Utah Point Multi-User Bulk Export Facility

Port Hedland
Servicing Australias future trade growth

2011 WA Engineering Excellence Awards

Resource Development Category
 Contents

Contents

Project Overview 1

Categorisation Statement 4

Mandatory Criteria 6

Optional Criteria 21

AppendiCES 30

Acknowledgements 46

Project Overview Project Overview
The Utah Point Multi-User Bulk Export Facility
(Utah Facility) addresses the resource industrys
need for expanded port facilities to meet current
and future growth in global demand for Western
Australian mineral resources and to facilitate
export for emerging mineral producers in the
Port Hedland region.
The Utah Facility was constructed on Finucane
Island opposite the existing public berths and
within the narrow neck of the Port Hedland
harbour. The Utah Facility development concept
consisted of a new dredged berth pocket and
270 metre long concrete wharf, travelling ship
loader, 24 hectare stockyard and associated
materials handling infrastructure, administration
and controls facility, and a 10 kilometre dedicated
access road.
Originally designed for a maximum export
capacity of 12 to 15 million tonnes per annum,
increased industry demand resulted in design
modifications to accommodate an export volume
of up to 21 million tonnes per annum. Expanded
capacity was achieved by increasing the dredged
depth of the berth pocket, introduction of an
innovative new automatic mooring system to
berth larger vessels and increasing the materials
handling system peak loading rate from 5,000
to 7,500 tonnes per hour. These innovations
allow the current facility and stage one of the
stockyards to reach up to 14Mtpa prior to the
construction of future stockpiling.
Using an integrated client team approach, the
Port Hedland Port Authority (PHPA) worked
collaboratively with project management
consultants, Pinc Group Pty Ltd (Pinc) to deliver
the project. Project planning commenced in
September 2006 and first ore on ship was
achieved within 4 years on 17 September 2010
after a 20 month construction phase.
Project Overview
A number of sustainable technology initiatives
and innovative engineering practices were
adopted and significant studies and consultation
undertaken as part of a full Public Environmental
Review. This process addressed the complexities
associated with designing and constructing
a port facility to transport, store and export a
multitude of minerals with potentially adverse
environmental and community impacts.
Innovations were introduced to achieve
operation efficiency and to mitigate health risks
and other community concerns including: a
45,000m3 water recirculation and stormwater
harvesting system; bentonite geosynthetic lined
stockyard floor with plastic reinforced seawall
embankments; custom designed automatic
vessel mooring system; real time vibration
monitoring of the BHPBIO tunnel; quad road train
wash facilities; unique mobile hopper train ore
reclaim system and a commitment to a mangrove
propagation farm.
The Utah Facility performed beyond expectation
in achieving nameplate capacity within 6 months
of operation and has proved capable of delivering
9 million tonnes of trucked ore per annum
throughout representing estimated export sales
of $1.5 billion per annum.
Future increases in industry demand can
be accommodated within the Utah Facility
with provision made for receiving product via
alternative ore transport modes such as rail
or slurry pipeline. Additional land has been
allocated adjacent to Utah Point to increase
opportunities for new and emerging mining
companies that would otherwise be denied
access to export markets.
2
 Utah Point Multi-User Bulk Export Facility Port Hedland
Servicing Australias future trade growth

About Port Hedland Port Authority

The Port Hedland Port Authority
(PHPA) is a statutory authority
owned by the Western Australian
Government. The Port Authority
has a charter to operate along
commercial lines with a primary
purpose to facilitate trade
through the port.
Categorisation StatemenT
PHPAs major functions are the control of all
shipping, and maximising the loaded capacity
of ships through the use of world leading
technology that allows the Authority to maintain
minimum safe under keel clearances. The Port
Authority also has a responsibility to plan for and
manage new developments whilst protecting the
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. Pincs
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
 Utah Point Multi-User Bulk Export Facility Port Hedland
Servicing Australias future trade growth
CATegorisation statement
The Utah Facility addresses the resource industry
need for expanded port facilities to meet current
and future growth in global demand for Western
Australian mineral resources.
Construction of a new multi-user bulk export
facility on the west side of the harbour at Utah
Point, with a capacity to receive small cape
size ships up to 120,000 tonnes deadweight,
resolves current pressure placed on existing port
facilities within Port Hedland, and allows Western
Australias junior mining companies to export
their products to a resource hungry
global market.
5
Mandatory Criteria
Implementation of sustainability initiatives
and innovative engineering practices and
technologies have not only improved operational
efficiency across the port, but reduced
environmental and health risks to Port Hedland
residents, whilst improving amenity for all.
Within the 2010/11 financial year, the Utah
Facility is expected to increase export tonnage
over the PHPA operated berths by 360% from
the previous year achieving the facilitys designed
nameplate capacity of nine million tonnes per
annum with an estimated total export value of
$1.5 billion.
 Utah Point Multi-User Bulk Export Facility Port Hedland
Servicing Australias future trade growth
Mandatory Criterion 1 - Occupational Health & Safety
As the first major construction project undertaken
by PHPA, the Utah Facility presented a number
of occupational health and safety (OH&S)
challenges for the project management team and
contractors given the absence of established
safety management policies and procedures,
and minimum safety standards for construction.
This situation was further complicated by
a contracting strategy that required the
construction management team to control
the interfaces between multiple independent
contractors occupying the same work spaces,
along with Port Hedlands difficult environmental
working conditions where dust exposure and
high ambient temperatures and humidity pose
significant health and safety risk.
A carefully crafted project management strategy
was established to ensure safe design and
construction outcomes. The projects OH&S
Plan set minimum standards and procedures
based on industry standards and statutory
requirements. Outlining site specific requirements
for entering and working on site, the Plan relied
heavily on the contractors own quality and safety
management systems and procedures. The need
for cooperation, trust, individual responsibility
and accountability were adopted as a basic
undertaking by all parties.
7 8
The Utah Facility is committed to
ensuring the highest possible standards
of occupational health and safety, the
minimisation and control of all risks, and
to zero harm.
Excerpt from the Utah Facilitys Safety
Management Plan.
Safety management initiatives targeted
training, risk assessment and problem solving in
high risk areas. It was recognised early that the
most impact could be achieved by focusing on
improving behaviour and attitudes of front line
workers and supervision to improve the overall
safety awareness and culture.
Backed by a high visibility, supportive and
positive leadership culture in which the entire
project management team and contractor
personnel were genuinely engaged in
decisions affecting workforce safety, the
project management team led work planning
and communication through daily Tool Box
meetings and weekly contract meetings with the
Construction Manager that focused primarily
on safety and environmental issues.
Seawall construction using concrete impregnated miracell
An example of an effective safety initiative is
evident in the implementation of safety controls
over the dredging and piling operations over the
BHPBIO tunnel as detailed in Appendix A.
Real-time vibration monitoring with direct
contractor communication was established to
predict when dredging and piling operations
might exceed pre-determined safe vibration
limits. This allowed the extent of further work to
be forecast and quickly agreed upon to ensure
work undertaken by third parties within the tunnel
could continue safely and without disruption.
Despite the difficult environmental conditions,
relative remoteness of the site and high risk
nature of the construction work, the safety
management strategy delivered a Lost Time
Injury Frequency Rate (LTI FR) of 1.4 resulting
from one lost day through injury from a total
850,000 site manhours.
This LTI FR represents only 10% of the WA
construction industrys average of 13.9 and
only surpassed by the best performing
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.
Mandatory criteria
Key OH&S initiatives employed across the
project included:
H
 igh weighting to safety performance and
systems in the evaluation of tenders.
H
 azard Identification Analysis (HAZID) and
formal risk assessments undertaken regularly.
Early identification of unacceptable risks that
could lead to unsafe outcomes.
Empowering all personnel to stop work where
unsafe practices or risks were observed.
Daily, unobtrusive observation of work
practices with positive feedback for safe work.
A
 voidance of safety clichs or rules for which
the rationale could not be justified.
Elimination of unnecessary paper work,
especially for workers and supervisors.
A
 genuine no blame system and no penalties
for lapses or mistakes.
Early and comprehensive incident/near
miss reporting.
 Utah Point Multi-User Bulk Export Facility Port Hedland
Servicing Australias future trade growth
Mandatory Criterion 2 Sound Engineering Practices & Principles
A fresh approach to project management
Successful delivery of the Utah Facility can
be attributed to the selection of contract and
procurement strategies matched to project and
commercial risks and the implementation of an
effective client integrated team.
Flexible contracting strategy matched to risk
A significant element of the projects success
lay in the careful selection of contract strategies
to minimise scope, cost and time risks. When
the project was assessed as requiring a full
Public Environmental Review (PER), the planned
fixed lump sum design and construction model
had unacceptable prolongation risk and was
therefore replaced with a client integrated project
and construction management team.
This allowed close management of project
approvals and funding requirements, with
preliminary engineering and procurement
undertaken whilst the scope continued to be
developed during the PER process. This strategy
led to PHPA taking responsibility for long lead
item procurement, managing engineering at a
pace consistent with PER outcomes and to stage
9 10
Mandatory criteria
the award of construction contracts in line with
the availability of funds.
The financial benefit of adopting a fresh approach
to contracting was evident in the supply and
installation of the sites high voltage electrical
feeder. A risk loaded fixed price offer presented
by the service authority was renegotiated to a
reimbursable contract (cost plus fixed fee) that
netted a 57% cost saving for the augmentation of
power to the site.
An integrated team approach to project and
construction management
Following completion of the concept
development phase, PHPA commissioned the
services of Pinc Group Pty. Ltd. (Pinc) to work
collaboratively as project manager in a genuine
integrated team approach where Pinc was
empowered to think and behave like the client
Sample of 3D Computer Model Used in Designing the Utah Facility
During design and procurement, Pinc provided
the flexibility required, with part-time and full-time
multi-disciplined staff allocated according to the
changing needs of project implementation
Pinc was able to provide PHPA with the approach provided a more efficient and cost
Refer Appendix B for Utah Facility resources, procedures and systems required to effective project management solution.
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 Pincs 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
Project Management
communication, eliminate duplication of
and Procurement 1.76 %
management and encourage fast decision
making. With PHPAs limited experience in Engineering 4.30 %
the development of major capital assets, this Construction Management 4.11 %
Utah Facility Construction team Photo
 Utah Point Multi-User Bulk Export Facility Port Hedland
Servicing Australias future trade growth
Mandatory Criterion 3 - Originality & Ingenuity
Utah Facility Stockyard
The Utah Facility has a 24 hectare (1030m
x 235m) multi-user bulk materials stockyard
designed to receive nine million tonnes per
annum of ore delivered by road train. This facility
is the first of its size and purpose in the world
and is truly unique in the design and construction
methods used in its creation.
Size
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.
11
Mandatory criteria
Design Flexibility
As selection of facility clients and their products
were indeterminate during the design phase and
expected to change over time, the stockyard
layout, loading and stacking infrastructure,
materials handling and electrical systems were
designed to manage a range of minerals, loading
rates, material properties and ore sizes ranging
from 120mm abrasive chromite lump to superfine
mineral concentrate.
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
12
 Utah Point Multi-User Bulk Export Facility Port Hedland
Servicing Australias future trade growth
Operations
Given the volume of trucks and variety of
ores being transported to multiple stockpiles
within the facility, customised transport, truck
management and communications systems were
designed to manage stockyard efficiency.
A two lane elevated perimeter road allows trucks
to circulate, pull out safely and right side dump
into hoppers capable of automatically identifying
the truck and its contents before unloading. A
CCTV system linked to a central control room
at the entrance was also constructed to ensure
efficient facility management and security.
13
Quad Road Train Adjacent to Stockyard Dump Pocket
Refer Appendix C - Utah Facility General
Arrangement Plan and Process Flowsheet for
more further information.
Significant cost savings were achieved by
replacing the traditional fixed hoppers with two
originally designed hopper trains. These rail
trains were designed to operate over the central
reclaim load-out conveyor with trailing power and
water cables. The six hoppers and two motor
control centres required for this solution achieved
considerable capital cost and operating savings.
Refer Appendix D - Mobile Hopper Train General
Arrangements 1 and 2 for further information.
Mobile Hopper Train Schematic
Mandatory criteria
A safer, more efficient way to moor vessels
Catovecs MoorMaster Automatic Mooring
System uses new technology to improve safety,
time and operational costs associated with
berthing large ships and significantly increase the
ports throughput.
Innovative 200MM units designed to withstand
Port Hedlands extreme tidal, heat and dust
conditions have not only improved safety
compared to traditional rope mooring, but
reduced vessel capture, moor and release times
by approximately 2.5 hours per vessel.
More information on the innovative application
of Cavotec technology is found in Mandatory
Criteria 8.
3D model view of stockyard
14
 Utah Point Multi-User Bulk Export Facility Port Hedland
Servicing Australias future trade growth
Mandatory Criterion 4 - Economic Contribution
Increasing Port Hedlands export capacity
The development of the Utah Facility has had a
fundamental impact on Western Australias future
export potential and economic activity.
The Utah Facility signals a vital opportunity
for new and emerging miners to export their
products to international markets. Commencing
the export chain through affordable trucking
options is expected to provide a starting point
for the generation of valuable cash-flow to new
market entrants, which will in turn provide future
opportunities for expansion through capital
development and encourage investment in
minerals mining well into the future.
PHPAs strategic plan to expand the Ports inner
harbour capacity from 200 million tonnes to 495
million tonnes per annum cannot be achieved
without the Utah Facility. Through clever design
and use of technology, the facility accommodates
15
Mandatory criteria
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
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
export capacity of other port users. The BHPBIO materials handling system.
under harbour tunnel that crosses at shallow
depth under the Utah Wharf constrained the
depth of the Facility berth pocket such that it
was only suitable for Panamax and Small Cape
vessels with low drafts capable of accessing the
harbour during low tide when larger ore carriers
cannot operate.
Custom built to manage between 85,000 and
100,000 road trains per year, the Utah Facility
stockyard delivers a diverse range of ores from
mines within a 550 kilometre radius of Port
Hedland. Within the first year of operation, the
Utah Facility has achieved nameplate export
capacity of 9 million tonnes of trucked ore per
annum worth an estimated $1.5 billion in export
sales and facilitated a 360% increase in annual
export tonnage for PHPA public berths.
Ore being conveyed onto ore carrier
docked at Utah Point berth
16
 Utah Point Multi-User Bulk Export Facility Port Hedland
Servicing Australias 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 Hedlands 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 Hedlands 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 Hedlands
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 Hedlands 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
 Utah Point Multi-User Bulk Export Facility Port Hedland
Servicing Australias future trade growth
Mandatory Criterion 6 - Sustainable Development
Water conservation and mangrove preservation
were significant drivers for the development
of sustainable engineering solutions for the
Utah Facility.
Preserving Port Hedland mangroves
Twenty four hectares were required to establish
a stockyard capable of stockpiling trucked
ores with a nine million tonne per annum
export potential.
Consistent with the requirements of EPA
Guidance Statements No. 1 (Tropical Arid Zone
Mangroves; EPA 2001) and No. 29 (BPPH
protection; EPA 2004c) to minimise mangrove
loss and in particular, to protect valuable closed
canopy mangroves, the stockyard footprint was
minimised and re-oriented.
A partially disturbed calcarenite (limestone)
outcrop at Stanley Point was selected as the
most appropriate stockyard location given its
low ecological value as a result of being
previously disturbed and consisting mostly of
sandy saline flats with low open shrubs.
Multiple layers of plastic geogrid (Securgrid
120/20) were also installed within the six to eight
19
metre high perimeter seawalls. This allowed the
embankment to be steepened and prevented the
loss of 1.2 hectares of mangroves at the seawall
toe at a cost of $0.63m (investment of $52 per
square metre of mangroves preserved).
Refer Appendix E for Stockyard Embankment
Road Details.
Care was also taken to ensure that
mangroves outside of the construction footprint
were not disturbed. At the conclusion of
construction activities, mangroves were thriving
at the toe of the seawall as a result of careful
construction practices.
In total, 18 hectares of mangroves were
removed during construction of the stockyard
and access road. A commitment has been
given by PHPA to the Environmental Protection
Authority and local community to meet the
Guidance Statement target of 10% historic
loss of mangrove environments since European
settlement through the establishment of a
mangrove offset project. This work will further
generate local jobs in its construction and will
support ongoing eco-tourism and aboriginal
heritage opportunities.
Closed canopy mangroves
Mandatory criteria
Seawall construction using concrete impregnated miracell
Water Quality and Conservation A 45,000m3 lined recirculation water pond and
controlled discharge pipe system and three
The potential adverse eco-toxicological effect of
1,000m3 storage tanks were installed to enable
chromite and manganese on mangrove
fire and dust suppression, and management
and marine systems was studied by PHPA
of potable water across the site to deliver the
during the PER and led to a requirement to
abovementioned water conservation outcomes.
prevent ores containing chromite and manganese
from contaminating groundwater systems and Contaminated stockyard stormwater harvested
the harbour. through a ring main pipe system to the
recirculation water pond will provide an estimated
The project team developed the following
6 weeks reprieve per year from the need
initiatives to prevent mineral contamination of
for expensive scheme water representing a
ground and harbour waters:
considerable cost saving.
P
 hysical separation of iron ore from other
contaminating ores in the stockyard.
Installation of a bentonite barrier layer with
sub-surface drainage collection system.
Installation of sealed internal roads.
C
 onstruction of an automatically operated
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
system to settle out contaminants from the wharf wash down contaminants
wharf wash down.
20
 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 worlds 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
Cavotecs 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
 Utah Point Multi-User Bulk Export Facility Port Hedland
Servicing Australias future trade growth Optional criteria

Since the implications of system failure or under-
design were significant, PHPA commissioned
OMC-International to modify the existing
Port Hedland hydrodynamic harbour mooring
model to simulate ropes as stiff springs. This
conservative assessment of MoorMaster system
capabilities predicted that the impact of passing
vessels would potentially exceed the capacity
of the design specifications on the end units.
Revised bollard designs for secondary rope
protection were implemented as a precaution
and options for piggy backing the two end units
were explored.
Post-installation, the initial hydrodynamic
interaction force concerns did not eventuate
as the MoorMaster units perform much better
in dampening the impacts of wind, current and
passing vessel forces than during simulation.
The technology has proved itself to be a more
than effective and simple replacement of
traditional rope technology.
PHPA challenged long established practices and
put their faith in new and conceptually simply
technology with the MoorMaster Automatic
Mooring System. This decision may drive a
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

Greater port export efficiency through
elimination of vessel creep, lost time due to
passing vessel interactions and reduction in
the time required to capture, moor and release
individual vessels which combined provide an
estimated time saving per vessel of 2.5 hours.
Eradication of the need to construct large and
expensive Mooring Dolphins.
200MM unit factory acceptance testing in France
capacity and berth efficiency with maximum
vessel size increased to a length overall (LOA)
of 270 metres compared to 225 metres using
traditional rope mooring methods.
Reduced port operating costs for tug boats
and personnel involved with stevedoring and
corresponding reduction in fuel emissions.
Refer Port Strategy May 2007 article in
Appendix G for more information on the
Cavotec Automatic Mooring System.

23 24
 Utah Point Multi-User Bulk Export Facility Port Hedland
Servicing Australias future trade growth Optional criteria

OPTIONAL CRITERION 13 -
LEVEL OF IMPORT REPLACEMENT

Utah Point Travelling Ship Loader and

Tripper Conveyor

In accordance with the projects 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 I&E 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. GEC&M (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
I&E Systems (Perth) Utah electrical & control system commissioning/ramp-up Schedule of rates
heavy lift ship to Utah wharf

25 26
 Utah Point Multi-User Bulk Export Facility Port Hedland
Servicing Australias future trade growth
Optional Criterion 16 - Environmental Implications
From inception, the Utah Facility project was
motivated by the need to solve a number of
significant environmental and health issues
affecting the Port Hedland community as a
consequence of bulk ore exports (in particular
chromite and manganese) from Port Hedlands
west end.
Transporting and loading large volumes of
mineral ores by road train and front end loader to
poorly designed stockpile and materials handling
systems have previously produced significant
27
Optional criteria
negative impacts on town amenity, community
health and the environment. The Utah Facility
project addressed these issues to improve overall
conditions for Port Hedland residents.
Reduced dust emissions
Dust is a major environmental and health issue
in Port Hedland. Moving the export of chromite
and manganese from the west end to Utah Point
enabled a reduction in dust levels to built up
areas as is evident in PER Dust Contour Charts
(refer to Appendix F).
Bentonite geosynthetic clay lining being applied to stockyard floor
This was achieved through: P
 roviding concrete dump pockets to feed ore
directly into automatic stackers with
Transferring road trains from the west end
dust suppression.
of Port Hedland to a dedicated 10 kilometre
S
 torage of ore in a custom built stockyard
long private access road located outside
with elevated perimeter road and dust
the township.
suppression cannons throughout.
Mandating covered loads from mine to port.
P
 rovision of efficient materials handling
S
 tockpiling ores at Finucane Islands Utah
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.
U
 tilising a single and efficient stack and reclaim
Introduction of truck wash facilities to
operation to dispense with the need to double
remove dust residue from transport
handle materials.
vehicles post delivery.
P
 rovision of bulk mineral controls over the
P
 rovision of chutes to reduce product
receipt of properly conditioned ores at the gate.
degradation and direct ore into ship holds
Lined 45,000m3 recirculation pond
28
 Utah Point Multi-User Bulk Export Facility Port Hedland
Servicing Australias future trade growth
Reduced noise emissions
Moving the export operations to the Utah Facility
shifted quad and triple road trains and front
end loader operations away from the township,
thereby considerably reducing noise emissions at
Port Hedlands west end.
Covered drives and transfer stations and efficient
mechanical and electrical infrastructure has also
reduced operating noise levels at the Utah Facility.
Reduced groundwater and harbour
contamination risks
Operations at the Utah Facility have implemented
measures to prevent potentially dangerous levels
of manganese and chromite contaminating local
groundwater or the harbour.
All current and future potentially contaminating
ores are now environmentally contained within
the stockyard by a bentonite barrier layer and
groundwater collection system that prevent ore
residue and dissolved solids from contaminating
the groundwater and harbour. Bentonite was
selected as the preferred lining material given
its chemical stability, self-sealing properties and
ability to adjust to differential movement in the
stockyard floor.
Perimeter Seawall Protecting Stockyard
from Cyclone Surge Tides
29
Groundwater collection discharge and stormwater
AppendiCES
is pumped to a 45,000m3 recirculation water pond
from where it is settled and harvested for dust
suppression.This recirculated water will provide up
to 6 weeks reprieve from the need for expensive
scheme water representing a considerable cost
saving to exporters and conserving water.
Long term environmental risks have also been
mitigated in the construction of the stockyard, with
a 6-8 metre high perimeter sea wall built to
prevent inundation of stockpiled ores by seawater
in cyclone surge tides.
The size of the stockyard and recirculation
water pond ensures this facility successfully
contains contaminated stormwater in a 1 in
100 year flood event to prevent contaminated
run off into the harbour.
Protection of native flora
Carefully orienting the stockyard position and
minimising its footprint by steepening the seawall
embankment prevented the loss of 1.2 hectares of
mangroves at a total cost of $0.63 million ($52 per
square metre of mangroves preserved).
Further details on the PHPAs commitment to
protecting native flora at Utah Point can be found
in Mandatory Criterion 6.
Workers installing Geogrid to
seawall embankment
 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
AppendiX A: BHPBIO tunnel raking pile general arrangement

33
 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
I&E Systems

Accounts Payable Senior

Site HV
Electrical Switching
Eng. Officer

34
AppendiX C: Utah Facility General Arrangement Plan

35
AppendiX C: Process flowsheet

36
AppendiX D: Mobile Hopper Train General Arrangement (page 1)

37
AppendiX D: Mobile Hopper Train General Arrangement (page 2)

38
AppendiX E: Stockyard Embankment Road General Arrangement

39
 AppendiX F: Public environmental review dust contour charts Australia Port Survey Port G:
AppendiX Hedland Extract (World
australian port Port Development
survey, July/August
july/august 20102010)

Graphic
Predicted 1024
1: PM10 24Hour
hourDust
average with no Utah
Concentrations Point development
Exports from PHPA Public Berth

Graphic
Predicted 1010
2: PMPM 2424hour
Houraverage with Utah Point
Dust Concentrations development
Exports from the Utah Facility

40 41
 AppendiX G: port strategy, May 2007 AppendiX G: WA Business news, October 2007

Search Archives





Miners to co-fund $225m Port Hedland
upgrade

42 43
 AppendiX G: North west telegraph, october 2007 AppendiX
Port expansion to help small miners : thewest.com.au G: Thehttp://www.thewest.com.au/default.aspx?MenuID=146&ContentID=44452
west australian, october 2007

44 45
 Utah Point Multi-User Bulk Export Facility Port Hedland
Servicing Australias future trade growth

Acknowledgements

Port Hedland Port Authority and Pinc Group Pty Ltd extends special thanks to the Utah Point Multi-User
Bulk Export Facility team and internal support staff who contributed to the success of this project.

Members of the project team would also like to thank the following contractors and suppliers contractors
who contributed to delivering this state of the art project:

ABB Fremantle Steel ProMet Engineers

Australian Marine Complex Goodline Pty Ltd Rocktec
Baggerman Associates GEC&M Joint Venture Sandvik Mining and
BigLift (Always Shipping) Horizon Power Construction Aust Pty Ltd
Utah Point Multi-User Bulk Export Facility
Brierty Constructions I&E Systems Schneider Utah Point Multi-UserPort
BulkHedland
Export Facility Port Hedland
Environmentally
Servicing
Servicing Australias
sustainablefuture
engineering
trade
trade growth
in practice
Cavotec MoorMaster Jan De Nul SEW Eurodrive Australias future growth

Coffey Geotechnics J Steel Sinclair Knight Merz

Concep Pty Ltd Logicamms Tanis
Delta Engineering MakJap United Industries
DM Gerloff & Associates Marapikurrinya Pty Ltd University of WA
Engineering Dynamics Marine and Civil V & C Semeniuk
Ertech Pty Ltd OMC International Van Der Meer Group
Fenner Dunlop Conveyor Plummers Vipac Engineers and Scientists
Belting Aust Pty Ltd POAGS Wanati Pty Ltd
Formaction Concrete and Civils

2011 WA
2011 WAEngineering
Engineering Excellence Awards
Excellence Awards
Resource
Resource Development
Environment
Development Category
Category
Category
More information

Port Hedland Port Authority Pinc Group Pty. Ltd.

Warren Farrow Neil Parker
Port Development Manager Managing Director
P: 08 9212 8107 P: 08 6218 9000
E: warren.farrow@phpa.wa.gov.au E: neil.parker@pincgroup.com.au
W: phpa.wa.gov.au W: pincgroup.com.au