Western Hub
- Client: Fortescue
- Location: Pilbara, WA
- Date: 2020-2023
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Project Overview and Scope
The C6 conveyor is a critical overland conveyor in the Bingham Canyon Mine ore handling system, transporting material from the primary crusher to the Copperton Concentrator. Following catastrophic overspeed and braking failures in March 2023 and January 2024, confidence in the conveyor’s ability to safely operate at its design capacity of 11 ktph was lost.
EMtek was engaged by Rio Tinto Kennecott to support operational recovery, assess the conveyor’s stopping performance, and develop the engineering upgrades required to restore safe, reliable operation at full capacity. Following earlier recovery and study works, EMtek progressed into Phase 2 detailed design to enhance the braking, safety and control systems and improve confidence in ongoing operation of the conveyor at 11 ktph.
Services and Outcome
EMtek delivered Phase 2 detailed design and implementation support across structural, mechanical, electrical, instrumentation and control disciplines for the C6 return-to-11 ktph project. The scope included project management, design reviews, risk and constructability workshops, and development of updated functional safety documentation, including safety management plans, risk assessment documents, verification and validation plans, safety requirements specifications and commissioning plans. EMtek also completed detailed design for the mechanical brake system upgrades, including civil and structural drawings, footing details, equipment datasheets, equipment lists, layout drawings, hydraulic piping isometrics and updated 3D models, together with shop detailing packages for brake caliper frames, maintenance platforms and support frames.
In parallel, EMtek developed the electrical, instrumentation and control deliverables required for the upgraded brake and safety systems, including cable schedules, equipment and instrument lists, tie-in lists, single line diagrams, schematics, terminations, layouts, PLC code, functional specifications, SCADA/HMI updates, software FAT and SAT documentation, and safety PLC development. The project also included structural review of the C6 intermediate drive station and implementation design for conveyor monitoring and SIL 1 overspeed interlock functions, providing the detailed engineering package required to support safer full-capacity conveyor operation.
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