
850,000 site manhours.
• genuine no blame system and no penalties
A
This LTI FR represents only 10% of the WA for lapses or mistakes.
construction industry’s average of 13.9 and
• Early and comprehensive incident/near
only surpassed by the best performing
miss reporting.
industry sector, that of the finance and
insurance industry1.
1
Work Related Lost Time Injuries and Diseases in WA
2006-07 to 2008-09,Worksafe WA.
7 8

7. Utah Point Multi-User Bulk Export Facility Port Hedland
Servicing Australia’s future trade growth Mandatory criteria
Mandatory Criterion 2 – Sound Engineering Practices Principles
A fresh approach to project management the award of construction contracts in line with
the availability of funds.
Successful delivery of the Utah Facility can
be attributed to the selection of contract and The financial benefit of adopting a fresh approach
procurement strategies matched to project and to contracting was evident in the supply and
commercial risks and the implementation of an installation of the site’s high voltage electrical
effective client integrated team. feeder. A risk loaded fixed price offer presented
by the service authority was renegotiated to a
Flexible contracting strategy matched to risk
reimbursable contract (cost plus fixed fee) that
A significant element of the project’s success netted a 57% cost saving for the augmentation of
lay in the careful selection of contract strategies power to the site.
to minimise scope, cost and time risks. When
An integrated team approach to project and
the project was assessed as requiring a full
construction management
Public Environmental Review (PER), the planned
fixed lump sum design and construction model Following completion of the concept
had unacceptable prolongation risk and was development phase, PHPA commissioned the
therefore replaced with a client integrated project services of Pinc Group Pty. Ltd. (Pinc) to work
and construction management team. collaboratively as project manager in a genuine
integrated team approach where Pinc was
This allowed close management of project
empowered to think and behave like the client
approvals and funding requirements, with
Sample of 3D Computer Model Used in Designing the Utah Facility
preliminary engineering and procurement During design and procurement, Pinc provided
undertaken whilst the scope continued to be the flexibility required, with part-time and full-time
developed during the PER process. This strategy multi-disciplined staff allocated according to the
led to PHPA taking responsibility for long lead changing needs of project implementation
Pinc was able to provide PHPA with the approach provided a more efficient and cost
item procurement, managing engineering at a
Refer Appendix B for Utah Facility resources, procedures and systems required to effective project management solution.
pace consistent with PER outcomes and to stage
Organisational Chart. effectively manage project planning, scheduling,
Total engineering, procurement and construction
procurement, contract management, project
management (EPMC) services from concept
controls and reporting. This service was
development (excluding the PER and associated
simplified by the adoption of Pinc’s innovative
studies) through to commission and handover
proprietary Integrated Project Management
were delivered for a minimal 10.2% of total
Software (PincSys) which continues to be utilised
project capital (as summarised below) in an
by PHPA in its ongoing operations.
industry where the costs of EPMC services are
The client integrated team approach typically in the range of 15-25%.
required a high degree of trust to foster close
• roject Management
P
communication, eliminate duplication of
and Procurement 1.76 %
management and encourage fast decision
making. With PHPA’s limited experience in • Engineering 4.30 %
the development of major capital assets, this • Construction Management 4.11 %
Utah Facility Construction team Photo
9 10

8. Utah Point Multi-User Bulk Export Facility Port Hedland
Servicing Australia’s future trade growth Mandatory criteria
Mandatory Criterion 3 - Originality Ingenuity
Utah Facility Stockyard Design Flexibility
The Utah Facility has a 24 hectare (1030m As selection of facility clients and their products
x 235m) multi-user bulk materials stockyard were indeterminate during the design phase and
designed to receive nine million tonnes per expected to change over time, the stockyard
annum of ore delivered by road train. This facility layout, loading and stacking infrastructure,
is the first of its size and purpose in the world materials handling and electrical systems were
and is truly unique in the design and construction designed to manage a range of minerals, loading
methods used in its creation. rates, material properties and ore sizes ranging
from 120mm abrasive chromite lump to superfine
Size
mineral concentrate.
Designed for 20 hour operation (allowing a 4 hour
traffic curfew for evening peak hour), this facility is
the only one in the world capable of receiving one
quad road train transporting up to 106 tonnes
of multiple ore products every 5 minutes in a
continuous operation.
Workers rolling out Geogrid layer to marine mud stockyard floor
Construction selected as the preferred lining material given
its chemical stability, self-sealing properties and
The stockyard was constructed over potential
ability to adjust to differential movement in the
acid sulphate marine mud to depths up to 2.5
stockyard floor.
metres. Too environmentally unstable to expose
to oxygen and expensive to treat, the stockyard Each of the 13 stockpiles housed in the
was designed to “float” on the mud. To minimise stockyard are capable of exerting a pressure
earthwork haulage costs, the stockyard floor was equivalent to a 30 storey building. Two Securgrid
restricted to a depth of 2 metres, which required 400/40 geogrid layers with tensile strength of
strengthening of the fill to avoid overturning slip 400KN were chosen as the preferred method
failure from the weight of stockpiled ores. of reinforcing the stockyard base given their
superior strength and environmental stability.
The stockyard base contains a bentonite barrier
Stockpile height restrictions were imposed on
layer and groundwater collection system installed
initial stacking operations to allow consolidated
0.9 metres below the stockyard surface to
marine mud to develop strength. Fill settlement
prevent ore residues and dissolved solids from
of up to 20cm was forecast and the stockyard
contaminating the groundwater. Bentonite was
design accommodated this predicted movement.
Preparing marine mud for geogrid layer
11 12

9. Utah Point Multi-User Bulk Export Facility Port Hedland
Servicing Australia’s future trade growth Mandatory criteria
A safer, more efficient way to moor vessels
Catovec’s MoorMaster Automatic Mooring
System uses new technology to improve safety,
time and operational costs associated with
berthing large ships and significantly increase the
port’s throughput.
Innovative 200MM units designed to withstand
Port Hedland’s extreme tidal, heat and dust
conditions have not only improved safety
Quad Road Train Adjacent to Stockyard Dump Pocket compared to traditional rope mooring, but
reduced vessel capture, moor and release times
by approximately 2.5 hours per vessel.
Operations Refer Appendix C - Utah Facility General More information on the innovative application
Arrangement Plan and Process Flowsheet for of Cavotec technology is found in Mandatory
Given the volume of trucks and variety of
more further information. Criteria 8.
ores being transported to multiple stockpiles
within the facility, customised transport, truck Significant cost savings were achieved by
management and communications systems were replacing the traditional fixed hoppers with two
designed to manage stockyard efficiency. originally designed hopper trains. These rail
trains were designed to operate over the central
A two lane elevated perimeter road allows trucks
reclaim load-out conveyor with trailing power and
to circulate, pull out safely and right side dump
water cables. The six hoppers and two motor
into hoppers capable of automatically identifying
control centres required for this solution achieved
the truck and its contents before unloading. A
considerable capital cost and operating savings.
CCTV system linked to a central control room
at the entrance was also constructed to ensure Refer Appendix D - Mobile Hopper Train General
efficient facility management and security. Arrangements 1 and 2 for further information.
3D model view of stockyard
Mobile Hopper Train Schematic
13 14

10. Utah Point Multi-User Bulk Export Facility Port Hedland
Servicing Australia’s future trade growth Mandatory criteria
Mandatory Criterion 4 - Economic Contribution
Provision was also made for ship loading rates
of up to 7,500 tonnes per hour, well in excess of
the rate required to service the stockyard. When
“This was a development that needed coupled with the increased operating efficiency
to happen… it is necessary to meet the provided by the Cavotec Automatic Mooring
significant growth that has come through system, the Utah Facility can increase throughput
the port but also facilitate iron ore juniors to capacity well beyond the current 9 million tonnes
get their products out.”1 per annum.
Andre Bush, CEO, Future expansion of the facility has also been
Port Hedland Port Authority. considered in its establishment. Additional
land has been assigned for the construction
of a second stockyard capable of receiving
mineral products through a variety of alternative
transport modes such as rail, overland conveyor
or slurry pipeline. Existing facility capability and
Increasing Port Hedland’s export capacity existing public berth infrastructure to increase access road design will permit these options to
inner harbour capacity without reducing the be pursued without modification to the current
The development of the Utah Facility has had a
export capacity of other port users. The BHPBIO materials handling system.
fundamental impact on Western Australia’s future
under harbour tunnel that crosses at shallow
export potential and economic activity.
depth under the Utah Wharf constrained the
The Utah Facility signals a vital opportunity depth of the Facility berth pocket such that it
for new and emerging miners to export their was only suitable for Panamax and Small Cape
products to international markets. Commencing vessels with low drafts capable of accessing the
the export chain through affordable trucking harbour during low tide when larger ore carriers
options is expected to provide a starting point cannot operate.
for the generation of valuable cash-flow to new
Custom built to manage between 85,000 and
market entrants, which will in turn provide future
100,000 road trains per year, the Utah Facility
opportunities for expansion through capital
stockyard delivers a diverse range of ores from
development and encourage investment in
mines within a 550 kilometre radius of Port
minerals mining well into the future.
Hedland. Within the first year of operation, the
PHPA’s strategic plan to expand the Port’s inner Utah Facility has achieved nameplate export
harbour capacity from 200 million tonnes to 495 capacity of 9 million tonnes of trucked ore per
million tonnes per annum cannot be achieved annum worth an estimated $1.5 billion in export
without the Utah Facility. Through clever design sales and facilitated a 360% increase in annual
and use of technology, the facility accommodates export tonnage for PHPA public berths.
Ore being conveyed onto ore carrier
docked at Utah Point berth
15 16

11. Utah Point Multi-User Bulk Export Facility Port Hedland
Servicing Australia’s future trade growth Mandatory criteria
Mandatory Criterion 5 – Community Benefit
Development of the Utah Facility and Strengthening community links
relocation of chromite and manganese exports
The Utah Facility initiated the establishment of
from Port Hedland’s west end to Utah Point
the Port Collaboration and Heritage Agreement
has resolved a number of significant
between PHPA and the local Marapikurrinya
environmental issues affecting the local
community, the original custodians of the land
community. In addition to the significant
occupied by the Utah Facility. This agreement
environmental and health improvements outlined
initiated a number of benefits for the community
in Optional Criteria 16, the following have also
that were not in place prior to the project,
contributed to a significantly improved amenity
including a commitment to the provision of
for the Port Hedland community.
employment, ongoing business development
Increasing employment opportunities in assistance, development of a Cultural Heritage
the region Masterplan and provision of assistance with
cultural heritage training and awareness by
The number of employees working for the PHPA
the PHPA.
increased from 25 to 90 with a diverse range
of skill sets, following completion of the project. Traditional land owners also secured JV
These personnel were either sourced from the partnerships with three of the major contractors
local community or new residents following during construction which resulted in direct
a commitment made from staff to live in Port employment, traineeships and dry-hire of
Hedland. Given Port Hedland’s typically transient equipment. The project also employed a heritage
population, PHPA has made a significant monitor to oversee all construction activities.
contribution to strengthening Port Hedland’s
Improved traffic flow and road safety
permanent employment base.
The project improved traffic safety by removing
Many local contractors and services were utilised
road train traffic from Port Hedland’s suburban
during the construction phase. Upon completion
and feeder roads. Trucks now enter the Utah site
of the facility, three of the four major contractors
via a new dedicated 10 kilometre sealed access
employed have made long term commitments
road, and significant improvements have been
to working in the local community and have
made to address safety issues associated with
set up local offices and established permanent
road train and light vehicle interaction on the
accommodation arrangements.
Great Northern Highway network.
Further benefits included the mandated
requirement to cover all truck loads to prevent
dust and contaminants affecting suburban areas.
Utah wharf construction
17 18

12. Utah Point Multi-User Bulk Export Facility Port Hedland
Servicing Australia’s future trade growth Mandatory criteria
Mandatory Criterion 6 - Sustainable Development
Water conservation and mangrove preservation metre high perimeter seawalls. This allowed the
were significant drivers for the development embankment to be steepened and prevented the
of sustainable engineering solutions for the loss of 1.2 hectares of mangroves at the seawall
Utah Facility. toe at a cost of $0.63m (investment of $52 per
square metre of mangroves preserved).
Preserving Port Hedland mangroves
Refer Appendix E for Stockyard Embankment
Twenty four hectares were required to establish
Road Details.
a stockyard capable of stockpiling trucked Seawall construction using concrete impregnated miracell
ores with a nine million tonne per annum Care was also taken to ensure that
export potential. mangroves outside of the construction footprint
were not disturbed. At the conclusion of Water Quality and Conservation A 45,000m3 lined recirculation water pond and
Consistent with the requirements of EPA
construction activities, mangroves were thriving controlled discharge pipe system and three
Guidance Statements No. 1 (Tropical Arid Zone The potential adverse eco-toxicological effect of
at the toe of the seawall as a result of careful 1,000m3 storage tanks were installed to enable
Mangroves; EPA 2001) and No. 29 (BPPH chromite and manganese on mangrove
construction practices. fire and dust suppression, and management
protection; EPA 2004c) to minimise mangrove and marine systems was studied by PHPA
loss and in particular, to protect valuable closed In total, 18 hectares of mangroves were of potable water across the site to deliver the
during the PER and led to a requirement to
canopy mangroves, the stockyard footprint was removed during construction of the stockyard abovementioned water conservation outcomes.
prevent ores containing chromite and manganese
minimised and re-oriented. and access road. A commitment has been from contaminating groundwater systems and Contaminated stockyard stormwater harvested
given by PHPA to the Environmental Protection the harbour. through a ring main pipe system to the
A partially disturbed calcarenite (limestone)
Authority and local community to meet the recirculation water pond will provide an estimated
outcrop at Stanley Point was selected as the The project team developed the following
Guidance Statement target of 10% historic 6 weeks reprieve per year from the need
most appropriate stockyard location given its initiatives to prevent mineral contamination of
loss of mangrove environments since European for expensive scheme water representing a
low ecological value as a result of being ground and harbour waters:
settlement through the establishment of a considerable cost saving.
previously disturbed and consisting mostly of
mangrove offset project. This work will further • hysical separation of iron ore from other
P
sandy saline flats with low open shrubs.
generate local jobs in its construction and will contaminating ores in the stockyard.
Multiple layers of plastic geogrid (Securgrid support ongoing eco-tourism and aboriginal • Installation of a bentonite barrier layer with
120/20) were also installed within the six to eight heritage opportunities. sub-surface drainage collection system.
• Installation of sealed internal roads.
• onstruction of an automatically operated
C
quad road train truck wash station installed
with water recirculation system.
• Materials handling system designed for wash
down and collection of contaminants between
shipments for treatment and recirculation.
• On site collection and treatment of stormwater
that is harvested for dust suppression.
• Installation of two Stormceptor units to operate
in conjunction with the wharf wash down Stormceptor adjacent to wharf to settle
Closed canopy mangroves system to settle out contaminants from the wharf wash down contaminants
wharf wash down.
19 20

13. Optional criteria
Optional Criteria Optional Criterion 8 - Simplicity of the Engineering Solution
Cavotec Automatic Mooring System Utah Point is located in the narrow neck of Port
Hedland Harbour where passing vessels (up to
Striving for world’s best practice and simple
270KT bulk carriers) exert significant hydrodynamic
low cost options for maximising the throughput
interaction forces that act to suck vessels from
capacity of the Utah Point berth, PHPA made a
their moorings. Port Hedland experiences large
decision to replace the centuries old practice of
tides (7.5 metres) that produce in excess of 2 knot
mooring vessels using ropes with an innovative
currents, design wind speeds of 23 m/s (45 knots),
and simple new technology.
fine iron ore dust issues and extreme heat (+45
Cavotec’s MoorMaster Automatic Mooring System degrees Celsius) conditions.
uses simple design concepts involving large
As Cavotec had not previously designed units
manoeuvrable suction cups held under vacuum
to withstand these conditions, PHPA contracted
to safely capture, berth and release vessels in
Cavotec to design and test 14 completely new
considerably less time than traditional mooring
200MM units capable of handling the large tidal
methods. The time saved in mooring and releasing
ranges experienced at Port Hedland. The revised
vessels using the MoorMaster technology and
design replaced the previous top mounted winch
its ability to maintain continuous safe loading
mechanism with a rail mounted travelling bus
operations has improved vessel turn around
(motor) to provide a robust structure capable
efficiency in Port Hedland by up to 2.5 hours.
of withstanding forces equivalent to 20 tonnes
perpendicular (280 tonnes total) and 10 tonnes
parallel to the berth face.
Cavotec units mounted vertically on wharf rails Cavotec wharf mounting close up
22

14. Utah Point Multi-User Bulk Export Facility Port Hedland
Servicing Australia’s future trade growth Optional criteria
Since the implications of system failure or under- Post-installation, the initial hydrodynamic
design were significant, PHPA commissioned interaction force concerns did not eventuate
OMC-International to modify the existing as the MoorMaster units perform much better
Port Hedland hydrodynamic harbour mooring in dampening the impacts of wind, current and
model to simulate ropes as stiff springs. This passing vessel forces than during simulation.
conservative assessment of MoorMaster system The technology has proved itself to be a more
capabilities predicted that the impact of passing than effective and simple replacement of
vessels would potentially exceed the capacity traditional rope technology.
of the design specifications on the end units.
PHPA challenged long established practices and
Revised bollard designs for secondary rope
put their faith in new and conceptually simply
protection were implemented as a precaution
technology with the MoorMaster Automatic
and options for piggy backing the two end units
Mooring System. This decision may drive a
were explored.
revolutionary change in ship berthing practices
around the world with significant potential to
improve safety, time and operational costs in
the future.
Aerial view of Utah Point berth showing 14 equidistant Cavotec units
Key Benefits
Through simplicity of operation and design concepts, the MoorMaster system delivers the following
significant benefits to PHPA and facility proponents:
• Improved safety of mooring operations. • Improved Utah Point Berth throughput
capacity and berth efficiency with maximum
• Greater port export efficiency through
vessel size increased to a length overall (LOA)
elimination of vessel creep, lost time due to
of 270 metres compared to 225 metres using
passing vessel interactions and reduction in
traditional rope mooring methods.
the time required to capture, moor and release
individual vessels which combined provide an • Reduced port operating costs for tug boats
estimated time saving per vessel of 2.5 hours. and personnel involved with stevedoring and
corresponding reduction in fuel emissions.
• Eradication of the need to construct large and
expensive Mooring Dolphins. Refer Port Strategy May 2007 article in
Appendix G for more information on the
200MM unit factory acceptance testing in France Cavotec Automatic Mooring System.
23 24

15. Utah Point Multi-User Bulk Export Facility Port Hedland
Servicing Australia’s future trade growth Optional criteria
OPTIONAL CRITERION 13 -
LEVEL OF IMPORT REPLACEMENT
Utah Point Travelling Ship Loader and
Tripper Conveyor
In accordance with the project’s stated objective
and tendering criteria whereby preference was given
to locally manufactured products, PHPA rejected
the cheapest tender offer from a reputable Chinese
manufacturer in favour of project managing the
design and manufacture of the ship loader using a
range of local contractors and suppliers.
Perth based Delta Engineering were awarded the
contract to design the ship loader and manufacture
associated mechanical and electrical components Ship loader main frame erection, January 2010
for delivery to the Australian Marine Complex (AMC)
Ship loader transfer to
Common User Facility at Henderson, south of Perth.
Henderson Wharf, May 2010
Upon completion, the 600 tonne ship loader and Table 1: Local contract partners for construction of the Utah Point ship loader
80 tonne boom were transferred to a heavy lift ship
Contractor/Location Description of Service Contract Type
for transport to Port Hedland where it was placed Pinc Group (Perth) Project Managers for all Utah Point Henderson Schedule of rates
directly onto the rails of the Utah Point wharf. scope of work
Delta Engineering (Malaga) Overall design supply of structural Fixed lump sum
Erection of the superstructure using multiple mechanical components
contractors who had not previously collaborated on United Industries Manufacture of the steel superstructure components Sub-contract to Delta
such a complex, schedule critical project required (Henderson) Engineering
tight management of technical, schedule and scope IE Systems (Perth) Electrical and control system engineer Sub-contract to Delta
Engineering
risks to ensure the structure was delivered on time.
Engineering Dynamics Design Auditor certification to Australian Standards Schedule of rates
A list of contractors employed on the ship loader
(Perth)
construction is outlined in Table 1. Engineering Dynamics Designer of heavy lift ship fatigue Schedule of rates
(Perth) transportation requirements
PHPA were successful in providing new
ProMet Engineers (Perth) Lead Engineer for the design management of Schedule of rates
opportunities for local contractors to increase Delta Engineering
their competitiveness in the manufacture of United Industries Erection of ship loader super structure at Henderson Fixed lump sum
major capital equipment and ensured the use of (Henderson)
locally manufactured steel in construction of the ProMet Engineers (Perth) Erection construction management consultants Schedule of rates
(Henderson)
ship loader. The all inclusive cost of the Western
AMC (Henderson) Facility Manager at Henderson Facility lease agreement
Australian designed and manufactured ship loader
BigLift (Always Shipping) Heavy lift ship transport from Henderson to Port Hedland Fixed lump sum and
was $16.9m which is in line with standard industry schedule penalties
costs per tonne for comparative equipment. GECM (Perth) Structural, mechanical electrical Outfitting Cost reimbursement
(Utah Henderson) with incentives
Transferring ship loader from Pinc Group (Perth) Utah Point construction and commissioning managers Schedule of rates
IE Systems (Perth) Utah electrical control system commissioning/ramp-up Schedule of rates
heavy lift ship to Utah wharf
25 26

16. Utah Point Multi-User Bulk Export Facility Port Hedland
Servicing Australia’s future trade growth Optional criteria
Optional Criterion 16 - Environmental Implications
From inception, the Utah Facility project was negative impacts on town amenity, community
motivated by the need to solve a number of health and the environment. The Utah Facility
significant environmental and health issues project addressed these issues to improve overall
affecting the Port Hedland community as a conditions for Port Hedland residents.
consequence of bulk ore exports (in particular
Reduced dust emissions
chromite and manganese) from Port Hedland’s
west end. Dust is a major environmental and health issue
in Port Hedland. Moving the export of chromite
Transporting and loading large volumes of
and manganese from the west end to Utah Point
mineral ores by road train and front end loader to
enabled a reduction in dust levels to built up
poorly designed stockpile and materials handling
areas as is evident in PER Dust Contour Charts
systems have previously produced significant
(refer to Appendix F).
Bentonite geosynthetic clay lining being applied to stockyard floor
This was achieved through: • roviding concrete dump pockets to feed ore
P
directly into automatic stackers with
• Transferring road trains from the west end
dust suppression.
of Port Hedland to a dedicated 10 kilometre
• torage of ore in a custom built stockyard
S
long private access road located outside
with elevated perimeter road and dust
the township.
suppression cannons throughout.
• Mandating covered loads from mine to port.
• rovision of efficient materials handling
P
• tockpiling ores at Finucane Island’s Utah
S
infrastructure to limit dust emissions and
Point to move dust emissions away from
to enable wash down between shipments.
populated areas.
• Covered tripper conveyor at the back of wharf.
• tilising a single and efficient stack and reclaim
U
• Introduction of truck wash facilities to
operation to dispense with the need to double
remove dust residue from transport
handle materials.
vehicles post delivery.
• rovision of bulk mineral controls over the
P
• rovision of chutes to reduce product
P
receipt of properly conditioned ores at the gate.
degradation and direct ore into ship holds
Lined 45,000m3 recirculation pond
27 28

17. Utah Point Multi-User Bulk Export Facility Port Hedland
Servicing Australia’s future trade growth
Reduced noise emissions Groundwater collection discharge and stormwater
AppendiCES
Moving the export operations to the Utah Facility is pumped to a 45,000m3 recirculation water pond
shifted quad and triple road trains and front from where it is settled and harvested for dust
end loader operations away from the township, suppression.This recirculated water will provide up
thereby considerably reducing noise emissions at to 6 weeks reprieve from the need for expensive
Port Hedland’s west end. scheme water representing a considerable cost
saving to exporters and conserving water.
Covered drives and transfer stations and efficient
mechanical and electrical infrastructure has also Long term environmental risks have also been
reduced operating noise levels at the Utah Facility. mitigated in the construction of the stockyard, with
a 6-8 metre high perimeter sea wall built to
Reduced groundwater and harbour prevent inundation of stockpiled ores by seawater
contamination risks in cyclone surge tides.
Operations at the Utah Facility have implemented The size of the stockyard and recirculation
measures to prevent potentially dangerous levels water pond ensures this facility successfully
of manganese and chromite contaminating local contains contaminated stormwater in a 1 in
groundwater or the harbour. 100 year flood event to prevent contaminated
All current and future potentially contaminating run off into the harbour.
ores are now environmentally contained within Protection of native flora
the stockyard by a bentonite barrier layer and
groundwater collection system that prevent ore Carefully orienting the stockyard position and
residue and dissolved solids from contaminating minimising its footprint by steepening the seawall
the groundwater and harbour. Bentonite was embankment prevented the loss of 1.2 hectares of
selected as the preferred lining material given mangroves at a total cost of $0.63 million ($52 per
its chemical stability, self-sealing properties and square metre of mangroves preserved).
ability to adjust to differential movement in the
Further details on the PHPA’s commitment to
stockyard floor.
protecting native flora at Utah Point can be found
in Mandatory Criterion 6.
Perimeter Seawall Protecting Stockyard Workers installing Geogrid to
from Cyclone Surge Tides seawall embankment
29

18. AppendiCES
Contents
Appendix A 33
BHPBIO tunnel raking pile General Arrangement
APPENDIX B 34
Utah Facility Organisational Chart
Appendix C 35
Utah Facility General Arrangement Plan
Process Flowsheet
Appendix D 37
Mobile Hopper Train General Arrangement (page 1/2)
Mobile Hopper Train General Arrangement (page 2/2)
Appendix E 39
Stockyard Embankment Road Details
Appendix F 40
Public Environmental Review Dust Contour Charts
Appendix G 41
Australian Port Survey, July/August 2010
Port Strategy, May 2007
WA Business News, October 2007
North West Telegraph, October 2007
The West Australian, October 2007
32

19. AppendiX A: BHPBIO tunnel raking pile general arrangement
33

20. AppendiX B: UTAH facility organisational chart
CEO PHPA
LEGEND
Pinc Group Resources
PHPA Resources Port Development
External Consultants Manager
Project Manager
Administration
Site Construction
Administration Manager
Executive Secretary
Senior
Receptionist Assistant Project
Planner /
Scheduler Manager
Procurement Deputy
Commercial Manager Construction Port Engineer
Manager
Manager
Project Controls Contracts OHSE Engineering Commissioning
Site Engineer
Manager Manager Manager
Lead Engineer Commissioning
Promet Engineers Manager
Senior Cost Contracts Environmental Site S'intendents Detailed Designer Mechanical Comm.
Controller Clerk Office Engineer
Civil/ Concrete Van Der Meer
Site Mechanical Stockyard Infras'ture
Safety Maintenance
Manager SuperIntendent
Services
POAGS (Stevedore)
Project Cordinator
Accountant Site
Electrical Process Electrical
Control SuperIntendent
IE Systems
Accounts Payable Senior
Site HV
Electrical Switching
Eng. Officer
34

21. AppendiX C: Utah Facility General Arrangement Plan
35

22. AppendiX C: Process flowsheet
36

23. AppendiX D: Mobile Hopper Train General Arrangement (page 1)
37

24. AppendiX D: Mobile Hopper Train General Arrangement (page 2)
38

25. AppendiX E: Stockyard Embankment Road – General Arrangement
39

26. AppendiX F: Public environmental review dust contour charts Australia Port Survey – Port G: australian(World Port Development July/August 2010)
AppendiX Hedland Extract port survey, july/august 2010
10 24 hour average with no Utah Point from PHPA Public Berth
Graphic 1: PM10 24 Hour Dust Concentrations – Exportsdevelopment
Predicted
Graphic 2: PM1010 24 Hour Dust Concentrations – Exports from the Utah Facility
Predicted PM 24 hour average with Utah Point development
40 41