Project Background
Client: BHP
Date: April 2020 – September 2024
Location: Port Hedland, Western Australia
BHP required a partner to provide a fully integrated control system that met rigorous functional safety standards. The project necessitated a comprehensive approach, including mechanical, electrical, fabrication, design drafting, detailed testing and commissioning. GTE was selected for their ability to manage complex, multidisciplinary engineering projects effectively.
Challenges
We ensured the project met client functional safety standards, achieving Safety Integrity Level 2 (SIL2) by managing hazard assessment, design, installation and validation in-house. Our expertise in electrical engineering, control systems and mechanical design allowed for seamless integration across disciplines, backed by detailed operational procedures for long-term reliability. As BHP’s needs evolved, we adapted the design and implementation to keep the system aligned with their requirements.
Approach and Solution
Functional Safety Implementation
We demonstrated our expertise by meticulously following the Functional Safety Framework as per SEP-93, covering all aspects from Hazard and Risk Assessment to Safety Requirements Specification, Design, Engineering, Installation, Commissioning and Validation. This comprehensive approach ensured that every stage of the project was executed with precision and in full compliance with safety standards.
Operational and Maintenance Procedures
Beyond technical execution, we developed detailed operational and maintenance procedures to ensure that the design would be operated and maintained correctly. This focus on long-term reliability and safety underscores our thorough approach to project management.
Adapting to Evolving Requirements
As the project progressed, our team integrated changes in operational requirements into the site environment. GTE continues to adapt and refine the solution to meet BHP’s evolving needs, ensuring the project remains aligned with operational goals.
Results and Impact
Delivering BHP’s Ship loader Automation, GTE implemented a rigorous safety system meeting Safety Integrity Level 2, enabling autonomous operations and reducing risks to personnel and machinery.
The implementation of the Ship loader Automation project resulted in a highly functional safety system that allows for fully autonomous operation, significantly reducing risks to personnel and machinery. The system’s autonomous capabilities have also led to improved operational efficiency by minimising the need for manual intervention. Our ongoing support ensures the system remains aligned with BHP’s evolving operational needs, providing a future-proofed solution that enhances both safety and productivity.
Conclusion and Future Impact
Our work on the Ship loader Automation project at BHP Port Hedland exemplifies our ability to deliver complex engineering solutions with a focus on safety and efficiency. By leveraging our multidisciplinary expertise and a deep understanding of client needs, we have provided a system that addresses current challenges and is equipped to handle future demands. This project reinforces our reputation as a crucial partner for Tier 1 companies seeking innovative and reliable engineering services.
