Industrial & Infrastructure

AEP Elical provided engineering, project management, detailed design, 3D modelling, and project controls services for the upgrade of Nyrstar's Port Pirie lead smelting facility. This included the design of structural, mechanical, piping, and electrical systems for various plant areas.

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AEP Elical provided extensive project management and project controls services for the successful delivery of the Victorian Ports Corporation (Melbourne) VTS Equipment Upgrade Project. The scope included project scheduling, review of contract compliance, document control, procurement and inventory management, analysis of cost reporting  documentation and perform analytical reviews and checks of cost reporting documentation.

AEP Elical conducted a Business Interruption Critical Controls Audit for the Mackay, Townsville, and Bundaberg bulk sugar terminals for Sugar Terminals and Queensland Sugar. The aduit involved verifying the planning, implementation, monitoring and review of the criticals controls for business interruption risks. 

AEP Elical was engaged to undertake a concept study, followed by detailed design of structural modifications required to provide access for slag removal under the Slag Caster tail end support frame. As part of this project, AEP Elical undertook a structural integrity audit for the TSL Slag Caster Support Structure as well as additional scope in replacement of existing primary beam in the TSL plant and shedder plates to lengthen design life.

AEP Elical undertook the detailed design engineering works for Nyrstar Port Pirie to provide process engineering and design and project delivery services for Nyrstar's preferred option to install a new settling pond, cooling tower, pumps and other associated equipment to upgrade the current open loop Slag Granulation and Dewatering System to a closed loop system for the granulation water

AEP Elical developed an overarching Functional Safety Management Plan (FSMP) for the Invicta Mill boiler Controls Systems. Within this plan, a number of operations (maintenance/ testing) procedures were developed. Additionally, an assessment of maintenance staff capabilities was conducted, with respect to requirements for maintaining SIFs (as per the developed FSMP).

AEP Elical was engaged for the detailed design of a number of modifications to the newly commissioned TSL Furnace Building. This included lowering of the slag launder, adjustable support for slag caster fish-tail, strengthening of the floor, extended access at slag caster fish-tail, stairwell column bases, monorail set out and extension to the tapping floor. The client eventually extended the purchase order amount from the original $ 90,781 to $ 170, 218 for additional works.

AEP Elical completed an Arc Flash Study for Dyno Nobel Plant in Moranbah for Incitec Pivot Limited. This study reviewed all the arc flash points for the functional levels on each plant switchboard from 11kV down to 415V. AEP Elical gave advice on appropriate levels of PPE with respect to electrical operators operating and switching electrical equipment at the Dyno Nobel Moranbah site.

Nyrstar Port Pirie engaged AEP Elical for the concept and detailed engineering design of the Slag Caster Bin Discharge Chute, replacing the original surge bin system with a direct feed to a product bunker by extending the overflow chutes due to cost constraints during the Port Pirie Transformation Project.

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AEP Elical facilitated the HAZOP for Mackay Sugar’s Locomotive Remote Shunting Unit (RSU). AEP Elical applied its expertise in Functional Safety, Machine Safety, operations and project experience, to extend the life of key aging assets and mitigating risks.

AEP Elical was engaged to undertake a structural assessment of designs by others for the new launder and tapping floor (replacing the plant installed during Transformation). Later on, AEP was engaged to undertake additional scope including design of the fishtail walkways, new southern and northern laydown platforms, and clash checks for the monorail system.

AEP Elical was engaged to undertake detailed design for modifications to the slag caster fume hoods. These modifications were required to provide clearance for a launder cleaning machine to be transported via the Monorails to/from the new northern and southern platform via the new launders.

AEP Elical facilitated a HAZOP / CHAZOP process for the Proserpine Mill Locomotive Control System. As part of the project AEP Elical offered a 3-day HAZOP and 2-day CHAZOP facilitation as well as preparation of a final report. 

AEP Elical was engaged to undertake a structural inspection and condition report on the copper smelter crushing plant, a concept design to improve access to the bosh tank and a preliminary inspection of one of the two cooling towers.

 AEP Elical deemed that the overall condition of the structure was good with no significant risks identified. ‘Red Dingo’ action sheets were prepared by AEP Elical for all notable defects found.

AEP Elical conducted an audit on Wilmar’s recent control systems projects. The scope was later extended to include the development of a functional safety management plan, maintenance plan, and SIL verification/SIF testing intervals for the Invicta Mill Boiler Management System.

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