KEY PROJECT EXPERIENCE

Darling Downs Solar Farm

Client:         

Origin Energy

Location: 

Dalby, QLD

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Early in 2016, RCR was awarded an ECI contract by Origin Energy to provide design and engineering expertise for Origin’s proposed large-scale solar farm located in Dalby, Queensland. Upon successful completion of the ECI work, achievement of state and federal regulatory approvals and other considerations, RCR will enter into a Design and Construct (“D&C”) Contract for the development of the proposed Solar Farm.

The installation of the solar infrastructure, which is permitted to deliver up to 200 MW of generation capacity, will create up to a 200 Ha solar footprint. The project leverages our intellectual capital in the design and construction of large-scale energy generation assets and reflects RCR’s standing as one of the country’s leading energy solutions specialists.


 

Broken Hill Solar Farm

Client:         

First Solar/AGL Ltd

Location: 

Broken Hill, NSW

 solar farm

 

 

 

 

The Broken Hill Solar Plant is a 53 MW solar PV power station located five kilometres southwest of Broken Hill. The solar plant occupies approximately 140 hectares and has over 650,000 solar PV modules installed at the site.

The solar plant was connected to the electrical grid via a 22 kV transmission line that connected into an existing substation, located 2.7 km to the east of the site.

RCR was responsible for the installation, testing and commissioning of the DC and AC plant, including the thin film PV modules. RCR undertook the detail civil and trenching works, AC/DC/Communication cable installation, terminations and earth grid works, in addition to installing 40 invertor stations, two 22kV Switchrooms, SCC (SCADA) and OEM buildings. RCR successfully completed 130,000 man hours within 6 months, one month ahead of schedule with 0 Lost Time Injuries.


Gorgon - Barrow Island SMP/E&I and Commissioning

Client:         

CKJV

Location: 

Barrow Island, WA

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RCR was awarded a construction support contract at the Chevron-operated Gorgon Project in North-West WA.

RCR’s scope in this landmark project is to support CKJV with SMP/E&I construction and commissioning works on the 15 mtpa LNG Plant on Barrow Island. This contract showcases some of RCR’s core capabilities within one of Australia’s most exciting and iconic resources projects.

RCR’s experience at Barrow & Curtis Islands; Pluto LNG and Karratha Gas Plants for Woodside Energy; and the Moomba and GLNG facilities for Santos has positioned us for growth in the key oil & gas sector, particularly for major ongoing maintenance revenues.

RCR delivers fully integrated mechanical and E&I services for construction, brownfield modification and asset lifecycle support services to both onshore and offshore facilities.

 

 


  

Wynyard Station Upgrade - Novo Rail Alliance

Client:         

Transport for NSW

Location: 

Sydney, NSW

 

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The Novo Rail Alliance draws on RCR’s industry leading rail infrastructure and electrical expertise to deliver safe, timely and affordable solutions for some of Sydney’s most complex rail and infrastructure projects. Novo Rail’s seventh year of operation saw it awarded the $81.0 million Wynyard Station Upgrade. This critical upgrade will create a new gateway for Sydney’s financial district and western CBD. Wynyard is one of Sydney’s busiest stations and it needs significant improvement to meet growing demand; these works will increase station capacity, improve pedestrian movement and provide improved facilities for customers and staff.

The Novo Rail alliance has been engaged to deliver the construction phase of the Wynyard Station Upgrade, following completion of the early works and initial design work. Temporary pedestrian corridors were installed in August 2015 to minimise impact on customers while construction takes places at the station. Construction of phase one of the Wynyard Station Upgrade  will finish in mid 2016. Work will take place behind construction hoardings 24 hours a day, seven days a week.

Wynyard Upgrade - Novo Rail Alliance from RCR on Vimeo.

 


 

Roy Hill Iron Ore Project

Client:         

Samsung C&T

Location: 

Pilbara, WA

 

 roy hill 1

 

 

RCR has been engaged to carry out Structural, Mechanical, Piping, Electrical & Instrumentation (SMP/E&I) works at the Roy Hill Iron Ore Project in Western Australia.


Under the direction of the EPC contractor (Samsung C&T), RCR has been awarded multiple packages to support construction of the Ore Processing Facility and associated mine infrastructure.

The work, won on the back of our strong capability and contracting models developed for Fortescue’s Solomon Project, has RCR constructing Ore Processing Facilities to high quality with a rigorous schedule.
RCR has also designed & supplied 35 apron/belt feeders to support operations at Roy Hill.


 

Picton Wastewater Treatment Plant

Client:         

Sydney Water

Location: 

Picton, NSW

 

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RCR was awarded a contract with Sydney Water for a major upgrade to the Picton Recycled Water Treatment Plant in NSW.  The project scope included construction of a new inlet works, biological process tanks and associated infrastructure.

The amplification to the Picton Water Recycling Plant was needed to accommodate forecasted population growth and development within the Picton catchment area.

 


 

APLNG - HVAC & Permanent Communications Infrastructure

Client:         

APLNG - Conoco Phillips/Bechtel

Location: 

 QLD 

 

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RCR scope at the Curtis Island facility included installation of CCTV, Access Control, VOIP and LAN systems; installation, termination and testing of  fibre optic and copper cabling.

Additional services provided included HVAC consultancy, repairs, maintenance and training delivery.

 

 

 


 

Water Networks & Facilities Renewals Panel

Client:         

Sydney Water

Location: 

 NSW

 

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RCR is a Panel member delivering a programme of works for the Mechanical/ Electrical/ Controls renewals of Sydney Water’s infrastructure, including water and sewage treatment plants and pumping stations.

Key services provided include pumping station upgrades, water and sewage treatment plant renewals and HV asset upgrades

 

 


 

QGC Upstream Project - Compression Stations

Client:         

QGC

Location: 

Curtis Island, QLD 

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RCR was engaged to perform Electrical and Instrumentation installation and testing.

Scope included HV & LV cables and terminations, Cable Ladder installation, Instrument Calibration, Installation and Commissioning, Communications cable and terminations,General light and power installations within Hazardous area Zone 1 and Zone 2

  


Solomon Ore Processing Facilities
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Client:          

Fortescue Metals Group

Location: 

Solomon Mine, Pilbara WA

 

 

 

RCR was contracted to carry out Engineering, Procurement & Construction works (EPC) and pre-commissioning of Fortescue's Kings Valley and Firetail Ore Processing Facilities at the Solomon Mine.

The scope included RCR core competencies of Structural, Mechanical, Piping and Electrical (SMPE) works.

The contract was valued at over $700 million. RCR also designed, built and supplied 8 apron feeders and 15 belt feeders.

During the height of construction over 1,000 personnel were mobilised, and these facilities will produce over 65 mtpa, a major component of Fortescue's exansion activity.

The first OPF (Firetail) was completed in April 2013, and the second (Kings Valley) in October 2013.

The Kings Valley OPF was completed ahead of schedule, in a record 29 weeks.  The Timelapse footage below, showing RCR's construction of the Kings Valley Facility is provided courtesy of Fortescue. 

You can also watch highlights of the Kings Valley Facility's Opening Ceremony here

 


altUnderground Structural, Mechanical and Piping Installation 

Client:         

Newcrest Mining

Location: 

Cadia Valley, New South Wales

 

 

 

 

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.


 

essoGas Plant Facilities - Maintenance, Upgrade & Repair

Client:         

Esso

Location: 

Longford Gas Plant (Victoria), Long Island Point & Offshore Oil Rigs

 

 

 

 

RCR, through its Haden subsidiary provided maintenance, upgrade and repair work  to the electrical and mechanical systems to a wide range of buildings including laboratories, switch rooms, workshops, stores, canteens, sleeping quarters, mining facilities on the oil rigs and administration offices.

Scope included Preventative maintenance; Reactive works, scheduled on a priority basis; Compliance testing and repairs to fire dampers on oil rigs; high-voltage circuit breaker maintenance and repairs

As a “critical contractor”, RCR was required to become accredited according to Esso’s Operational Integrity Maintenance System (OIMS).

 

 

 


Structural, Mechanical and Piping Worksalt

Project:      

Worsley Efficiency & Growth Project

Location: 

Collie, Western Australia

 

 

 

 

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)alt

Project:      

Pluto LNG Project

Location: 

Western Australia

 

 

 

 

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.

 


 

altMobile Mining Plants – Second Generation

Client:          

Iluka Resources Limited

Location: 

Jacinth Ambrosia, South Australia

Awards:

WA Engineers Australia Engineering Excellence Awards 2010 - Products & Manufacturing category Winner
National Engineers Australia Engineering Excellence Awards 2010 - Products & Manufacturing category Finalist

 

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.

 


 

 

altMobile Mining Plants – First Generation
    

Client:         

Iluka Resources Limited

Location: 

Murray Basin Stage 2 Project, Victoria

Awards:

WA Engineers Australia Engineering Excellence Awards 2009 - Products & Manufacturing category Winner
National Engineers Australia Engineering Excellence Awards 2009 - Products & Manufacturing category Finalist

 

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

Client:         

Macquarie Generation

Location: 

Liddell Power Station and Bayswater Power Station, situated between Singleton and Muswellbrook, Upper Hunter Valley, New South Wales

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 Plantnestle chile 2012-02

Client:

Nestlé

Location:

Osorno, Chile, South America

 

 

 

 


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 is 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)nestle gympie

Client:

Nestlé

Location:

Gympie, Queensland

 

 

 

 

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

 


 

altRecovery Boiler Lower Side Wall Replacement

Client:

Carter Holt Harvey Tasman (CHH)

 

 

 

 

 

 

RCR Energy provided shutdown services for the replacement of 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

 



fonterra edendale b4 018Steam Boiler Design, Installation, Commission 

Client:

Fonterra

Location:

Edendale, Southland, New Zealand

 

 

 

 

 

 

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

 


 


altStructural, Mechanical, Piping (SMP) Underground Package

Client:         

Newcrest Mining

Location: 

Ridgeway Deeps Project, Orange NSW

 

 

 

 

 

 

 

 

 

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.

 

 


 

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Structural, Mechanical and Piping Installation

Client:         

Newcrest Mining

Location: 

Cadia Valley Operations, New South Wales

 

 

 

 

 

  

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.  

  

 


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Dragline Outages

Client:

Wesfarmers

Location:

Curragh Mine Site, Queensland

 

 

 

 

 

 

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 Constructionalt
RCR Power

Client:

IHI Engineering

Location:

Rio Tinto - Yurralyi Maya Power Station, Karratha, Western Australia

 

 

 

 

 

 

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

Client:

Oz Minerals

Location:

Prominent Hill, South Australia

 

 

 

 

 

 

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

Client:

BHP Billiton

Location:

Cliffs Nickel, Western Australia

 

 

 

 

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