Project: Nickel West Air Compressor Replacement

Client: Billiton Nickel West, Western Australia

Project Highlights:

  • More than 30% savings in engineering and capital costs of compressors
  • Savings of over $1.6 million per year in operating costs (power, water and maintenance) compared to the original plant setup
  • Technical and Commercial review of Air Compressor Replacement proposed for BHP’s Kalgoorlie Nickel Smelter, and option evaluation and pricing of several compressor packages
  • Eliminated the use of water-cooled compressors, resulting in OPEX savings on cooling towers and circulating pumps
  • Design and manufacture of 7 Ingersoll Rand skid-mounted modular screw compressor packages
  • Detailed Engineering for BHP Nickel West Compressor House
  • Supervision and execution of package fabrication at Ingersoll Rand, China facility
  • Manufacturing documentation (MDR’s) in compliance with BHP Billiton Standards

Project: Brine Injection Facilities for Gladstone LNG

Client: Santos Gladstone LNG Project, Queensland

Project Highlights:

  • Reducing the total cost of ownership to Santos by 23%
  • Engineering and equipment supply under one roof with reduced interface and thus time saving.
  • Detailed Engineering in Australia to ensure compliance with AS standards
  • Majority of drafting in India with engineering checks carried out in Australia
  • Software Development in India under the supervision of our Australian team, enabling major savings in software development costs
  • Sourcing electronic components including PLCs from European and American manufacturers who are approved by Santos
  • Modular design panel to be installed within a self-contained transportable container
  • System is designed for a remote unmanned site location
  • Assembly of panels in India
  • FAT offered in Perth, Australia, prior to despatch to site

Project: Fuel Storage and Refuelling Facilities

Client: Rio Tinto, Western Australia

Project Highlights:

  • Increasing cost-savings by 30% due to sourcing from emerging markets
  • Carried out Fuel Storage and Distribution facilities design in compliance with Rio Tinto specifications and Australian Standards
  • Majority of drafting in India with engineering checks carried out in Australia
  • Software Development in India under the supervision of our Australian team, enabling major savings in software development costs.
  • Sourcing electronic components including PLCs from European, American and Japanese manufacturers who are approved by Rio Tinto
  • Assembly of panels in India
  • FAT offered in Perth, prior to despatch to site

Project: BHP Billiton Rolling Stock Replacement

Client: BHP Billiton Nickel West, Western Australia

Project Highlights:

  • Reducing total cost of ownership to BHP Billiton by 30%
  • Engineering and equipment supply under one roof with reduced interface and thus time saving
  • Total fabrication tonnage of 500 tons
  • Fabrication of 49 nos. pressure vessels were completed in a record time of 8 months
  • Evaluation of several design and fabrication options
  • Detailed Engineering design in Australia to ensure compliance with AS1210 standards and Australian Dangerous Goods (ADG) Code 7
  • Approval of Worksafe and Department of Mines & Petroleum (DMP)
  • Fabrication in our facilities located in Baroda, India
  • Inspection by Lloyds and Bureau Veritas
  • Manufacturing documentation (MDR) in compliance with AS1210 and AS3990
  • Achieving the logistical challenge of the sea-transportation of 49 huge vessels to Australia
  • Vessels ready to go for operation after arrival in Australia

Project: Ammonia Evaporator Replacement

Client: Wesfarmers CSBP, Western Australia

Project Highlights:

  • Reducing the total cost of ownership to CSBP by 20%
  • Engineering and equipment supply under one roof with reduced interface and thus time saving
  • Total fabrication tonnage of 14 tons
  • Fabrication of a one-off Shell and Tube Heat Exchanger was completed in a record time of 4 months
  • Approval of Worksafe
  • Fabrication at our Partner facilities located in Baroda, India
  • Inspection by Lloyds
  • Manufacturing documentation (MDR) in compliance with AS1210

Project: F2E‐40 Tail Gas Scrubber Intercooler

Client: BHP Nickel West, Kwinana Nickel Refinery WA

Project Highlights:

  • Engineering and equipment supply under one roof with reduced interface and thus time saving
  • Design and Construction to AS1210 Class 3 and TEMA C
  • Stainless Steel 316L fabrication with custom Kammprofile Gaskets
  • Design Verification and Registration with WorkSafe Australia
  • Manufacturing Documentation (MDR) in compliance with AS1210 and AS4458

Project: Bubble Columns, Sulphur Pit Steam Coils, Antifoam Pots, Sulphur Locks & Funnels for KIPIC Al‐Zour Refinery Kuwait

Client: FDH JV, India

Project Highlights:

  • Engineering and equipment supply under one roof with reduced interface and thus time saving
  • Total fabrication tonnage of 101 tons total of 54 equipment tags
  • Fabrication at our facilities located in Baroda, India
  • Fabrication in compliance with ASME Sec. VIII Div 1. and Shell DEP and FDH JV standards
  • Inspection by TUV Nord & Bureau Veritas
  • Road and sea-transportation of 54 equipment tags of various sizes and weights
  • Vessels ready to go for operation after arrival in Kuwait

Project: Air Dryer for Sulphuric Acid Unloading Facility

Client: BHP Billiton / Coogee Chemicals, Kwinana Refinery WA

Project Highlights:

  • Engineering and equipment supply under one roof with reduced interface and thus time saving
  • Detailed Engineering design in Australia to ensure compliance with AS1210 standards
  • Unique split-flow and purge-less air dryer design with the elimination of any emissions
  • The air dryer and auxiliary components were all manufactured onto a skid for ease of use and transport
  • Stainless steel cladding and aluminium wool insulation were applied to all surfaces exceeding 60⁰C
  • All pressure vessels on skid ASME U-Stamp approved and compliant to AS1210 standards
  • Manufacturing Documentation (MDR) in compliance with AS1210 and AS4458

Project: Nickel Reduction Autoclave H2C-8 E and H2C-8-H for Replacement and Expansion of Nickel Refinery

Client: BHP Billiton Nickel West, Kwinana Nickel Refinery WA

Project Highlights:

  • Reducing total cost of ownership to BHP Billiton Nickel West by 25%
  • Engineering and equipment supply under one roof with reduced interface and thus time saving
  • Total fabrication tonnage of 66 tons for 2 Autoclaves in Duplex Stainless Steel with 40mm-thick plates used in Shell and 45 mm thick plates used for the dishends
  • Plates were imported from Outokumpu, Sweden and Arcelor Mittal, France
  • Fabrication of the first Autoclave was completed in record time of 5 months and the second one followed 3 months later
  • Detailed Engineering design in Australia to ensure compliance with AS1210 standards
  • Approval of Worksafe and Department of Mines 8. Petroleum (DNP)
  • Fabrication at our facilities located in Baroda, India
  • Inspection by lmel Australia and BHP Billiton
  • Manufacturing documentation (MDR) in compliance with A81210 and AS3990
  • Vessels ready to go for operation after arrival in Australia

Project: Nitrogen Receiver Expansion of Nickel Refinery

Client: BHP Billiton Nickel West, Kwinana Nickel Refinery WA

Project Highlights:

  • Engineering and equipment supply under one roof with reduced interface and thus time saving
  • Fabrication at our facilities located in Baroda, India
  • Total fabrication tonnage 60 tons with 50mm shell plates and 63mm dished end plates
  • Fabrication was completed on time and within 5 months of the contract being awarded, as well as the equipment arriving on-site before the required delivery date
  • Detailed Engineering design in Australia to ensure compliance with AS1210 standards
  • Approval of Worksafe and Department of Mines & Petroleum (DMP)
  • Manufacturing Documentation (MDR) in compliance with AS1210 and AS4458
  • Post Weld Heat Treatment to AS4458
  • Vessel underwent full Radiography and additionally Magnetic Particle and Ultrasonic testing

Project: 6 Sodium Cyanide Containers Replacement

Client: CSBP / Australian Gold Reagent Pty Ltd, WA

Project Highlights:

  • Reducing the total cost of ownership to AGR by 30%
  • Fabrication of 6 nos. 20-foot Isotainers delivered in December 2015
  • Fabrication in compliance with AS1210 standards and Australian Dangerous Goods (ADG) Code 9
  • Specialised corrosion-resistant internal coating (Corrocoat Vinyl Ester Glass flake)
  • Fabrication at our facilities located in Baroda, India
  • Inspection by Bureau Veritas
  • Manufacturing documentation (MDR) in compliance with AS1210 and AS3990
  • Isotainers are capable of mounting on railway undercarriages or trucks as required

Project: Ventillation System Study

Client: BHP Billiton Nickel West, Kwinana Nickel Refinery WA

Project Highlights:

  • Successfully implemented vent system solution resulting in increased production by 50% and achieving BHP Billiton’s goals of increasing plant throughput
  • Analysis of the existing vent system on-site to determine operating data
  • 3D-Scanning of the existing venting system
  • Process Modelling via HYSIS simulations performed to evaluate optimal solutions
  • Design and Engineering for installation of new vent lines
  • Design drawings created for new vent lines
  • Solution was implemented and solved the existing throughput problems

Project: Apollo 2 Project, Geismar Plant, Louisiana, USA

Client: Honeywell USA

Project Highlights:

  • Engineering Design, Manufacture and Delivery of 16 off-pressure vessels compliant to ASME Section VIII Division 1 for Honeywell’s new Refrigerant Plant in Louisiana, USA
  • Fabrication at our facilities located in Baroda, India
  • Manufacturing documentation (MDR) in compliance with ASME Section VIII (Div 1) and U-Stamp Certification
  • Third Party Inspection by TUV Nord

Project: Modification of Underground Fire Water System

Client: BHP Nickel West Leinster

Project Highlights:

1. Identifying current issues in the Existing Underground Fire Water System.

  • Not adequate water discharge from the deluge system.
  • Not meeting the pressure criteria for the deluge nozzles.
  • Not a reliable system at some of the UG Levels where Process Water is also drawn for the Fire Water line after Pressure Reducing Station.

2. Development of Schematic Concept

  • Vertical Dam Option.
  • Horizontal Dam Option.
  • New Steel Tank Option.

3. Definition Phase Engineering

  • Access Petrotec/BHP jointly explored several options while selecting the FW storage tanks and piping arrangements in Level 5. Various discussion and exchange of sketches and drawings occurred during this period on a collaborative approach to finding the right solution with high reliability. The general arrangement sketch received from BHP for 5L was very helpful to finalise the design. AP incorporated the comments for FW system Equipment Layout and Pipe Routing (Tanks at Level 5), and finalised tank and piping Sizes.
  • Preparation of Technical data for major items including tanks and control valves.
  • Piping Schematics draft version was prepared and will be submitted once the hole location is finalised by BHP.

Project:Iron Bridge Project – HV Drives Piping Design and Supply

Client:ABB/FMG

Project Highlights:

1. Detailed Engineering Design

  • Access Petrotec carried out the detailed engineering design of piping between the VSDs and the chiller and produced necessary Engineering deliverables including Piping and Instrumentation Diagram (P&ID), 3D Models, GA, Isometrics and Pipe support drawings for all seven switch rooms.

2. Supply of Equipment

  • CS Pipe Spools.
  • All valves and fittings.
  • Structural Supports.
  • Expansion Vessel.
  • IBC – International Bulk Container.

3. Fabrication and Documentation

  • Access Petrotec carried out all fabrication and Manufacturing Data Records (MDR) for all piping and pipe supports in compliance with ASME and Project Specifications.

Project:Development of P&ID and Control System Philosophy for Water Management and Discharge in Nelson Bay River

Client: Shree Minerals - Tasmania

Project Highlights:

  • Flow Assessment and Development of Control Philosophy.
  • Flow Assessment and Development of Control Philosophy.
  • Provide inputs to drafting team.
  • Review P&ID prepared by Drafting team.
  • Obtain Client Approval on the submissions.

Project:Supply and Retrofit of Variable Speed Drives (VSD)

Client:Various Mining sites in kalgoorlie

Project Highlights:

1. Equipment Analysis

  • Access Petrotec carried out a complete analysis of the equipment to ascertain the operating parameters, site constraints and determination of optimal placement of a new VSD. Upon successful analysis it was found that the issue was only with IGBT converters as part of the inverter circuit. Access Petrotec requested BHP to replace only the IGBT converts instead of the whole VSD unit saving significant costs to BHP.

2. Supply of Equipment

  • IGBT converters as part of the inverter circuit.
  • Gate Driver Board.
  • Supply of 6 VSDs.