Projects
Power Generation Works
RCR Energy
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Client: |
BHP Billiton Iron Ore |
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Location: |
Yarnima Power Station, Newman WA |
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Duration: |
January 2012 - Ongoing |
RCR has been awarded a contract to provide power generation works for BHP Billiton Iron Ore's Yarnima Combined Cycle Power Station in Newman, Western Australia.
The scope of works includes the design, manufacture and supply of three Heat Recovery Steam Generators (HRSGs) and associated equipment.
Due for completion in the second quarter of 2013, the contract is valued at approximately $30 million and is the first major power contract awarded to RCR using AE&E Australia technology, which was acquired by RCR in May 2011.
It demonstrates the depth of RCR's intellectual property in energy technologies, with capabilities including design, supply and installation of Combined Cycle Power Plants which incorporate HRSGs. RCR's technology base is suitable for gas and liquid fuels, biomass, renewable energy and coal.
Structural, Mechanical, Piping & Electrical (SMPE)
RCR Resources/RCR Power
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Client: |
Fortescue Metals Group |
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Location: |
Solomon Mine, Pilbara WA |
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Duration: |
Nov 2011 - Ongoing |
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RCR has been contracted to carry out Engineering, Procurement & Construction works (EPC) and pre-commissioning of Fortescue's King's Ore and Firetail Ore Processing Facilities at the Solomon Mine.
The scope includes RCR core competencies of Structural, Mechanical, Piping and Electrical (SMPE) works and is scheduled for completion in December 2012.
The contract is valued at over $600 million, and follows receipt of equipment orders for apron feeders and belt feeders to RCR's Mining Business by Fortescue for the Solomon project totalling $30 million.
Underground Structural, Mechanical and Piping Installation
RCR Resources
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Client: |
Newcrest Mining |
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Location: |
Cadia Valley, New South Wales |
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Duration: |
October 2010 - Ongoing |
RCR Resources is the primary construction contractor for the provision of fabrication and construction services for the underground cope of the Cadia East Project
The scope of works comprises the materials handling system and mine infrastructure. Additional works awarded include the installation of the tailings thickener tank, pipe and mechanical equipment.
In FY11 RCR provided the design, supply and install of raw/fire water tank to feed reticulation system and commenced work on the incline conveyors and transfer stations.
Safety is our highest priority and underpins all activities with the pleasing result of zero Lost Time Injuries on the project to date.
Structural, Mechanical and Piping Works
RCR Resources
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Project: |
Worsley Efficiency & Growth Project |
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Location: |
Collie, Western Australia |
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Duration: |
2008-March 2012 |
RCR provided structural, mechanical & piping works for an alumina refinery in Western Australia. On completion of the contract RCR will have completed over $70 million in works.
The scope has been primarily piping and structural works including the manufacture, fabrication and installation of tie-ins with electrical and civil activities.
The contract has been extended to include pre-commissioning activities and works associated with an upgrade of the client's Bunbury port operations.
The works are supported by RCR's Bunbury facility and feature 90 per cent local employment.
In 2011, RCR achieved 2000 tie-ins on the expansion project without a Lost Time Injury (LTI).
Structural, Mechanical and Piping & Electrical Works (SMPE)
RCR Resources
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Project: |
Pluto LNG Project |
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Location: |
Western Australia |
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Duration: |
2008-March 2012 |
RCR continues involvement at Woodside's Pluto LNG Project, in joint venture (JV) with Freo Machinery.
On completion of the contract the JV will have completed over $100 million in works.
RCR Power provided electrical and instrumentation work associated with the main storage and condensate tanks and underground cable installation in the off-plots and untilities areas.
Mobile Mining Plants – Second Generation
RCR Mining
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Client: |
Iluka Resources Limited |
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Location: |
Jacinth Ambrosia, South Australia |
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Duration: |
2009 - 2010 |
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Awards: |
WA Engineers Australia Engineering Excellence Awards 2010 - Products & Manufacturing category Winner |
RCR designed, manufactured, installed and commissioned the second generation fully integrated track-mounted mobile mining plant as a single module.
The innovative mobile equipment incorporates an ore recovery and full in-pit primary processing unit and sophisticated relocation system. The advanced technology for the customised hydraulically driven track-module enables the 1000 tonne machine to raise and lower itself to relocate to the next mining position via remote control.
The mobile mining plant reduces infrastructure and operation costs, improving efficiencies and reducing waste, energy and emissions.
The project was delivered within nine months with an outstanding incident-free safety record.
Mobile Mining Plants – First Generation
RCR Mining
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Client: |
Iluka Resources Limited |
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Location: |
Murray Basin Stage 2 Project, Victoria |
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Duration: |
2007 - 2000 |
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Awards: |
WA Engineers Australia Engineering Excellence Awards 2009 - Products & Manufacturing category Winner |
RCR designed and manufactured a fully mobile ore recovery, screening and processing facility. Separated into three distinct track-mounted modules, the design incorporates an apron feeder with dozer trap and primary screen on the first module, a rotating autogenous scrubber on the second module and rotating scrubber/trommel screen and oversize conveyors on the third module.
All three modules work in conjunction passing ore through RCR’s traditional materials handling equipment. The modules are housed in specially designed superstructures that are built on customised track systems, operated by remote control.
Power Station Major Outage Services
RCR Energy – Stelform VRBT
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Client: |
Macquarie Generation |
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Location: |
Liddell Power Station and Bayswater Power Station, situated between Singleton and Muswellbrook, Upper Hunter Valley, New South Wales |
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Duration: |
100,000 man hours |
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Safety: |
Zero LTI during more than 100,000 RCR man hours |
As part of the ongoing alliance agreement with Macquarie Generation established in 2007. The projects were conducted at the Liddell Power Station and Bayswater Power Station in New South Wales.
The scope of works at the Liddell Power Station encompassed boiler and valve overhaul services. At the Bayswater Power Station the scope included the replacement of both main condenser and steam feed pump expansion joints, and inspection and repair of cooling tower diffusion packs.
Safety was a vital component of the projects. RCR delivered both the Liddell and Bayswater Power Station projects with zero LTI’s during 100,000 man hours.
EPC Biomass-Fired Steam Boiler Plant
RCR Energy – New Zealand
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Client: |
Nestlé |
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Location: |
Osorno, Chile, South America |
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Duration |
2010 |
RCR was awarded an EPC order from Nestlé to supply steam boiler plant for a new factory being built in Osorno in southern Chile, South America.
RCR was contracted to design and supply a complete, biomass-fired steam boiler plant, including a back-up boiler (LPG-fired) and all ancillary plant required within the boiler house. The main boiler will be a B&W Towerpak® boiler designed by RCR under license from Babcock & Wilcox Power Generation Group Inc. USA.
RCR’s state-of-the-art boiler plant incorporates a number of innovations to maximise energy efficiency and ensure clean combustion, using vibrating grate technology suited for high moisture biomass fuels.
Three-dimensional modelling design technology enabled operation and maintenance to be optimised, with modular design incorporated to improve planning and execution of shipping, road transport and erection.
Turnkey Engineer, Procure, Construct (EPC)
RCR Energy
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Client: |
Nestlé |
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Location: |
Gympie, Queensland |
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Duration |
2009 |
RCR Energy supplied a 16MW Babcock & Wilcox® Towerpak™ BFB Boiler to one of Nestlé's largest facilities in Gympie, Australia.
- Turnkey Engineering, Procurement, Construction (EPC)
- Mechanical works
- Electrical installation
- Commissioning
- Training
The BFB boiler, designed under license from Babcock & Wilcox Power Generation Group Inc. USA, was identified as the only option capable of dealing with the special high moisture biomass fuel mix of sawdust and coffee production waste. The boiler featured:
- BFB combustion system
- High efficiency boiler with economiser and recuperative air heater for energy recovery
- Particulate emission control using Electrostatic Precipitator
Recovery Boiler Lower Side Wall Replacement
RCR Energy
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Client: |
Carter Holt Harvey Tasman (CHH) |
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RCR Energy provided a shutdown services for the replacement the Kraft Recovery Boiler lower furnace side walls. This was the second major boiler rebuild project at the Tasman site, following the successful replacement of the entire superheaters and roof section of the same boiler in 2006. The project scope included:
- Pre-manufacture of lower side wall composite furnace panels and auxiliary equipment
- Detailed advanced planning to minimize overall shutdown duration to 18 days, working a 24/7 routine
- Site management and coordination of resources associated with critical path works
Steam Boiler Design, Installation, Commission
RCR Energy
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Client: |
Fonterra |
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Location: |
Edendale, Southland, New Zealand |
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RCR Energy provided a 37MW Babcock & Wilcox® Towerpak™ steam boiler at Fonterra's new number four Milk Powder Plant. The scope included:
- Design
- Installation
- Commission
Structural, Mechanical, Piping (SMP) Underground Package
RCR Resources
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Client: |
Newcrest Mining |
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Location: |
Ridgeway Deeps Project, Orange NSW |
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RCR Resources provided assembly and installation underground of all structural steel, mechanical equipment and piping associated with the East and West Crushers.
This included the manufacture, transportation and underground installation of an apron feeder from the Perth workshop, the construction of two large jaw crushers, a 2km materials handling conveyor system, installation of the RAW water and de-watering pipe reticulation and the installation of the de-watering pumps in the pump station located 1km underground.
RCR’s integrated resources were demonstrated where RCR Mining designed and manufactured four apron feeders, RCR Energy provided the fabricated piping and RCR Resources installed the components as part of their overall construction package.
Structural, Mechanical and Piping Installation
RCR Resources
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Client: |
Newcrest Mining |
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Location: |
Cadia Valley Operations, New South Wales |
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RCR Resources provided structural, mechanical and piping installation on the VTM3000 Vertimill project, the largest of its kind in the world.
RCR Resources has since been awarded its third contract at the Cadia Valley Operations for structural, mechanical and piping installation works for the underground portion of the expansion the Cadia Valley Operations.
Dragline Outages
RCR Resources – Eagle
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Client: |
Wesfarmers |
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Location: |
Curragh Mine Site, Queensland |
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RCR Resources together with RCR Power delivered its sixth consecutive dragline outage on-site at the Wesfarmers Curragh mine site in Queensland.
Removal of the major dragline components utilised an innovative “Lift-n-Lock” crane system, saving on both costs and the duration of the outage.
Electrical and Mechanical Construction
RCR Power
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Client: |
IHI Engineering |
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Location: |
Rio Tinto - Yurralyi Maya Power Station, Karratha, Western Australia |
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RCR provided construction, testing and commissioning services for four new gas turbines at the Yurralyi Maya Power Station site near Karratha, Western Australia.
The scope of services included the provision of electrical and mechanical services, engineering services, procurement of materials and equipment, and testing and commissioning services for the power station’s construction.
Electrical Instrumentation
RCR Power
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Client: |
Oz Minerals |
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Location: |
Prominent Hill, South Australia |
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RCR managed a workforce in excess of 200 employees on the electrical, pneumatic, instrumentation, control and structural elements for the production of the concentrate from primary crushing through process to storage. During more than 200,000 man hours, RCR installed:
- More than 230km of cable
- 15km of cable ladder
- 12km of conduit
- Five switch rooms, two of which were over 140 metres long
- Pneumatic air control for flotation and frother areas
- Quality control and quantity surveying
Structural, Mechanical, Piping and Electrical Construction
RCR Power and RCR Resources
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Client: |
BHP Billiton |
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Location: |
Cliffs Nickel, Western Australia |
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Duration |
February 2008 – September 2008 |
Together with RCR Resources, RCR Power supplied structural, mechanical, piping and electrical construction services. RCR’s SMPE works included:
- All mining surface infrastructure
- Construction and installation of paste plant
- Electrical site services
- 100V reticulation
- Manufacture, supply and install of four
- 1000/415 volt skid-mounted substations
- SB01, SB02 33,000 volt and 11,000 volt high voltage substations
- Communication works