Copper Sulphate Thickener Feed Tank – BHP Kwinana Nickel Refinery

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Client BHP Kwinana Nickel Refinery
Location Kwinana, Perth, Western Australia
Job Title Copper Sulphate Thickener Feed Tank
Service Capital Works (EPCM Projects)

Specialised Welding & Fabrication

Industrial Tanks

Copper Sulphate Thickener Feed Tank   BHP Kwinana Nickel Refinery     Copper Sulphate Thickener Feed Tank   BHP Kwinana Nickel Refinery     copper-sulphate-feed-tank-bhp-6

 

Scope of Work

Material procurement, fabrication, non-destructive testing, hydrotesting, loadout, delivery and installation of a SAF2205 Duplex storage tank for BHP Kwinana Nickel Refinery. Fabrication occurred over a period of 10 weeks, from receipt of purchase order to delivery onsite.

Project Resourcing

• Workshop personnel included specialised coded welders and boilermakers. The support team included project management, quality management, project engineering and project supervision

• Sub-contract management of plate cutting, rolling/pressing, machining, rigging & scaffolding, NDT, hydro-testing, cranage and transport logistics

Project Achievements

  • Approx. 3,000 man-hours completed on workshop fabrication and site installation activities with zero recordable incidents or accidents.
  • Project was delivered on time and on budget.
  • The Tank achieved complete conformance with the technical and quality requirements of API 650.
  • Dayshift and nightshift rosters were implemented to achieve a challenging delivery date in order to meet the site installation window during a critical shutdown.
  • At 6.5m dia and 7.5m high the Tank was the largest structure fabricated by APMS in our Workshop facility.
  • APMS is a specialist supplier, capable of undertaking project of this nature while still being approachable and receptive to our client’s needs.

Activities

• Project and Quality Management – Preparation of quality documents (Welding Procedures, Welder Qualifications, Inspection and Test Plans, Quality Plan, Manufacturers Data Record

• Project Planning and Reporting – Preparation of detailed and resourced schedules including identification of critical path activities. Weekly client progress reporting addressing safety and technical issues and providing progress and schedule updates.

• Design and Build of temporary structural section base to ensure the correct alignment of the Tank during fabrication and to dissipate the 250t hydrotest weight.

• Specialised tank welding to ASME and Australian standards using GTAW and FCAW processes.

• Management and co-ordination of multiple sub-contract service providers - plate cutting, rolling/pressing, machining, rigging & scaffolding, NDT, hydrotesting, cranage and transport logistics.

• Full Class One Manufacturers Data Report including welding documentation, ITP, material traceability, NDT testing reports, hydrostatic testing reports, as-built drawings and technical clarifications.

Project Images

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