Roy Hill

Roy Hill is an iron ore mine, rail and port project in West Australia’s Pilbara region. The mine itself processes 55 million tonnes per annum (Mtpa). The project consisted of 4 packages. Package 1 included the Mine Process Plant whilst Package 2 included Rail. Package 3 and 4 covered the Port Landside (stockyard) and Port Marine.

DBM Vircon’s Scope of Work:

• DBM Vircon was engaged by multiple contractors for various scopes of work on this project.
• DBM Vircon were engaged by Roy Hill to survey and redesign some of the existing HDPE piping and mining hoses with more robust rubber-lined spools. The survey was utilized to remove the need for site measurements and design the new pipework and supports to millimetre precision to reduce the time and costs of site works and allow the plant to maintain operable throughout 90% of the installation.
• DBM Vircon were engaged by Goodline to review and finalise the Ultrafine pipework design prior to providing piping and pipe support design and fabrication deliverables. During this process DBMV was able to manage and identify multiple design issues mitigating the need to cut and refit piping on site. As the spools were all rubberlined this resulted in large savings in time and site costs.
• DBM Vircon were engaged by Laing O’Rourke to support the delivery of the Port Landside (package 3). DBM Vircon’s scope for this portion included in excess of 5,500 tons of 3D modeling and shop detailing of structural, mechanical steelwork including the car dumper, 8 conveyors, 7 sampling, transfer and drive stations, screening and re-screening buildings. DBM Vircon additionally reviewed and audited a further 88 work packages undertaken by third parties to ensure deliverables complied with the design and fabrication requirements.
• DBM Vircon were engaged by McConnell Dowell to undertake detailed 3D modelling and shop detailing of the Port Marine (package 4) scope. This package included a dedicated two berth facility capable of receiving, stockpiling, screening and exporting the iron ore. DBM Vircon’s scope included over 19,000 tonnes of structural, mechanical and platework steelwork and piping for the wharf, overland conveyor, 3 berth conveyors and 3 transfer stations.
• DBM Vircon completed the engineering, design and detailing deliverables for Roy Hill’s Diesel Fuel Storage Infrastructure for Decmil Australia. The scope included two bulk fuel farms, Rail Fuel Yard and the Mine Fuel Yard and refueling facilities at the Mine Services area and Go Line.
• DBM Vircon also provided input regarding module plan breakdown to assist the constructibility and modularization process. DBM Vircon was also contracted to convert a screening building model to Australian sections for fabrication by a local fabricator.
• Samsung C&T later engaged DBM Vircon to provide contractor work packaging support and to provide Digital Engineering support to consolidate all subcontractors’ models into one overall fully intelligent Navisworks model. This model will be used for facilities management and will be the single point of truth for all drawings and data.

Roy Hill Project Highlights & Challenges:

• A global work sharing platform was utilized
• DBM Vircon supplied regularly updated quantities and visual/model-based reporting to support client progress claims and resolution of project issues.
• DBM Vircon’s experience and expertise in managing and minimizing the impact of changes was vital to controlling project costs. We had the ability to resolve design issues and worked collaboratively with design and fabrication teams to minimize the impact and cost of change.
• DBM Vircon was able to optimize the bulk fuel containment to minimize bunding, oily water treatment and disposal requirements.