Project photo gallery

The following list of projects were critical projects that Jack B Khallahle (Director of JBCS) was tasked to take the lead role in implementing as a Project Manager leading a small team of design engineers, designers, construction supervisors and safety officers throughout Australia with the exception of Mineral Sand Separation Plant Project at Broken Hill in NSW for Parsons Brinkerhoff where JBCS Principal was part of the Leadership team working as a Construction Manager and later as Senior Project Engineer.

 

 

10,000 Tonne Sulphuric Aid Storage Tank, Nyrstar Lead/Zinc Smelter, Port Pirie, SA

This project involved design, procurement and supervision of new acid airculation pump, valves, pipelines and new self draining bund construction for the 10,000 tonne Sulphuric Acid Storage Tank. JBCS Principal was a Project Manager leading a small team of WorleyParsons design engineers, designers, safety coordinator and construction supervisor to complete this project for Nyrstar from concept design to practical completion and handover in September 2011. The overview of the scope of works are summarised below:

  • Remediate soil;
  • Construct new containment area and pump plinth;
  • Construct / rebuild open drain channel ( around new containment area);
  • Install new pump;
  • Supply and install new pipeline, valves and fittings;
  • Supply and install new pipe supports;
  • Supply and install new pressure transmitter;
  • Relocate and commission pneumatic valves;
  • Supply, install and commissioned two new eye wash facilities.
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120 Persons Exploration and construction Camp for Karara Iron Ore Project, Karara, WA

JBCS Principal was tasked to managed this project from concept design to final commissioning and handover to Gindalbie Metals (Karara Mining Ltd). The scope of works includes the design, engineering, installation, site works, headworks, services, commissioning for an 80 room extension to the exploration camp at Karara. All relevant facilities were transportable modular units with metal external cladding, insulation and air-conditioning as specified and contained all specified services, furniture, fixtures, fittings and equipment and was made ready for occupancy.

 

The exploration camp extension was sized for 120 rooms with all appropriate common facilities sized to allow for this number of personnel. The Contractor was Pindan Contracting and was required to design and supply the extension to the potable water tank(s), reticulation, dosing system, pumps and pipe work including the installation and commissioning of 120 persons Kitchen/Diner set with all equipments etc to a fully functional stage for immediate occupancy.

 

The scope of work and contract specification was developed by JBCS Principal and project managed from concept design to practical completion and handover in December 2008.

 

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Exploration Camp presentation by Pindan Contractor-120 Persons Camp

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gas turbine diesel transfer Fuel line, Paraburdoo, WA

Detail engineering design by PCT Engineers and reviewed and approved for construction for the layout and scope of works for the projects based on Rio Tinto design specification put together by JBCS Principal. Capital expenditure application (CEA) submitted and approved to a value of $770,000 by Rio Tinto Pilbara Iron General Manager (GM). Construction began in November 2006 by Monadelphous and completed in December 2006. JBCS Principal managed this project as a Project Manager for all project phases such as detail design and documentation, installation, commissioning including pressure testing.

 

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CV555/CV604 Transfer Stations, Paraburdoo, WA

This is a growth project under CV555/CV604 transfer station at Paraburdoo plant. JBCS Principal  was tasked to carry out the concept design of the wash-down pad, silt trap, pumps sump design and selection of submersible slurry pumps and developed a contract specification for mechanical, electrical and civil works. Detail engineering design and scope of work for civil and mechanical work was developed by Jack Khallahle (JBCS Principal) and electrical scope of works was done on site by Berkerly Engineering managed by JBSC Principal. CEA submission to Pilbara Iron GM was approved to a value of $400,575. Construction works began in November 2006 by Byblos & ICM Electricals and completed in December 2006. JBCS Principal  was the Project Manager for all phases of the project life-cycle.

 

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Construction drawings for the transfer station wash-down pad-Copy of Drawings

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2.2 kM Mine Access Road construction for light vehicle, Paraburdoo, WA

JBCS Principal (Jack B Khallahle) coordinated and managed the design of the 2.2 kilometers mine access road to a value of A$1.7 Million dollar and the installation of Culverts for the access road and associated earthworks to a value of $560, 000. The total project cost was estimated at A$2.3 Million dollars. The CEA for culvert installation was submitted and approved and construction began in Nov 2007 and completed in December 2007 by GLH of Geraldton. JBCS Principal developed both scope of work and specification for the earthworks. The light vehicle access road was designed by consulting firm Cardno Buckland Engineers of Perth and managed by JBCS Principal as a Project Manager.

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greater Paraburdoo Conveyor 25 (CV25) Train-Load-out Take-up system Modification Work, Paraburdoo, WA

This project was a critical one innovatively designed by Jack B Khallahle (JBCS Principal) in that it was a shut down related and had to be implemented during the 3 days maintenance shut down period for the Greater Paraburdoo train-loadout Conveyor 25 (CV25).

 

JBCS Principal was tasked to develop the concept design and came out with this innovative hybrid take-up system for the Paraburdoo Train Load-out conveyor CV25. The design was Innovative in that it was developed based on a combination of existing Horizontal Gravity Take-up system and Festoon (Vertical Gravity) Take-up system on site by JBCS Principal with inputs from a team of operation and maintenance personnel (end users) at the Paraburdoo process plant.

  

The final design included the following components; a new take-up tower; take-up box; sheaves; take-up trolley; take-up pulley & Plummer bearings; lubrication system; winch; wire rope and new layout design for CV25 all based on JBCS Principal concept design and specifications developed involving site based operation and maintenance personnel. Cardno Buckland Engineers in Perth was engaged by Jack (JBCS Principal) to carryout detail structural design while mechanical layout was designed by Jack B Khallahle (JBCS Principal) on site and also reviewed and approved all detail design, drawings and scope of work for tender and construction. CEA to a value of $860,000.0 was approved by Management. Fabrication for Steel work was done at Newman by Bilfinger Berger Services and coordinated and inspected by J.Buckhill.

 

Fabrication of sheaves, wire rope, festoon safety hook system and winch system was custom designed in Perth by Supercrane Engineering and Technology and managed and coordinated by J.Buckhill. All shop drawings was contracted to South West Group of Bunbury and lubrication was awarded to leptek of Perth. All contracts was coordinated and managed by Jack (JBCS Principal).

 

Construction works began in November 2007 by Bilfinger Berger Services of Newman and Supercrane Technology of Perth in stages and finally completed in January 2008 as part of a three days maintenance shut down work. J.Buckhill was the Project Manager from concept design to detail engineering design, installation, commissioning and handover to Paraburdoo operation team.

 

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For detail information on this innovative project, Clients are encouraged to refer to project update report which can be downloaded from this website.

 

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Cristal Mining Limited (Bemax Resouces Ltd) Mineral Sand Separation Plant (MSP) project, Broken Hill, NSW.

The Principal and Director of JBCS (Jack B Khallahle) was engaged as a Construction Manager by Parsons Brinckerhoff for the Cristal Mining Limited Mineral Sand Processing Plant Project on a one year Contract, based in Adelaide, South Australia.

 

Cristal Mining Limited (Bemax) has two heavy mineral mining operations located in the Northern Murray basin region. The two operations, named Ginkgo and Snapper, are located approximately 40 km west of the township of Pooncarie in Western NSW.

 

The mining operations produce a heavy mineral concentrate using spirals. These concentrates are then fractionated according to the various minerals magnetic susceptibility into magnetic products, MAG1 and MAG2, and a non-magnetics.

 

Parsons Brinckerhoff was appointed by Bemax Resources Limited to provide the Engineering, Procurement and Construction Management (EPCM) services for the BHT Circuit Addition to Broken Hill Mineral Sand Processing Plant for the processing of Ilmenite material as an independent circuit to an existing Leucoxene circuit. Jack Khallahle (JBCS Principal) was engaged on a contract as a Construction Manager and Senior Project Engineer from the early phase of the project DD1 level (Detail Design Level 1) and eventually as Senior Project Engineer during construction and commissioning phase of the project.

 

Whilst working as a Construction Manager, Jack was asked to complete the following tasks on the Mineral Sand Separation Plant project in project engineering role;

  • Coordinated and developed all Project Plans such as Project Execution Plan, Construction Management Plan, Project Procurement Plan, Safety Management Plan,  Environmental Management Plan and Quality Management Plan
  • Prepared Scope of Work and layout drawings for temporary site facilities to be used to stage construction of Bemax MSP Project.
  • Coordinated Building Certification Process with NSW Private Certifying Authority (PCA) for the Mineral Separation Plant Process Building and Product Storage Shed and issue of Construction Certificate and Construction Inspection.
  • Coordinated and Managed NSW accredited Fire Engineers in the preparation of Fire Engineering Brief (FEB) and Fire Engineering Report (FER) review and submission to PCA and Fire Brigade NSW for MSP Process Building.
  • Managed Fire Protection Service design to suit FER requirements for the Process Building
  • Coordinated and prepared Construction Safety Study, Fire Safety Study and Hazop Study for submission to the Director General of NSW Department of Planning for approval as part of the Construction Environmental Management Plan (CEMP) as stipulated in the development Consent.
  • Coordinated Quality Assurance including reviewing and approving ITPs by liaising with Contractors and Construction Coordinators to deliver projects in compliance with Client and other statutory requirements.
  • Coordinated Pre Commissioning Activities.
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