DDGT- Tubridgi Gas Storage Facilities- Design & MDR Validation

Sustech was engaged by DDGT to provide an independent 3rd party verification of design of the 42 PJ Tubridgi gas storage facility which is the largest in WA. The project involves multiple injection and recovery wells, wellhead filtration, flowlines, slug catcher, two stage two trains compressor station, gas processing facilities, dehydration, regeneration, hot oil system, mercury removal, metering stations, pipelines, pig launching and receiving facilities. The goal of the verification was to perform an independent desktop review of the design documents, that will ensure accordance with AS2885 and ASME B31.3 under the WA Petroleum Act 1969 and prodcution license. The project also involved the use of relifed mothballed vessels under AS3788 and API579. Sustech performed a diligent review, maintaining detailed verification records, raising and closing queries to satisfaction and noting obervations that may not affect the integrity of the project but could lead to uncontrolled hazards. Sustech issued a report for the safety-integrity of the design and MDR for a fit for purpose gas storage and processing facility. The report was submitted to the regulator.

AGIG-Pluto Compressor Station and Metering Station-Facilities Design & MDR Validation

Sustech is currently undertaking the independent 3rd party verification of the Pluto interconnect compressor station, metering station, pig launcher at the pipeline and facility transition for its design and MDR. The goal of the verification is to perform an independent desktop review of the design documents within the ambit of AS2885 under the WA Petroleum Act 1969. Sustech is performing a diligent review, maintaining detailed verification records, raising queries with the constructor for clarification and closing queries to satisfaction. Sustech is issuing a report for the safety-integrity of the design and a fitness for purpose for the facilities. The report will be submitted to the regulator.

AGIG-Tanami-Pipeline and Facilities Design & MDR Validation

Sustech is currently undertaking the independent 3rd party design and MDR verification of the 440 km Tanami natural gas pipeline, its scrapper stations and metering stations at the head and lateral ends. The goal of the verification is to perform an independent desktop review of the design and MDR documents under the regulations of DPIR of the Northern Territory as per Energy Pipelines act 2015 and Energy Pipelines Regulations 2015. Sustech has been engaged from the design review stage, attending HAZOP and Pipeline risk assessment workshops and keeping close contact with the operator and regulator and performing a diligent review, maintaining detailed verification records, raising queries with constructor for clarification, closing queries to satisfaction. Sustech is issuing a report for the safety-integrity of the design and a fit for purpose pipeline and facilities. The report will be submitted to the NT regulator.

YPFL-Karratha-Seawater Supply and Desalination Plant Technical Due Diligence Study

Sustech was engaged by YPFL to conduct a technical due diligence study of an existing seawater supply system ~300MLD & desalination plant. The study results were essential for YPFL in taking investment decision and taking strategic policy decision. Sustech did a thorough job in assessing the technology, design, MDR, condition assessment reports, incident reports, failure reports, equipment fitness certificates, maintenance records, operational history, OPEX and CAPEX/ Project OPEX spent by operator. Sustech’s engineers visited site, assessed asset conditions analysed the records and submitted a conclusive report that was well received by the client.

 

GDF Suez-Crondall Energy – FLNG Mechanical and Piping Design Basis and Scope of Work Review

As an independent reviewer, Sustech was entrusted by Crondall to review the mechanical and piping section from the Basis of design for a 4 Mtpa floating LNG developed by another consultant of the owner. Sustech referred to the following documentation: owners requirements, key decision logs, site data, project philosophies, owner’s company guidelines to review the basis of design to identify the anomalies, deficiencies and advise functional sufficiency, safety points and improvement scopes to make the document as robust as possible to develop a proper FEED design. Sustech reviewed the scope of work on the basis of these documents to provide the FEED contractor with a clear understanding of the work.

 

UGL-Santos Sole Gas Project – Process Design ReviewSustech was appointed by the construction company, UGL as the independent reviewer of the process design of the Sole Gas project which is upcoming. The design house Jacobs was the designer who prepared the design for UGL. The process design and the technology selected was innovative and required highly skilled and experienced process engineers to look through the functionality, safety and fitness for purpose. Sustech reviewed all key process engineering deliverables like Process Flow Diagrams / Block flow diagrams / Heat & Mass Balance Diagrams / PIDs / Basis of Design data sheets / Performance guarantees / equipment selections / hydraulics / flare sizing / cause & effect charts / specifications / and data sheets. Sustech prepared the list of queries for the area of concerns; identified the risks associated with the process design; prepared the risk matrix (for the identified process risks) and provide suggestions to mitigate the risks; reviewed and confirmed the process guarantee parameters to meet the contract requirements. Sustech also highlighted if there were any issues in meeting the performance guarantees; identified the list of opportunities to improve the design to reduce both time and cost; prepared a consolidated report on the findings / remarks / recommendations / risks. Sustech’s engineering team with special expertise and a combined experience of over 100yrs completed the job and earned kudos from both Jacobs and Santos.

DBP- Ashburton to Onslow Gas Pipeline- Pipeline and Facilities Design Validation

Sustech performed the independent 3rd party verification of the 123 km natural gas pipeline lateral and its facilities’ MDR. The goal of the verification was to do an independent desktop review of the design documents within the ambit of AS2885 under the WA Petroleum Act 1969. Sustech undertook a diligent review, whilst maintaining detailed verification records, raised queries with the constructor for clarification and closed queries to satisfaction. Sustech issued a report for safety-integrity of the design and a fit for purpose pipeline and facilities. The report was submitted to the regulator.

 

DBP- Fortescue River Gas Pipeline- Pipeline and Facilities MDR Validation

Sustech performed the independent 3rd party verification of the 277 km natural gas pipeline lateral and its facilities’ Manufacturer’s Data Records (MDR). The facilities include Hot Tap, Metering Station, Pig Launcher- Receiver, Main Line Valve, Pressure Reduction, Heating and Custody Transfer. The goal of the validation was to perform an independent multi-disciplinary desktop review of the MDR documents within the ambit of AS2885 under the WA Petroleum Act 1969. Sustech completed diligent review, maintained detailed verification records, raised queries with constructor for clarification and closed queries to satisfaction. Sustech issued a report for the safety-integrity of the installation and a fit for purpose pipeline and facilities. The report was be submitted to the regulator.

 

DBP Wheatstone-Ashburton-CS2 Gas Pipeline and Facilities MDR Validation

Sustech performed the independent 3rd party verification of the 100 km natural gas pipeline lateral and its facilities’ MDR. The goal of the verification was to complete an independent desktop review of the MDR documents within the ambit of AS2885 under the WA Petroleum Act 1969. Sustech has done a diligent review, maintained detailed verification records, raised queries with constructor for clarification, closed queries to satisfaction. Sustech issued the report for safety-integrity of the installation and a fit for purpose pipeline and facilities. The report was submitted to the regulator.

 

 

 

DBP -GGPI Metering Station- Upgrade and Interconnecting Gas Pipeline MDR Validation

Sustech performed the independent 3rd party MDR verification of the existing Gorgon gas metering station upgrade and the interconnecting natural gas pipeline. The goal of the verification was to complete an independent desktop review of the MDR documents within the ambit of AS2885 under the WA Petroleum Act 1969.

 

 

 

NBG –Review of Water Distribution System

Sustech was engaged to review the report and calculations done by the owner’s other consultant and provide suggestions on the recommendations to solve the problems faced in the water distribution network. The system involved different pressure, flow requirements at different points. Material of construction was different. This is an important utility service for the mine. Sustech executed the role of owner’s engineer to the best interest of the client.

 

 

APA Group- South Hedland Gas Metering Station -Design Verification – Mechanical Verification

Sustech performed the independent 3rd party verification of Mechanical/Piping portion and total job management of the natural gas metering station for a lateral as a sub consultant. The goal of the verification was to do an independent desktop review of the construction documents and records within the ambit of AS2885 under the WA Petroleum Act 1969. Sustech maintained detailed verification records, raised queries with the client for clarification and closed queries satisfactorily. Sustech contributed in issuing a report for safe operation and a fit for purpose facility. The report was submitted to the regulator.

 

APA Group- Boonamichi Gas Metering Station -MDR Verification – Mechanical MDR verification

Sustech completed an independent 3rd party verification of Mechanical/Piping portion and total job management of this natural gas metering station for a lateral as a sub-consultant. The goal of the verification was to complete and submit an independent desktop review of the design documentation, within the ambit of AS2885 under the WA Petroleum Act 1969. Sustech performed a diligent review, maintained detailed verification records, raised queries with the designers for clarification and closed queries satisfactorily. Sustech contributed in issuing a report for safe operation and a fit for purpose facility. The report was submitted to the regulator.

 

Yara Consumer Gas Piping & Reformer Burner Efficiency Enhancement Regulatory Approval

Yara was replacing the existing burners for enhancing the thermal efficiency of the reformer. Sustech was engaged by Yara to assess the extent of changes of the burners being replaced in light of the gas act 1972 and engage qualified gas inspectors and gas fitters and co-ordinate with Energy Safety via gas inspector and obtain the approval for operation of the reformer. Also Sustech engaged Energy Safety certified gas fitter for supervising all gas fitting work in the consumer piping witnessing leak tests and working closely with Yara commissioning team, gas fitter and gas inspector to ensure a safe and regulator approved gas piping system inside Yara plant.

 

Australian Marine Complex-Henderson – Pontoon Dry Dock FRP Piping Analysis and Detail Design of Brownfield Modification

Wenco had been awarded to replace valves in the seawater suction and discharge FRP piping system inside the pontoon floating decks at Australian Marine Complex, Henderson, WA. This needed using special couplings to join the FRP pipes and some butt and wrap joints. Sustech was engaged by Wenco to do the engineering drawings and pipe stress analysis and supports design and deliver the detail brownfield engineering. We visited the floating dock, entered the confined space, took pictures and dimensions and checked support feasibility inside the pontoon. We shall also look at the naval structure of the floating deck as relevant and deliver the design.

 

Yara H₂SO₄ piping – Karratha – Stress Analysis and Detail Design of Brownfield Modification

Wenco engaged Sustech Engineering to visit and site and perform a survey for the brownfield modification of the piping of the H₂SO₄ system. On a successful assessment and budgeting provided to Yara, Wenco was awarded the job and Sustech was in turn engaged to complete the piping design and pipe stress analysis and support design for the modification package for cooling tower dosing, storage, mixed bed exchangers etc. Sustech developed the design keeping the shutdown planning in mind to allow maximum prefabrication and minimum site work during the shutdown periods. Pipe stress analysis was performed in Caesar II for all possible scenarios and drawings were produced to the fabrication level.

 

Yara Pilbara Fertiliser- Karratha-Seawater Cooling and closed-circuit Freshwater cooling GRE Pipe Replacement and Refurbishment

Sustech was entrusted with the owner’s engineering role for developing the scope of work for detail engineering consultant, technical bid evaluation of manufacturer and installation contractor, managing/co-ordinating the total project, reviewing the design of the seawater cooling and freshwater cooling system of YPFL, providing D6 qualified inspectors. Glass Reinforced Epoxy (GRE) was chosen as the piping material with some pipes of GRVE. A flow analysis, stress analysis, construction feasibility was assessed for the new proposed piping system. Sustech was working on behalf of the owner to achieve a design that was safe, functional, code compliant and constructible and manage the project for the largest running Ammonia plant in Australia, whilst being commissionable within a very short turnaround time. Sustech helped YPFL to develop a scope of work for both supply and construction. A very carefully thought-out piping replacement and refurbishment procedure with minimum or no disruption to operation was the challenge. The empathetic understanding and efficient managing of the agencies from multi-country and directing to the common goal was the key to success. Project was completed ahead of time and commissioned successfully.

Alcoa-Specialised Welding Australia Boiler Attemperator Design

Specialised Welding Australia engaged Sustech Engineering to design the Alcoa boiler attemperator vessel including the shell (waterside); and the steam side tubebundles, tubesheet, steam header box; all nozzles as per AS1228; and internal and external supporting arrangements. Sustech has done the design with in-house spreadsheets, checked special components subjected to differential external pressure by FEA, got the design third party verified and helped in the registration of the vessel with Worksafe.

 

 

Wenco-Woodside Domestic Fuel Supply Project – FRP Fire Water Piping Engineering and Pipe Stress Analysis

Sustech was engaged by Wenco to design and perform stress analysis for the fire water system involving the buried FRP piping for the fire water mains, installed for the Woodside Pluto domestic gas supply project. Sustech is a niche player in the field of FRP piping engineering and pipe stress analysis with knowledge of NOV pipes and piping components as well as other manufacturers. FRP piping design and pipe stress analysis is very much a vendor entwined engineering process and Sustech has done that for Wenco numerous times and delivered the job correctly within the timeframe.

 

 

Yara-Wenco- Waste Water Discharge FRP Piping – Detail Design of Brownfield Modification

Yara put in a new waste water discharge line of RTRP material in their existing plant tied with its existing process. Wenco was engaged to design, build and install the plant with its equipment, piping and accessories. The piping material used was FRP Ameron Bondstrand 2400 series. Sustech developed the piping and civil design and engineering from project beginning for this brownfield modification by attending site visits, surveying and understanding client’s requirements and preferences and designing in accordance with ISO 14692, and AS codes. Sustech placed suitably skilled and experienced engineers and designers to perform the right engineering by Caesar II, STAAD PRO, SPACEGASS calculations and make the project a success.

 

Yara Fertiliser – Karratha- Waste Water Discharge System Engineering and Design

Sustech Engineering has been retained by Yara for engineering and designing a new waste water line from the existing sewage treatment plant to a brine line discharge. This complete engineering package involves pump sizing, pipe sizing, system process design, mechanical-piping detail design, electrical design as per available infrastructure, layout and route selection, making MTO, supporting procurement and construction. This is a fast track project for environmental compliance. Sustech is engaging senior professionals of the team for the timely and fit for purpose execution. 

 

 

Rio Tinto-Nammuldi Lube Storage – Pipe Stress Analysis in Caesar II of Engine Oil System

Sustech performed the pipe stress analysis of an engine oil system in CAESAR II together with tank, pump, supply end connections as a sub-consultant for Kerman. Sustech helped selecting supports and suggesting changes to special supports. All load cases were considered including wind and earthquake as per AS1170.2 and 1170.4 requirements. The analysis was performed in accordance with ASME B31.3.

 

 

Yara-Wenco-Fire Water Piping – Detail Design of Brownfield Modification to Hydrants & Pump Skids Interconnect

Yara extended its fire water network from existing hydrants to compressor stations and the related pump skids. The design, engineering, supply and installation of the fire water line with its accessories from the existing hydrants to the compressors was awarded to Wenco. Sustech developed the piping, pipe support, structural and civil design and engineering including the pump foundation design from startup for this brownfield modification. Sustech attended site visits, conducted surveys to understand Yara’s requirements and preferences. The Sustech team is experienced and performed all stress analysis, structural analysis, foundation analysis and design for a fit for purpose design.

 

Double Walled Portable Tank Design 

Sustech has developed a proprietary double walled self-containing tank design for diesel storage as per AS1692 and UL142. The design has been developed and all engineering calculations done to satisfy the Australian codes and regulatory requirements. This is a portable type of tank suitable for mine sites or camp sites. This is a modular design scalable to required storage volume requirements. The ergonomics, safety, operability fabrication cost savings, transportability has been optimised in the design. 

 

 

Geraldton Port Berth 4 Shiploader MCC room Transportable Structure – Structural design analysis and calculation for transportable MCC room

Sustech designed the transportable MCC room that was installed at Geraldton port, on the Shiploader located at Berth 4 as a subconsultant. Sustech analysed the building and included all major structural members and light sections using STAAD Pro. This included all types of probable loads, including; transportation loads, wind loads, shiploader movement loads and equipment loads. Calculations were performed as per Australian Standards to satisfy all regulatory requirements. The serviceability of the equipment was considered while selecting members. All connection details were calculated and provided for shop fabrication.

 

 

Cal Energy Wellhead Manifold -Skid-Offshore- Structural Design- Analysis and Fabrication Drawings

Sustech’s structural engineer and designer performed the calculations and drawings for the wellhead platforms, manifold skid, console frame within a fast turnaround period, beyond regular working hours. The criticality of the project was achieved through a conforming arrangement with the piping engineer, a design based on the availability of materials, with close co-ordination with the fabrication team under an activity in the highly critical path of the schedule.

 

 

 

H.I Fraser Group-Visy Smithfield-PSV Sizing Calculation & High-Level Process Review

HI Fraser designed and manufactured a natural gas pressure reduction skid for the Visy Smithfield NSW Facility. HIF engaged Sustech to do a high-level process review and perform a sizing calculation for the PSV installed in a skid as per API and Australian Standards. Sustech reviewed the likely overpressure scenarios, identified relevant process parameters and performed process calculations to accurately determine the adequacy of the PSV’s selected for each gas and water system of the shell and tube heat exchanger designed to AS1210. The work was completed with little notice and within a small timeframe, as the skid was already at site. The customer took Sustech findings on board and incorporated the calculation and review records.

Wenco-Perth- Workshop retaining wall – Detail design of brownfield modification

Wenco modified its workshop to optimise its space usage. Sustech designed a retaining wall to claim level space that can be used for workshop related work. The design was developed based on client requirements and considered soil pressure and all other relevant forces. The design was backed up by proper Space Gass calculations certified by a Chartered Engineer that was submitted to the local council.

 

 

M-I Australia Drilling Fluid Transfer Pipeline to Dampier Cargo Wharf – Project Management and Pipeline Design

Sustech was engaged as the project manager and the mechanical piping/pipeline consultant for this project in the form of a sub-consultant. The project involved a site visit for routing a pipeline and was a communication intensive project which Sustech handled skilfully. The fluids handled varied from slurry to hydrocarbons that involved adherence to different codes and standards. The range of materials considered for construction varied from carbon steel to duplex to GRE. All engineering disciplines were involved due to the variety of skills needed. The design team had people from Brisbane, Sydney and Perth. The engineering was done from scratch, as was the pipeline route selection. The route went under the wharf and was a combined land and marine pipeline. Accurate determination of Pipeline pressure was the most challenging aspect of the project, as different vessels came with different pumping capabilities. The pipeline route had an interface with other facility owners and other projects on the barge. This was a project full of challenges and Sustech overcame these and executed the project to the client’s satisfaction.

Conoco Phillips- Darwin LNG Nitrogen bypass line – Project Management Piping Engineering

Sustech was engaged as the project manager and mechanical-piping consultant for this brownfield modification project in the existing LNG plant as a sub-consultant. A bypass for the Nitrogen system was designed in a level of detail that the client could procure and install. After a site visit for both information and data collection, all the necessary calculations were done, datasheet were produced; isometric and instrumentation drawings and documents were produced – ready to use for installation; design, constructability and safety reviews were conducted. The project was delivered within the allocated timeframe, to fit into the shutdown schedule of the plant.

 

Yara Fertiliser – GRE Pipe Stress Analysis and Piping Engineering of Sea Water and Desalination System

For this project, Sustech contributed to the modifications of the existing system to suit the tying in needs with a new installation as a sub-consultant.  Sustech performed the pipe stress analysis of the existing GRE piping system and the modification work in CAESAR II and used inhouse software to ensure the installation was compliant with ISO 146920, in adherence with AS1170.2 and 1170.4 requirements. Sustech suggested changes to the existing piping support system to suit the proposed modification. Sustech designed an additional support for the modification as well as providing the footing design. Sustech also prepared fabrication isometric drawings with MTO.

 

Project Management – Underground and Aboveground Sea Cooling Water Service GRE, GRVE Pipe Assessment, Remediation Design, Refurbishment, Replacement Project Management for Yara Pilbara Fertiliser 

Project Management – Underground and Aboveground All Services GRE, GRVE Pipe Assessment, Remediation Design, Refurbishment, Replacement Project Management for Yara Pilbara Nitrates 

Project Management – Nursing Home Building for Aged Care Facilities 

Yara Pilbara – Ammonia Reformer Steam Coil, Hot Process Air Coil and Piping Life Extension Solutions

During a regular planned shutdown the client noticed distortions in the steam coils and displacement of coil headers. At high temperatures and pressures the coils were subjected to creep and fatigue. Metallurgical and NDT inspections done by Yara showed the remaining life of steam coils have reduced than original design life but still good to go for some years. Sustech was engaged by Yara to find the reason of the damage and suggest means of improvement to slow down the reduction. We did a site visit with the client’s maintenance engineer to do the initial visual assessment of the coil and header condition. We understood that the internal coil design of the reformer is not being able to withstand   the piping loads from the reformer external piping. We did pipe stress analysis of the coil connected steam piping to find solutions to ease the loads on the coil header. The high stress levels and distortions in the coils were reducing the remaining life. The solution was restricted to no piping layout change as that would delay the start up and result in huge loss of production and revenue. So we focused on the support modifications and releasing loads on the steam header. We designed new supports and selected new springs modified existing supports and provided solutions to stop accelerated remaining life reduction of the steam coils and headers. We did similar exercise for Hot process air in the same ammonia reformer. Lines are connected to secondary reformers also.

Yara Pilbara – Steam Turbine Shaft Misalignment Solution

During regular operation, the back-pressure steam turbine was tripping occasionally due to shaft misalignment. Further observations revealed that the turbine exhaust nozzle flange was having uplift and parallelity issues. The root cause was assessed to be the turbine exhaust steam piping configuration. The piping during the operating condition was pushing the exhaust nozzle up and tilting it, thus creating the turbine shaft misalignment. We did the pipe stress analysis of the line to simulate the situation and understand the problem. The layout was stiff and not qualifying the NEMA SM23 allowable loads at the exhaust nozzle. We provided a total solution with in line pressure balance expansion bellows to qualify the loads. But as the start up of the turbine was due in short time, so we had to come up with an in-service solution which could be implemented while in operation. We changed springs and modified supporting arrangements to provide for solutions to stop turbine flange lifting and tilting and stopped it from tripping.

Yara Pilbara – Synthetic Gas Piping Stress Analysis and Support Spring Replacement

The synthetic gas piping from gas heater to the ammonia converter had issues of non-functioning spring, cumbersome operating procedure of shimming rest supports at the start up, and high loads at equipment nozzles. Sustech was engaged by Yara to address the issues and suggest new springs. Sustech stress analysed the line suggested modified supporting arrangements and new springs to reduce loads at nozzles and get rid of shimming at the rest supports.

 

 

 

 

Chevron Pipe Stress and Finite Element Analysis of Propane Kettles Trunnion Temporary Supports 

EDG engaged Sustech Engineering for FEA and Pipe Stress Analysis of Propane Kettle connected DN500 and DN400 lines of Chevron Gorgon LNG plant. Sustech performed stress analysis using Caesar II considering increased slug loadings & heavy loadings of higher sized valves. Due to limitation of welding a temporary solution was planned till next shutdown. A temporary support next to the existing trunnion was provided to distribute the loads. The temporary support suggested was a special clamped shoe taking the vertical load and the existing trunnion will be taking care of the axial load. In order to confirm the integrity of the suggested support arrangement, FEA was performed using NozzlePRO on the Trunnion that has to withstand heavy axial load and special clamped support which is subjected to vertical and guide loads for Normal , Maximum Design and Upset Temperature conditions. The suggested design was meeting the codes and standards 

 

OGDCL -Fired Heater Tubes Fitness for Service Assessment – Mechanical analysis for fired heater tubes and advise on safety of equipment and start up

The client was on a shutdown and had concerns about starting up a fired heater because the wall thickness of the tubes had significant metal loss. Sustech did API579 Fitness for service assessment calculations and API 530 calculations and looked at other NDT test results to advise OGDCL for a safe start up but under a constant monitoring regime of fitness for service. This enabled OGDCL to come out of the shutdown without major delay and loss of production.

 

 

Nickel West Structural Integrity-Kwinana – Engineering Support for Structural Integrity Remedial Work

Nickel west had performed a preliminary integrity assessment of their aging plant structures and provided a package to Wenco to execute the suitable modification and integrity work. Sustech was engaged by Wenco to do detail integrity assessment of individual members, perform necessary calculations and develop the work method statements for each workpack. Sustech analysed the structures, inspecting and assessing the condition and suggesting the work for the field crew.

 

BHPB-Nickel West – HAZOP Facilitation

The goal for this project was to reduce the loss of energy by blowing off steam. Sustech was engaged as the facilitator of the HAZOP workshop for this design. Sustech organised and ran the workshop involving the client’s process engineer, the operations and maintenance representative, the designer of the project, the project manager and the safety representative. All probable hazards and operability issues were discussed and captured in the company format. A HAZOP report was issued.

 

 

BHP Iron Ore-Yandi Site–Condition Monitoring

Sustech provided data collection and analysis support for BHP’s Yandi site on subcontract for stationary rotating equipment condition monitoring.  Sustech performed vibrational analysis, reviewed oil reports, raised maintenance notifications, performed weld thickness testing and maintenance. The prompt capable support was appreciated by the client.

 

 

CSBP-Kwinana-Condition Monitoring

Sustech is providing support to CSBP for data collection and analysing of stationary rotating equipment for CSBP’s condition monitoring programme. Sustech aims to continue to improve the accuracy of remaining life prediction through improved awareness of the machine dynamics. The proficient experienced service is acknowledged by CSBP.

 

 

Yara Fertiliser – GRE pipe Incident Root Cause Analysis

Sustech was part of the expert team engaged in the initial root cause analysis study of the incident in the cooling water system as a sub-consultant. The pipes were constructed of GRE material with a buried and above ground combined installation. Sustech contributed to paving the way for a detailed pipe stress analysis, utility process and GRE material study and writing of the report identifying the root cause.

 

 

Cape PLC – Assessing Design and Construction of Structure and Engineer Retrofitting Design

Sustech was entrusted to find out the suitability of the industrial structure in a cyclonic region. This was an emergency job. Sustech immediately flew to site and assessed every aspect of the buildings from a strength point of view. Sustech provided the client with an immediate action plan to keep the structure safe in case of a cyclone. Sustech performed the engineering to make the building fit for purpose. This involved several retrofitting works at site. The engineering and design needed careful attention to ensure the existing functionalities and integrity are kept intact. Checks were completed to maintain that no new risks are brought into the installation.

Yara Syngas-Converter Rail-Anchor Bolt and Concrete Assessment 

Anchor bolts used to fix the rails on which the ammonia syngas converter head runs were corroded. New replacement bolt holes were drilled by maintenance contractor in the concrete. Sustech assessed and analysed the damage that happened on the reinforcement of the concrete and advised future course of action. 

 

 

 

 

Yara Pilbara Nitrate – Underground FRP Fire water Main Analysis and Assessment 

Sustech was entrusted to find out the reason of failure of underground large diameter fire water mains and suggest remedial action. Yara Pilbara Nitrate is a running plant and the solution was needed fast to minimise the downtime. Sustech collected the information about the existing installation and the failure history. Contacted vendors for proper MDR inputs. Simulated the conditions through pipe stress analysis. Worked out the right fittings parameters and soil conditions and supporting arrangement needed. The report with site instructions and methodology was provided for the contractor. The piping system is running right with the remedies executed. Sustech feels a sense of achievement by solving these odd problems and helping the client. 

 

NBG – Hydraulic Cylinder Mounting Bolt Troubleshooting

In this project Sustech dealt with a problem of a hydraulic cylinder mounting bolt. Sustech collected information from the client about the problem, defined the problem, reviewed all the reports suggested by its consultants. Sustech performed recalculations from the collected data and provided a viable solution. It worked, and the client saved a lot of money in terms of lost time.

 

 

Chevron Propane Kettle Piping Stress Analysis and Support FEA 

Sustech Engineering has been engaged by EDG for performing pipe stress analysis in Caesar II of Propane Kettle Piping after splitting supports types from single location to two adjacent locations and confirm the integrity of the system and local stresses by FEA by Nozzle Pro. The goal of this exercise to provide a safe solution  without hotwork on the pipe to avoid any shutdown. This is a fast track project in the critical path of plant operations and maintenance. Sustech is engaging senior professionals of the team for the timely and fit for purpose execution. 

 

 

Rio Tinto –Paraburdoo- Design of temporary structures for Gas Turbine Generator rotor pull out & Maintenance

Sustech was entrusted to design and check the safety and integrity and functionality of the modification performed in the temporary structure used for pulling and resting GTG rotors for maintenance. Sustech immediately flew to site and executed the job in record low time. Sustech co-ordinated with the site team round the clock to ensure that the suggested changes happen before the shutdown. Sustech issued the design and was signed off by our CP Engg. It is our aim to deliver efficiently to clients in their time of need. The client appreciated our efforts and rewarded us with a recommendation letter.

 

BHPB-Jimblebar Diesel Tank-Structural Risk Review, Structural Analysis and Verification of Temporary Structure

The client engaged Sustech to perform a maintenance job for a API12B tank. Sustech as a sub-consultant, analysed the tank structurally from both a serviceability aspect and from an ultimate limit state angle, to determine the stability of the tank without the central pole. Sustech calculated and advised on the requirement for further temporary supports for tank roof stability.

 

 

BHPB-Yarnima-Diesel Tank Construction Temporary Structure Analysis

Kerman wanted to do some maintenance job in an API12B tank. Sustech was engaged as a sub-consultant, analysed the tank structurally from serviceability aspect and also from an ultimate limit state angle to find out the stability of the tank without the central pole. Sustech calculated and advised on the requirements for further temporary supports for the tank roof stability.

 

Glencore Murin Murin – Steam Line Clamp 

Sustech was engaged by Taylors Engineering for designing and analysing a clamping system for a cracked drain pot line, which was at the verge of leaking. Sustech analysed the clamping arrangement through FEA to stop any leak and stress analysed the steamline to suggest new supporting system to stop further future deterioration of the steam line. The clamping system was out of the ordinary and tailor made to help the client perform live installation safely. We took pride in our prompt action in the matter for this running plant.

 

 

Anaconda Nickel Murin Murin – Steam Line Flange Clamp 

Sustech was engaged by Taylors Engineering for designing and analysing a clamping system for a leaking steam flange. Sustech analysed the clamping arrangement through FEA to stop any further leakage, taking care of the all the failure modes and avoid further future deterioration of the steam line. The clamping system was out of the ordinary and tailor made to help the client perform live installation safely. We took pride in our prompt action in this asset integrity design engineering work for this running plant.  

 

 

Anaconda Nickel Murin Murin – Sheared Air Line Clamp 

Sustech was engaged by Taylors Welding and Engineering for designing and analysing a clamping system for a broken sheared pressurised air line elbow joint. Sustech analysed the clamping arrangement through FEA taking care of the all the failure modes and putting together the line to functioning state. The clamping system was fit for purpose and tailor made to help the client perform live installation safely. We got appreciation for innovative solution and prompt action in this operation-maintenance work in resuming full service of the running plant. 

 

 

Yarra  – Sea water FRP pipe support design – Detail Design of Brownfield Remedial Modification

Sustech was engaged by Wenco to suggest and design a support for the large diameter sea water line. The pipe material was GRE. Sustech collected the information regarding the broader picture, assessed operating modes and conditions, suggested client the way forward and designed and engineered the special support for the retrofitted design to client’s requirement. An engineering analysis was performed for the pipe support with all possible load combinations. Detail shop drawing was developed for the ease of fabrication.

 

Cristal – Lifting ring-lug design solution and FEA 

Sustech was engaged by Taylors Welding and Engineering to provide design engineering solution and for lifting an installed pressure vessel and analysing the arrangement of lifting ring and lug to ensure integrity and safety during the lift. Sustech assessed the vessel and discussed the lifting methodology with Taylor came up with a fit for purpose solution to suit the lifting crew, designed and engineered the special arrangement. An FEA engineering analysis was performed for the lifting ring-lug considering all possible failure modes. 

 

Tronox – Maintenance solution with custom made pipe clamp – Design and FEA 

Sustech was engaged by Taylors Welding and Engineering to provide design engineering solution for containing a pipe. The conveyed fluid was hazardous so hotwork had to be avoided. Sustech worked with the Taylor team to work out a on-field solution that can be employed online. Sustech’s experienced  engineers assessed pipe, its operating conditions, materials, fluid, configuration and came up with a fit for purpose custom-made clamp solution, designed and engineered the special clamp. An FEA analysis was performed for the clamps defining the imposing loads to check the integrity. Detail shop drawing was developed for the ease of fabrication. 

 

Yara-Karratha- FRP & HDPE Sea Water Lines – Detail design of brownfield modification

Yara planned to put a chlorination plant in a suitable spot in its existing plant for water treatment purposes tied with its existing process. Wenco was asked to design, build and install the plant with its equipment, piping and accessories. The piping material is FRP and HDPE carrying sea water. Sustech developed the plant and piping design from startup for this brownfield modification by attending site visits and understanding client’s requirements and preferences. Sustech put experienced personnel and appropriate resources to make it a success.

 

 

Wenco-Perth-Rubber-lined pipe- Fabrication detail drawing

Wenco was given the fabrication order for rubber lined pipes for mining operations requirement. Sustech used its experience and knowledge of rubber lined piping in both the water industry and mining industry to produce the drawings in a fast turnaround period.

 

 

 

Roy Hill-Newman- Electrical Drawings – As Built Modification of Electrical Drawings of Roy Hill Project

Sustech updated the “As Built” marked ups in the final version of the Electrical single line diagrams, cable schedules and layouts. Sustech used its low cost overseas centres for its main drafting work with some application of design, engineering, and site knowledge. Sustech was given little notice with a fast approaching project deadline. Communication was the key factor which Sustech successfully established and exercised, to ensure a smooth and timely delivery.

 

 

BHPB-Nickel West Flash Tank – FRP Flooring and Walling – Structural Design-Drafting

Sustech participated in a joint site survey with the owner and defined the scope of work for the brownfield modification work as a sub-consultant. Sustech ran a design selection session for the optimum path for fabrication and performed necessary structural calculations. Sustech developed a 3D model of the FRP flooring and wall of different levels of the flash tank adjacent structure. Sustech got client agreement and developed detailed fabrication drawings and MTO for shopfloor fabrication and installation by Wenco.

 

Sustech has provided short and long-term support to clients by seconding highly capable and experienced engineers across a range of roles including; Owner’s Engineer, Project Engineers, Design Engineers, Field services & Inspection Engineers, Piping Specialists, piping project supervisor, ISO 14692 D6 qualified FRP pipe inspector, condition monitoring specialist and condition monitoring data collectors. Sustech secondment varies across a range of resource industries.

DDGT- Tubridgi Gas Storage Facilities- Design & MDR Validation

Sustech was engaged by DDGT to provide an independent 3rd party verification of design of the 42 PJ Tubridgi gas storage facility which is the largest in WA. The project involves multiple injection and recovery wells, wellhead filtration, flowlines, slug catcher, two stage two trains compressor station, gas processing facilities, dehydration, regeneration, hot oil system, mercury removal, metering stations, pipelines, pig launching and receiving facilities. The goal of the verification was to perform an independent desktop review of the design documents, that will ensure accordance with AS2885 and ASME B31.3 under the WA Petroleum Act 1969 and prodcution license. The project also involved the use of relifed mothballed vessels under AS3788 and API579. Sustech performed a diligent review, maintaining detailed verification records, raising and closing queries to satisfaction and noting obervations that may not affect the integrity of the project but could lead to uncontrolled hazards. Sustech issued a report for the safety-integrity of the design and MDR for a fit for purpose gas storage and processing facility. The report was submitted to the regulator.

AGIG-Pluto Compressor Station and Metering Station-Facilities Design & MDR Validation

Sustech is currently undertaking the independent 3rd party verification of the Pluto interconnect compressor station, metering station, pig launcher at the pipeline and facility transition for its design and MDR. The goal of the verification is to perform an independent desktop review of the design documents within the ambit of AS2885 under the WA Petroleum Act 1969. Sustech is performing a diligent review, maintaining detailed verification records, raising queries with the constructor for clarification and closing queries to satisfaction. Sustech is issuing a report for the safety-integrity of the design and a fitness for purpose for the facilities. The report will be submitted to the regulator.

 

AGIG-Tanami-Pipeline and Facilities Design & MDR Validation

Sustech is currently undertaking the independent 3rd party design and MDR verification of the 440 km Tanami natural gas pipeline, its scrapper stations and metering stations at the head and lateral ends. The goal of the verification is to perform an independent desktop review of the design and MDR documents under the regulations of DPIR of the Northern Territory as per Energy Pipelines act 2015 and Energy Pipelines Regulations 2015. Sustech has been engaged from the design review stage, attending HAZOP and Pipeline risk assessment workshops and keeping close contact with the operator and regulator and performing a diligent review, maintaining detailed verification records, raising queries with constructor for clarification, closing queries to satisfaction. Sustech is issuing a report for the safety-integrity of the design and a fit for purpose pipeline and facilities. The report will be submitted to the NT regulator.

YPFL-Karratha-Seawater Supply and Desalination Plant Technical Due Diligence Study

Sustech was engaged by YPFL to conduct a technical due diligence study of an existing seawater supply system ~300MLD & desalination plant. The study results were essential for YPFL in taking investment decision and taking strategic policy decision. Sustech did a thorough job in assessing the technology, design, MDR, condition assessment reports, incident reports, failure reports, equipment fitness certificates, maintenance records, operational history, OPEX and CAPEX/ Project OPEX spent by operator. Sustech’s engineers visited site, assessed asset conditions analysed the records and submitted a conclusive report that was well received by the client.

 

GDF Suez-Crondall Energy – FLNG Mechanical and Piping Design Basis and Scope of Work Review

As an independent reviewer, Sustech was entrusted by Crondall to review the mechanical and piping section from the Basis of design for a 4 Mtpa floating LNG developed by another consultant of the owner. Sustech referred to the following documentation: owners requirements, key decision logs, site data, project philosophies, owner’s company guidelines to review the basis of design to identify the anomalies, deficiencies and advise functional sufficiency, safety points and improvement scopes to make the document as robust as possible to develop a proper FEED design. Sustech reviewed the scope of work on the basis of these documents to provide the FEED contractor with a clear understanding of the work.

 

UGL-Santos Sole Gas Project – Process Design ReviewSustech was appointed by the construction company, UGL as the independent reviewer of the process design of the Sole Gas project which is upcoming. The design house Jacobs was the designer who prepared the design for UGL. The process design and the technology selected was innovative and required highly skilled and experienced process engineers to look through the functionality, safety and fitness for purpose. Sustech reviewed all key process engineering deliverables like Process Flow Diagrams / Block flow diagrams / Heat & Mass Balance Diagrams / PIDs / Basis of Design data sheets / Performance guarantees / equipment selections / hydraulics / flare sizing / cause & effect charts / specifications / and data sheets. Sustech prepared the list of queries for the area of concerns; identified the risks associated with the process design; prepared the risk matrix (for the identified process risks) and provide suggestions to mitigate the risks; reviewed and confirmed the process guarantee parameters to meet the contract requirements. Sustech also highlighted if there were any issues in meeting the performance guarantees; identified the list of opportunities to improve the design to reduce both time and cost; prepared a consolidated report on the findings / remarks / recommendations / risks. Sustech’s engineering team with special expertise and a combined experience of over 100yrs completed the job and earned kudos from both Jacobs and Santos.

DBP- Ashburton to Onslow Gas Pipeline- Pipeline and Facilities Design Validation

Sustech performed the independent 3rd party verification of the 123 km natural gas pipeline lateral and its facilities’ MDR. The goal of the verification was to do an independent desktop review of the design documents within the ambit of AS2885 under the WA Petroleum Act 1969. Sustech undertook a diligent review, whilst maintaining detailed verification records, raised queries with the constructor for clarification and closed queries to satisfaction. Sustech issued a report for safety-integrity of the design and a fit for purpose pipeline and facilities. The report was submitted to the regulator.

 

DBP- Fortescue River Gas Pipeline- Pipeline and Facilities MDR Validation

Sustech performed the independent 3rd party verification of the 277 km natural gas pipeline lateral and its facilities’ Manufacturer’s Data Records (MDR). The facilities include Hot Tap, Metering Station, Pig Launcher- Receiver, Main Line Valve, Pressure Reduction, Heating and Custody Transfer. The goal of the validation was to perform an independent multi-disciplinary desktop review of the MDR documents within the ambit of AS2885 under the WA Petroleum Act 1969. Sustech completed diligent review, maintained detailed verification records, raised queries with constructor for clarification and closed queries to satisfaction. Sustech issued a report for the safety-integrity of the installation and a fit for purpose pipeline and facilities. The report was be submitted to the regulator.

 

DBP Wheatstone-Ashburton-CS2 Gas Pipeline and Facilities MDR Validation

Sustech performed the independent 3rd party verification of the 100 km natural gas pipeline lateral and its facilities’ MDR. The goal of the verification was to complete an independent desktop review of the MDR documents within the ambit of AS2885 under the WA Petroleum Act 1969. Sustech has done a diligent review, maintained detailed verification records, raised queries with constructor for clarification, closed queries to satisfaction. Sustech issued the report for safety-integrity of the installation and a fit for purpose pipeline and facilities. The report was submitted to the regulator.

 

 

 

DBP -GGPI Metering Station- Upgrade and Interconnecting Gas Pipeline MDR Validation

Sustech performed the independent 3rd party MDR verification of the existing Gorgon gas metering station upgrade and the interconnecting natural gas pipeline. The goal of the verification was to complete an independent desktop review of the MDR documents within the ambit of AS2885 under the WA Petroleum Act 1969.

 

 

NBG –Review of Water Distribution System

Sustech was engaged to review the report and calculations done by the owner’s other consultant and provide suggestions on the recommendations to solve the problems faced in the water distribution network. The system involved different pressure, flow requirements at different points. Material of construction was different. This is an important utility service for the mine. Sustech executed the role of owner’s engineer to the best interest of the client.

APA Group- South Hedland Gas Metering Station -Design Verification – Mechanical Verification

Sustech performed the independent 3rd party verification of Mechanical/Piping portion and total job management of the natural gas metering station for a lateral as a sub consultant. The goal of the verification was to do an independent desktop review of the construction documents and records within the ambit of AS2885 under the WA Petroleum Act 1969. Sustech maintained detailed verification records, raised queries with the client for clarification and closed queries satisfactorily. Sustech contributed in issuing a report for safe operation and a fit for purpose facility. The report was submitted to the regulator.

 

APA Group- Boonamichi Gas Metering Station -MDR Verification – Mechanical MDR verification

Sustech completed an independent 3rd party verification of Mechanical/Piping portion and total job management of this natural gas metering station for a lateral as a sub-consultant. The goal of the verification was to complete and submit an independent desktop review of the design documentation, within the ambit of AS2885 under the WA Petroleum Act 1969. Sustech performed a diligent review, maintained detailed verification records, raised queries with the designers for clarification and closed queries satisfactorily. Sustech contributed in issuing a report for safe operation and a fit for purpose facility. The report was submitted to the regulator.

 

Yara Consumer Gas Piping & Reformer Burner Efficiency Enhancement Regulatory Approval

Yara was replacing the existing burners for enhancing the thermal efficiency of the reformer. Sustech was engaged by Yara to assess the extent of changes of the burners being replaced in light of the gas act 1972 and engage qualified gas inspectors and gas fitters and co-ordinate with Energy Safety via gas inspector and obtain the approval for operation of the reformer. Also Sustech engaged Energy Safety certified gas fitter for supervising all gas fitting work in the consumer piping witnessing leak tests and working closely with Yara commissioning team, gas fitter and gas inspector to ensure a safe and regulator approved gas piping system inside Yara plant.

Australian Marine Complex-Henderson – Pontoon Dry Dock FRP Piping Analysis and Detail Design of Brownfield Modification

Wenco had been awarded to replace valves in the seawater suction and discharge FRP piping system inside the pontoon floating decks at Australian Marine Complex, Henderson, WA. This needed using special couplings to join the FRP pipes and some butt and wrap joints. Sustech was engaged by Wenco to do the engineering drawings and pipe stress analysis and supports design and deliver the detail brownfield engineering. We visited the floating dock, entered the confined space, took pictures and dimensions and checked support feasibility inside the pontoon. We shall also look at the naval structure of the floating deck as relevant and deliver the design.

 

Yara H₂SO₄ piping – Karratha – Stress Analysis and Detail Design of Brownfield Modification

Wenco engaged Sustech Engineering to visit and site and perform a survey for the brownfield modification of the piping of the H₂SO₄ system. On a successful assessment and budgeting provided to Yara, Wenco was awarded the job and Sustech was in turn engaged to complete the piping design and pipe stress analysis and support design for the modification package for cooling tower dosing, storage, mixed bed exchangers etc. Sustech developed the design keeping the shutdown planning in mind to allow maximum prefabrication and minimum site work during the shutdown periods. Pipe stress analysis was performed in Caesar II for all possible scenarios and drawings were produced to the fabrication level.

 

Yara Pilbara Fertiliser- Karratha-Seawater Cooling and closed-circuit Freshwater cooling GRE Pipe Replacement and Refurbishment

Sustech was entrusted with the owner’s engineering role for developing the scope of work for detail engineering consultant, technical bid evaluation of manufacturer and installation contractor, managing/co-ordinating the total project, reviewing the design of the seawater cooling and freshwater cooling system of YPFL, providing D6 qualified inspectors. Glass Reinforced Epoxy (GRE) was chosen as the piping material with some pipes of GRVE. A flow analysis, stress analysis, construction feasibility was assessed for the new proposed piping system. Sustech was working on behalf of the owner to achieve a design that was safe, functional, code compliant and constructible and manage the project for the largest running Ammonia plant in Australia, whilst being commissionable within a very short turnaround time. Sustech helped YPFL to develop a scope of work for both supply and construction. A very carefully thought-out piping replacement and refurbishment procedure with minimum or no disruption to operation was the challenge. The empathetic understanding and efficient managing of the agencies from multi-country and directing to the common goal was the key to success. Project was completed ahead of time and commissioned successfully.

Alcoa-Specialised Welding Australia Boiler Attemperator Design

Specialised Welding Australia engaged Sustech Engineering to design the Alcoa boiler attemperator vessel including the shell (waterside); and the steam side tubebundles, tubesheet, steam header box; all nozzles as per AS1228; and internal and external supporting arrangements. Sustech has done the design with in-house spreadsheets, checked special components subjected to differential external pressure by FEA, got the design third party verified and helped in the registration of the vessel with Worksafe.

 

 

Wenco-Woodside Domestic Fuel Supply Project – FRP Fire Water Piping Engineering and Pipe Stress Analysis

Sustech was engaged by Wenco to design and perform stress analysis for the fire water system involving the buried FRP piping for the fire water mains, installed for the Woodside Pluto domestic gas supply project. Sustech is a niche player in the field of FRP piping engineering and pipe stress analysis with knowledge of NOV pipes and piping components as well as other manufacturers. FRP piping design and pipe stress analysis is very much a vendor entwined engineering process and Sustech has done that for Wenco numerous times and delivered the job correctly within the timeframe.

 

 

Yara-Wenco- Waste Water Discharge FRP Piping – Detail Design of Brownfield Modification

Yara put in a new waste water discharge line of RTRP material in their existing plant tied with its existing process. Wenco was engaged to design, build and install the plant with its equipment, piping and accessories. The piping material used was FRP Ameron Bondstrand 2400 series. Sustech developed the piping and civil design and engineering from project beginning for this brownfield modification by attending site visits, surveying and understanding client’s requirements and preferences and designing in accordance with ISO 14692, and AS codes. Sustech placed suitably skilled and experienced engineers and designers to perform the right engineering by Caesar II, STAAD PRO, SPACEGASS calculations and make the project a success.

 

Yara Fertiliser – Karratha- Waste Water Discharge System Engineering and Design

Sustech Engineering has been retained by Yara for engineering and designing a new waste water line from the existing sewage treatment plant to a brine line discharge. This complete engineering package involves pump sizing, pipe sizing, system process design, mechanical-piping detail design, electrical design as per available infrastructure, layout and route selection, making MTO, supporting procurement and construction. This is a fast track project for environmental compliance. Sustech is engaging senior professionals of the team for the timely and fit for purpose execution. 

 

 

Rio Tinto-Nammuldi Lube Storage – Pipe Stress Analysis in Caesar II of Engine Oil System

Sustech performed the pipe stress analysis of an engine oil system in CAESAR II together with tank, pump, supply end connections as a sub-consultant for Kerman. Sustech helped selecting supports and suggesting changes to special supports. All load cases were considered including wind and earthquake as per AS1170.2 and 1170.4 requirements. The analysis was performed in accordance with ASME B31.3.

 

 

Yara-Wenco-Fire Water Piping – Detail Design of Brownfield Modification to Hydrants & Pump Skids Interconnect

Yara extended its fire water network from existing hydrants to compressor stations and the related pump skids. The design, engineering, supply and installation of the fire water line with its accessories from the existing hydrants to the compressors was awarded to Wenco. Sustech developed the piping, pipe support, structural and civil design and engineering including the pump foundation design from startup for this brownfield modification. Sustech attended site visits, conducted surveys to understand Yara’s requirements and preferences. The Sustech team is experienced and performed all stress analysis, structural analysis, foundation analysis and design for a fit for purpose design.

 

Double Walled Portable Tank Design 

Sustech has developed a proprietary double walled self-containing tank design for diesel storage as per AS1692 and UL142. The design has been developed and all engineering calculations done to satisfy the Australian codes and regulatory requirements. This is a portable type of tank suitable for mine sites or camp sites. This is a modular design scalable to required storage volume requirements. The ergonomics, safety, operability fabrication cost savings, transportability has been optimised in the design. 

 

 

Geraldton Port Berth 4 Shiploader MCC room Transportable Structure – Structural design analysis and calculation for transportable MCC room

Sustech designed the transportable MCC room that was installed at Geraldton port, on the Shiploader located at Berth 4 as a subconsultant. Sustech analysed the building and included all major structural members and light sections using STAAD Pro. This included all types of probable loads, including; transportation loads, wind loads, shiploader movement loads and equipment loads. Calculations were performed as per Australian Standards to satisfy all regulatory requirements. The serviceability of the equipment was considered while selecting members. All connection details were calculated and provided for shop fabrication.

 

 

Cal Energy Wellhead Manifold -Skid-Offshore- Structural Design- Analysis and Fabrication Drawings

Sustech’s structural engineer and designer performed the calculations and drawings for the wellhead platforms, manifold skid, console frame within a fast turnaround period, beyond regular working hours. The criticality of the project was achieved through a conforming arrangement with the piping engineer, a design based on the availability of materials, with close co-ordination with the fabrication team under an activity in the highly critical path of the schedule.

 

 

 

H.I Fraser Group-Visy Smithfield-PSV Sizing Calculation & High-Level Process Review

HI Fraser designed and manufactured a natural gas pressure reduction skid for the Visy Smithfield NSW Facility. HIF engaged Sustech to do a high-level process review and perform a sizing calculation for the PSV installed in a skid as per API and Australian Standards. Sustech reviewed the likely overpressure scenarios, identified relevant process parameters and performed process calculations to accurately determine the adequacy of the PSV’s selected for each gas and water system of the shell and tube heat exchanger designed to AS1210. The work was completed with little notice and within a small timeframe, as the skid was already at site. The customer took Sustech findings on board and incorporated the calculation and review records.

 

Wenco-Perth- Workshop retaining wall – Detail design of brownfield modification

Wenco modified its workshop to optimise its space usage. Sustech designed a retaining wall to claim level space that can be used for workshop related work. The design was developed based on client requirements and considered soil pressure and all other relevant forces. The design was backed up by proper Space Gass calculations certified by a Chartered Engineer that was submitted to the local council.

 

 

M-I Australia Drilling Fluid Transfer Pipeline to Dampier Cargo Wharf – Project Management and Pipeline Design

Sustech was engaged as the project manager and the mechanical piping/pipeline consultant for this project in the form of a sub-consultant. The project involved a site visit for routing a pipeline and was a communication intensive project which Sustech handled skilfully. The fluids handled varied from slurry to hydrocarbons that involved adherence to different codes and standards. The range of materials considered for construction varied from carbon steel to duplex to GRE. All engineering disciplines were involved due to the variety of skills needed. The design team had people from Brisbane, Sydney and Perth. The engineering was done from scratch, as was the pipeline route selection. The route went under the wharf and was a combined land and marine pipeline. Accurate determination of Pipeline pressure was the most challenging aspect of the project, as different vessels came with different pumping capabilities. The pipeline route had an interface with other facility owners and other projects on the barge. This was a project full of challenges and Sustech overcame these and executed the project to the client’s satisfaction.

Conoco Phillips- Darwin LNG Nitrogen bypass line – Project Management Piping Engineering

Sustech was engaged as the project manager and mechanical-piping consultant for this brownfield modification project in the existing LNG plant as a sub-consultant. A bypass for the Nitrogen system was designed in a level of detail that the client could procure and install. After a site visit for both information and data collection, all the necessary calculations were done, datasheet were produced; isometric and instrumentation drawings and documents were produced – ready to use for installation; design, constructability and safety reviews were conducted. The project was delivered within the allocated timeframe, to fit into the shutdown schedule of the plant.

 

Yara Fertiliser – GRE Pipe Stress Analysis and Piping Engineering of Sea Water and Desalination System

For this project, Sustech contributed to the modifications of the existing system to suit the tying in needs with a new installation as a sub-consultant.  Sustech performed the pipe stress analysis of the existing GRE piping system and the modification work in CAESAR II and used inhouse software to ensure the installation was compliant with ISO 146920, in adherence with AS1170.2 and 1170.4 requirements. Sustech suggested changes to the existing piping support system to suit the proposed modification. Sustech designed an additional support for the modification as well as providing the footing design. Sustech also prepared fabrication isometric drawings with MTO.

 

Project Management – Underground and Aboveground Sea Cooling Water Service GRE, GRVE Pipe Assessment, Remediation Design, Refurbishment, Replacement Project Management for Yara Pilbara Fertiliser 

Project Management – Underground and Aboveground All Services GRE, GRVE Pipe Assessment, Remediation Design, Refurbishment, Replacement Project Management for Yara Pilbara Nitrates 

Project Management – Nursing Home Building for Aged Care Facilities 

Yara Pilbara – Ammonia Reformer Steam Coil, Hot Process Air Coil and Piping Life Extension Solutions

During a regular planned shutdown the client noticed distortions in the steam coils and displacement of coil headers. At high temperatures and pressures the coils were subjected to creep and fatigue. Metallurgical and NDT inspections done by Yara showed the remaining life of steam coils have reduced than original design life but still good to go for some years. Sustech was engaged by Yara to find the reason of the damage and suggest means of improvement to slow down the reduction. We did a site visit with the client’s maintenance engineer to do the initial visual assessment of the coil and header condition. We understood that the internal coil design of the reformer is not being able to withstand   the piping loads from the reformer external piping. We did pipe stress analysis of the coil connected steam piping to find solutions to ease the loads on the coil header. The high stress levels and distortions in the coils were reducing the remaining life. The solution was restricted to no piping layout change as that would delay the start up and result in huge loss of production and revenue. So we focused on the support modifications and releasing loads on the steam header. We designed new supports and selected new springs modified existing supports and provided solutions to stop accelerated remaining life reduction of the steam coils and headers. We did similar exercise for Hot process air in the same ammonia reformer. Lines are connected to secondary reformers also.

Yara Pilbara – Steam Turbine Shaft Misalignment Solution

During regular operation, the back-pressure steam turbine was tripping occasionally due to shaft misalignment. Further observations revealed that the turbine exhaust nozzle flange was having uplift and parallelity issues. The root cause was assessed to be the turbine exhaust steam piping configuration. The piping during the operating condition was pushing the exhaust nozzle up and tilting it, thus creating the turbine shaft misalignment. We did the pipe stress analysis of the line to simulate the situation and understand the problem. The layout was stiff and not qualifying the NEMA SM23 allowable loads at the exhaust nozzle. We provided a total solution with in line pressure balance expansion bellows to qualify the loads. But as the start up of the turbine was due in short time, so we had to come up with an in-service solution which could be implemented while in operation. We changed springs and modified supporting arrangements to provide for solutions to stop turbine flange lifting and tilting and stopped it from tripping.

Yara Pilbara – Synthetic Gas Piping Stress Analysis and Support Spring Replacement

The synthetic gas piping from gas heater to the ammonia converter had issues of non-functioning spring, cumbersome operating procedure of shimming rest supports at the start up, and high loads at equipment nozzles. Sustech was engaged by Yara to address the issues and suggest new springs. Sustech stress analysed the line suggested modified supporting arrangements and new springs to reduce loads at nozzles and get rid of shimming at the rest supports.

 

 

 

 

Chevron Pipe Stress and Finite Element Analysis of Propane Kettles Trunnion Temporary Supports 

EDG engaged Sustech Engineering for FEA and Pipe Stress Analysis of Propane Kettle connected DN500 and DN400 lines of Chevron Gorgon LNG plant. Sustech performed stress analysis using Caesar II considering increased slug loadings & heavy loadings of higher sized valves. Due to limitation of welding a temporary solution was planned till next shutdown. A temporary support next to the existing trunnion was provided to distribute the loads. The temporary support suggested was a special clamped shoe taking the vertical load and the existing trunnion will be taking care of the axial load. In order to confirm the integrity of the suggested support arrangement, FEA was performed using NozzlePRO on the Trunnion that has to withstand heavy axial load and special clamped support which is subjected to vertical and guide loads for Normal , Maximum Design and Upset Temperature conditions. The suggested design was meeting the codes and standards 

 

OGDCL -Fired Heater Tubes Fitness for Service Assessment – Mechanical analysis for fired heater tubes and advise on safety of equipment and start up

The client was on a shutdown and had concerns about starting up a fired heater because the wall thickness of the tubes had significant metal loss. Sustech did API579 Fitness for service assessment calculations and API 530 calculations and looked at other NDT test results to advise OGDCL for a safe start up but under a constant monitoring regime of fitness for service. This enabled OGDCL to come out of the shutdown without major delay and loss of production.

 

 

Nickel West Structural Integrity-Kwinana – Engineering Support for Structural Integrity Remedial Work

Nickel west had performed a preliminary integrity assessment of their aging plant structures and provided a package to Wenco to execute the suitable modification and integrity work. Sustech was engaged by Wenco to do detail integrity assessment of individual members, perform necessary calculations and develop the work method statements for each workpack. Sustech analysed the structures, inspecting and assessing the condition and suggesting the work for the field crew.

 

BHPB-Nickel West – HAZOP Facilitation

The goal for this project was to reduce the loss of energy by blowing off steam. Sustech was engaged as the facilitator of the HAZOP workshop for this design. Sustech organised and ran the workshop involving the client’s process engineer, the operations and maintenance representative, the designer of the project, the project manager and the safety representative. All probable hazards and operability issues were discussed and captured in the company format. A HAZOP report was issued.

 

 

BHP Iron Ore-Yandi Site–Condition Monitoring

Sustech provided data collection and analysis support for BHP’s Yandi site on subcontract for stationary rotating equipment condition monitoring.  Sustech performed vibrational analysis, reviewed oil reports, raised maintenance notifications, performed weld thickness testing and maintenance. The prompt capable support was appreciated by the client.

 

 

CSBP-Kwinana-Condition Monitoring

Sustech is providing support to CSBP for data collection and analysing of stationary rotating equipment for CSBP’s condition monitoring programme. Sustech aims to continue to improve the accuracy of remaining life prediction through improved awareness of the machine dynamics. The proficient experienced service is acknowledged by CSBP.

Yara Fertiliser – GRE pipe Incident Root Cause Analysis

Sustech was part of the expert team engaged in the initial root cause analysis study of the incident in the cooling water system as a sub-consultant. The pipes were constructed of GRE material with a buried and above ground combined installation. Sustech contributed to paving the way for a detailed pipe stress analysis, utility process and GRE material study and writing of the report identifying the root cause.

 

 

Cape PLC – Assessing Design and Construction of Structure and Engineer Retrofitting Design

Sustech was entrusted to find out the suitability of the industrial structure in a cyclonic region. This was an emergency job. Sustech immediately flew to site and assessed every aspect of the buildings from a strength point of view. Sustech provided the client with an immediate action plan to keep the structure safe in case of a cyclone. Sustech performed the engineering to make the building fit for purpose. This involved several retrofitting works at site. The engineering and design needed careful attention to ensure the existing functionalities and integrity are kept intact. Checks were completed to maintain that no new risks are brought into the installation.

Yara Syngas-Converter Rail-Anchor Bolt and Concrete Assessment 

Anchor bolts used to fix the rails on which the ammonia syngas converter head runs were corroded. New replacement bolt holes were drilled by maintenance contractor in the concrete. Sustech assessed and analysed the damage that happened on the reinforcement of the concrete and advised future course of action. 

 

 

 

 

Yara Pilbara Nitrate – Underground FRP Fire water Main Analysis and Assessment 

Sustech was entrusted to find out the reason of failure of underground large diameter fire water mains and suggest remedial action. Yara Pilbara Nitrate is a running plant and the solution was needed fast to minimise the downtime. Sustech collected the information about the existing installation and the failure history. Contacted vendors for proper MDR inputs. Simulated the conditions through pipe stress analysis. Worked out the right fittings parameters and soil conditions and supporting arrangement needed. The report with site instructions and methodology was provided for the contractor. The piping system is running right with the remedies executed. Sustech feels a sense of achievement by solving these odd problems and helping the client. 

 

NBG – Hydraulic Cylinder Mounting Bolt Troubleshooting

In this project Sustech dealt with a problem of a hydraulic cylinder mounting bolt. Sustech collected information from the client about the problem, defined the problem, reviewed all the reports suggested by its consultants. Sustech performed recalculations from the collected data and provided a viable solution. It worked, and the client saved a lot of money in terms of lost time.

Chevron Propane Kettle Piping Stress Analysis and Support FEA 

Sustech Engineering has been engaged by EDG for performing pipe stress analysis in Caesar II of Propane Kettle Piping after splitting supports types from single location to two adjacent locations and confirm the integrity of the system and local stresses by FEA by Nozzle Pro. The goal of this exercise to provide a safe solution  without hotwork on the pipe to avoid any shutdown. This is a fast track project in the critical path of plant operations and maintenance. Sustech is engaging senior professionals of the team for the timely and fit for purpose execution. 

 

 

Rio Tinto –Paraburdoo- Design of temporary structures for Gas Turbine Generator rotor pull out & Maintenance

Sustech was entrusted to design and check the safety and integrity and functionality of the modification performed in the temporary structure used for pulling and resting GTG rotors for maintenance. Sustech immediately flew to site and executed the job in record low time. Sustech co-ordinated with the site team round the clock to ensure that the suggested changes happen before the shutdown. Sustech issued the design and was signed off by our CP Engg. It is our aim to deliver efficiently to clients in their time of need. The client appreciated our efforts and rewarded us with a recommendation letter.

 

BHPB-Jimblebar Diesel Tank-Structural Risk Review, Structural Analysis and Verification of Temporary Structure

The client engaged Sustech to perform a maintenance job for a API12B tank. Sustech as a sub-consultant, analysed the tank structurally from both a serviceability aspect and from an ultimate limit state angle, to determine the stability of the tank without the central pole. Sustech calculated and advised on the requirement for further temporary supports for tank roof stability.

 

 

BHPB-Yarnima-Diesel Tank Construction Temporary Structure Analysis

Kerman wanted to do some maintenance job in an API12B tank. Sustech was engaged as a sub-consultant, analysed the tank structurally from serviceability aspect and also from an ultimate limit state angle to find out the stability of the tank without the central pole. Sustech calculated and advised on the requirements for further temporary supports for the tank roof stability.

 

Glencore Murin Murin – Steam Line Clamp 

Sustech was engaged by Taylors Engineering for designing and analysing a clamping system for a cracked drain pot line, which was at the verge of leaking. Sustech analysed the clamping arrangement through FEA to stop any leak and stress analysed the steamline to suggest new supporting system to stop further future deterioration of the steam line. The clamping system was out of the ordinary and tailor made to help the client perform live installation safely. We took pride in our prompt action in the matter for this running plant.

 

 

Anaconda Nickel Murin Murin – Steam Line Flange Clamp 

Sustech was engaged by Taylors Engineering for designing and analysing a clamping system for a leaking steam flange. Sustech analysed the clamping arrangement through FEA to stop any further leakage, taking care of the all the failure modes and avoid further future deterioration of the steam line. The clamping system was out of the ordinary and tailor made to help the client perform live installation safely. We took pride in our prompt action in this asset integrity design engineering work for this running plant.  

 

 

Anaconda Nickel Murin Murin – Sheared Air Line Clamp 

Sustech was engaged by Taylors Welding and Engineering for designing and analysing a clamping system for a broken sheared pressurised air line elbow joint. Sustech analysed the clamping arrangement through FEA taking care of the all the failure modes and putting together the line to functioning state. The clamping system was fit for purpose and tailor made to help the client perform live installation safely. We got appreciation for innovative solution and prompt action in this operation-maintenance work in resuming full service of the running plant. 

 

 

Yarra  – Sea water FRP pipe support design – Detail Design of Brownfield Remedial Modification

Sustech was engaged by Wenco to suggest and design a support for the large diameter sea water line. The pipe material was GRE. Sustech collected the information regarding the broader picture, assessed operating modes and conditions, suggested client the way forward and designed and engineered the special support for the retrofitted design to client’s requirement. An engineering analysis was performed for the pipe support with all possible load combinations. Detail shop drawing was developed for the ease of fabrication.

 

Cristal – Lifting ring-lug design solution and FEA 

Sustech was engaged by Taylors Welding and Engineering to provide design engineering solution and for lifting an installed pressure vessel and analysing the arrangement of lifting ring and lug to ensure integrity and safety during the lift. Sustech assessed the vessel and discussed the lifting methodology with Taylor came up with a fit for purpose solution to suit the lifting crew, designed and engineered the special arrangement. An FEA engineering analysis was performed for the lifting ring-lug considering all possible failure modes. 

 

Tronox – Maintenance solution with custom made pipe clamp – Design and FEA 

Sustech was engaged by Taylors Welding and Engineering to provide design engineering solution for containing a pipe. The conveyed fluid was hazardous so hotwork had to be avoided. Sustech worked with the Taylor team to work out a on-field solution that can be employed online. Sustech’s experienced  engineers assessed pipe, its operating conditions, materials, fluid, configuration and came up with a fit for purpose custom-made clamp solution, designed and engineered the special clamp. An FEA analysis was performed for the clamps defining the imposing loads to check the integrity. Detail shop drawing was developed for the ease of fabrication. 

Yara-Karratha- FRP & HDPE Sea Water Lines – Detail design of brownfield modification

Yara planned to put a chlorination plant in a suitable spot in its existing plant for water treatment purposes tied with its existing process. Wenco was asked to design, build and install the plant with its equipment, piping and accessories. The piping material is FRP and HDPE carrying sea water. Sustech developed the plant and piping design from startup for this brownfield modification by attending site visits and understanding client’s requirements and preferences. Sustech put experienced personnel and appropriate resources to make it a success.

 

 

Wenco-Perth-Rubber-lined pipe- Fabrication detail drawing

Wenco was given the fabrication order for rubber lined pipes for mining operations requirement. Sustech used its experience and knowledge of rubber lined piping in both the water industry and mining industry to produce the drawings in a fast turnaround period.

 

 

 

Roy Hill-Newman- Electrical Drawings – As Built Modification of Electrical Drawings of Roy Hill Project

Sustech updated the “As Built” marked ups in the final version of the Electrical single line diagrams, cable schedules and layouts. Sustech used its low cost overseas centres for its main drafting work with some application of design, engineering, and site knowledge. Sustech was given little notice with a fast approaching project deadline. Communication was the key factor which Sustech successfully established and exercised, to ensure a smooth and timely delivery.

 

 

BHPB-Nickel West Flash Tank – FRP Flooring and Walling – Structural Design-Drafting

Sustech participated in a joint site survey with the owner and defined the scope of work for the brownfield modification work as a sub-consultant. Sustech ran a design selection session for the optimum path for fabrication and performed necessary structural calculations. Sustech developed a 3D model of the FRP flooring and wall of different levels of the flash tank adjacent structure. Sustech got client agreement and developed detailed fabrication drawings and MTO for shopfloor fabrication and installation by Wenco.

Sustech has provided short and long-term support to clients by seconding highly capable and experienced engineers across a range of roles including; Owner’s Engineer, Project Engineers, Design Engineers, Field services & Inspection Engineers, Piping Specialists, piping project supervisor, ISO 14692 D6 qualified FRP pipe inspector, condition monitoring specialist and condition monitoring data collectors. Sustech secondment varies across a range of resource industries.

The principals and associates of Sustech have worked across several small and large projects in companies ranging from multinationals to locals. The projects are categorized into following:

 

 

OIL & GAS

UPSTREAM OIL & GAS

• Design and specification of oilfield waterflood network in GRE for Chevron, Barrow Island
• Design and specification of oilfield flowline network in GRE for Chevron, Barrow Island
• Engineering manager for Chevron, Barrow & Thevenard Island services contract
• Remediation of onshore oilfield pipelines in CS and GRE for Chevron, Barrow Island
• Development of piping specifications to ASME B31.3, AS 2885, EN 13480, ISO 14692
• Develop documentation for approval of spoolable RTP pipe for high pressure oilfield pipelines
• Independent engineer role for major investors and bankers in oilfield projects
• Thar Jath Development Project, Sudan (Upstream crude processing project) – Client: WNPOC (Joint Venture of Petronas, ONGC Videsh and Sudan Petroleum)
• Onshore Desander Skid Project and Offshore Desander Skid Project – Client: Exxonmobil; SHELL SARAWAK Sdn Bhd
• Piping maintenance support in off-shore platform – Client: MODEC
• Technical Trouble shooting in Puffin FPSO project – Client: AIBEL

GAS GATHERING

• CSG processing and compression facility – Client: QGC
• Option study of pipeline materials for flow lines of coal seam methane gas and CAPEX and OPEX estimate in GLNG Upstream Pipeline study – Client: Santos
• Member of ISO 14692 workgroup to re-write the standard for GRP pipe applications

GAS PROCESSING

• Bass Gas Asset and Operation Integrity Management Advisory Services project – Client: Origin energy

GAS TRANSMISSION

• Design of SEAGas pipeline compressor stations
• Compression unit and compressor wheel selections for DBNGP and SEAGas pipelines
• Independent third party validation/ verification of design, MDR and relifing study documents for gas pipeline, compressor stations, pipeline looping, metering stations, fuel gas conditioning and pressure reduction stations, gas heating system pipeline laterals – DBNGP Expansion, Parmelia Pipeline, Newman Power Station project; Karratha Power Station Project; HEGT Metering station; Neerabup Power Station – Client: DBP, APA, W.Net Energy, EPIC, Leighton, BBL.
• HEGT fuel gas pipeline, Domgas metering station, Gorgon upstream joint venture metering station FEED, EGP Capacity Expansion – Compression pre-FEED & QCS04 Construction Support, QGP Capacity Expansion – Compression FEED & Detailed Engineering, Cape Lambert power station gas conditioning project – Client: Verve Energy, Woodside, Chevron, Alinta Asset Management, Jemena, MCC CL, BBL
• Detailed audit and FEED engineering for MAOP upgrade of the DBNGP
• FEED engineering for DBNGP Stage 2 and Stage 3 capacity expansion upgrades
• Unaccounted for gas (UAFG) modeling and software development for DBNGP
• Prepare AS 2885 Issue Paper and Appendix AA on application of GRE to high pressure pipelines

GAS DISTRIBUTION

• Concept engineering and cost estimation for gas transmission and distribution to remote towns in the BAG pipeline route – Client: Department of State Development WA

CRUDE PROCESSING

• Tatipaka Refinery, ONGC in PV Elite & ADLPIPE.

PETROCHEMICAL REFINERIES

• Design and specification of water pipelines in GRE for BP Refinery Kwinana
• Independent third party design verification of pressure vessel modification as per AS1210 Wagga Wagga pressure vessel certification project – Client: Southern oil
• Ultra Low Sulphur Diesel revamp project – Client: Shell, Texas, USA
• CSPC Nan Hai Petrochemical Refinery Project – Client: Shell, CSPC, China

FUEL STORAGE – TANK FARM

• Diesel Storage Facility and fuel management system Concept, FEED, Detail Engineering and cost estimation – Pilbara Iron – Fuel Infrastructure & Logistics; Preliminary Engineering Study, RGP6 project; Sino Iron Ore fuel supply project – Client: BHPBIO through FAST JV; Darwin LNG fuel storage enhancement; Sino Iron; Conoco Philips
• Independent third party design verification of drilling base oil prefabricated tanks Dampier Port Authority – Client: Dampier Port Authority through Dialog Services

 

 

POWER GENERATION

COAL FIRED POWER PLANT

• Root cause analysis for ruptured turbine exhaust steamlines and turbine lube oil flange leakages; Re-running the breakdown boilers, fix the bailey header supports and yielded water walls; Review of Main Steam pipe, HRH, CRH and hanger system of boiler at CESC and WBPDCL
• 2×120 MW coal based power projects of Tata Electric Company, Jamshedpur.
• Cogen Power Plant, Sugar Tech. Int., Philippines.
• RLA study of old power plants MPSEB Korba, TISCO Jamshedpur.
• Giral mine pithead lignite based 125 MW power plants
• Springerville (UK) Power Project

COMBINED CYCLE POWER PLANT

• Rijnmond (Holland) Combined Cycle Power Project (CCPP); Spalding (UK) (CCPP) Capacity – Each 800 MW – Client: Intergen

COGENERATION PLANT

• Baggasse based cogeneration power plant in Globe Engineering/ UB Engineering, BOOT project

BIOGAS FIRED CHP PLANT

• Designing Bio Gas based Cogeneration plant with GEA – Client: Water Corp

SOLAR POWER PLANT

• Designing small to large scale Solar Power Installations in Australia and abroad

 

ENVIRONMENT

• Swan River Oxygenation project – Client: Swan River Trust

 

 

CHEMICAL

• HCL project of MDI train at CaoJing Shanghai; Client – Bayer Material Science
• Preliminary engineering and CAPEX estimation in Tiwest expansion project – Client: Tiwest

 

 

MINING

MINE SITE

• Design and detailing of mine headframes and shaft equipment – Client: Golden Spec JV Gold Mine
• Design and detailing of Mt Newman Ore Sampler – Client: BHP
• Planning and site installation of equipment Foundry Sand Plant Upgrade – client: Wundowie Iron and Steel
• Site management of contractors and site engineering Hill 50 Gold Mine Upgrade Client: Western Mining Corporation
• Site engineering at minesite and Fortescue River rail crossing – Client: Hammersley Iron
• West-cliff coal washery detail engineering, client BHP Billiton

METAL REFINERIES

• Project Engineering Management – hydrogen, syngas and anhydrous ammonia pipeline- Client: BHPB Nickel West Kwinana
• Duplex stainless steel tank replacement; Replacement of existing Copper Boils (Brownfield activity) – Client: BHPB Kwinana Nickel Refinery
• Comalco Alumina Refinery (Australia) tankage and pumping

STEEL PLANT

• Cooling water system and piping design of Blast Furnace LD converter & ; Client – TISCO
• Incident trouble shooting of LP steam turbine
• RH degasser unit by steam ejectors at Bhilai Steel Plant

UTILITIES

• Safety shower audit and re-engineering for all Western Mining minesites
• Fuel and Lube Oil storage and management system at different BHPB and Rio Tinto sites