SMART thinking, exceptional delivery

What can be achieved when people across disciplines, countries and time zones come together with a common goal?

For the Inteforge team supporting the Jimblebar Train Load Out (TLO) Replacement Project, it meant delivering something many would have thought impossible a few weeks earlier.

In just eight weeks, the team delivered the BHP SMART Module from concept to completion, successfully assembling and energising the module before its journey to Australia. Measuring 47 metres long, 12.5 metres high and 9.7 metres wide, with a total transported mass of 290 tonnes, the SMART Module will serve as the central control and electrical distribution hub for the new ore loading system at the Jimblebar TLO project site, housing critical electrical and control infrastructure for future operations.

This achievement is about far more than meeting a deadline. It showcases Monadelphous' full Structural, Mechanical, Piping, Electrical and Instrumentation (SMP E&I) capability and demonstrates what can be achieved when planning, innovation and collaboration come together.

"When you look at what the team delivered in such a short timeframe, it's pretty incredible," said Martin Cauble, Inteforge Operations Manager.

"Every part of the business played a role. We weren’t just building a module. We were bringing together our full SMP E&I capability and showing what's possible when everyone pulls in the same direction."

Originally planned for a later shipment, the module scope was brought forward by two months, creating a highly compressed schedule. The challenge grew further when the team was tasked with significantly increasing the amount of electrical and instrumentation work completed before shipment.

Working across Perth and Tianjin, the team rose to the challenge and delivered some impressive results.

By project completion, the team had:

• installed 7,814 metres of cabling;
• counted, terminated and tested 65 lighting fixtures;
• completed the entire termination scope in a single shift with 30 electricians;
• energised all nine lighting circuits before shipment; and
• finalised instrument and control cable testing within days of energisation.

Completing this work in a controlled workshop environment rather than on site delivered significant productivity, safety and cost benefits, including reducing installation hours, lowering project risk and creating greater value for the customer.

A standout moment came when the module was successfully energised, providing visible proof of what the team had achieved together.

The milestone was celebrated with more than 90 customers, suppliers and stakeholders, recognising not only the completion of the module but the teamwork behind it.

"Seeing the lights come on was a proud moment for everyone," said Russell McBain, General Manager, EC Projects.

"There was a huge amount of work behind the scenes to make it happen. We had people across Perth, Tianjin and the broader project team all working towards the same goal.

"Having members of our Perth team travel to China to work alongside the team and share in the celebrations made the achievement even more special."

The SMART Module has now departed China and is expected to arrive at the Jimblebar TLO project site in September for installation, marking the next chapter in a project that has set a new benchmark for Inteforge.