HPX3 Onshore and Offshore Project

The multi billion dollar third expansion at the Hay Point Coal Terminal involved building and commissioning a new berth to increase throughput capacity to 55 Mtpa and export capability to support eight mines located in the Bowen Basin.

KAEFER undertook the Structural, Mechanical, Piping and Electrical Instrumentation (SMP&EI) erection, installation and commissioning for all onshore materials handling structures and equipment. The works included the integration of seven pre-assembled towers and surge bin modules, and receipt and handling into position of pre-assembled conveyor gallery modules and buildings. Where works involved tie-in to existing operating equipment G&S undertook the shutdowns for each plant to allow works to be completed.

KAEFER’s fabrication workshop facilities were utilised for the pre-assembly of client supplied items, as well as supply and fabrication of structural and piping items required for brownfield and tie-in works.

KAEFER electrical team carried out installation, terminations and labeling of high, medium, low and extra low voltage cabling (over 250km), fibre optic cabling systems, light and power systems; relocation and rerouting of required electrical, instrumentation and communication infrastructure and services; all in-ground and plant earthing systems; onshore plant instrumentation and control systems; integration of site fire, CCTV and security systems; and installation of transportable substation buildings.

The safe, timely and high quality delivery of all scope services by KAEFER Integrated Services onshore works resulted in KAEFER being the contractor of choice to take on further packages outside the original contract scope. The extra packages included onshore and offshore tie-in shutdown planning and execution, as well as commissioning support from pre-commissioning through to wet commissioning, and handover.