WorleyParsons RSA credits an alternative proposal based on technology-driven design work and a one-team approach for successfully securing the Front End Engineering Design contract for Royal Bafokeng Platinum’s (BRPM) second phase 100 ktpm Merensky Concentrator. The first phase of the expansion, which is nearing completion, will increase the concentrator’s capacity to 250 000 tonnes a month from 200 000 tonnes a month. The second phase will update the concentrator’s capacity at the BRPM concentrator complex to 350 000 tonnes a month to accommodate Merensky ore production from BRPM’s new Styldrift mine.

“As this is a brownfield project in some areas, we had to take into consideration that we would need to work very closely with the existing operations and develop an engaged working relationship with the  customer’s team,” says Ian Hendry, Workshare Manager, WorleyParsons RSA. “Our two-fold approach incorporating our in-house developed integrated design platform and a one-team strategy between ourselves and the customer played a major role in successfully winning the bid.”

WorleyParsons’ integrated project platform combines sound engineering skills with computer gaming technology to produce high level 3-dimensional design models of a project coupled with cost and schedule to produce a real time 5-D model.

“We developed a 3-dimensional walk-through visual presentation of the proposed plant from existing 2-dimensional drawings produced by others as part of their feasibility study. By using 3-D virtual reality goggles in combination with Google Earth the customer could walk through the proposed design of the process plant and easily identify areas for improvement in the current design that will have a material bearing on cost and schedule,”  says Hendry.

The 5-D model includes a precise cost and schedule data using WorleyParsons’ integrated project platform that generates a plant breakdown structure. This in turn interfaces with the Work Breakdown Structure, providing numerical values for the project, connecting every single component to an item on the schedule from a time and cost perspective.
Murray Macnab, Director for Mining and Mine Business Development for WorleyParsons, believes that this integrated project platform is the most advanced project management tool currently available in the southern African market and that it is setting the benchmark in delivering engineering projects.

Macnab adds that brownfield projects often carry the risk of inaccurate existing 2-dimensional drawings that do not reflect topography and terrain in reality, posing time and cost implications to investors at a later stage. However, with the integrated design platform, these imprecisions are eliminated as the 3-D survey produces measurements capable in achieving accuracy within 4mm, while aerial views providing exact elevations are incorporated in the 3-D design model and viewed in virtual reality to enhance clash detection.

“Our focus is on utilising technology to drive a better design in order to easily identify challenges and realise solutions prior to commencement of construction. Our integrated project platform provides for greater accuracy and efficiency, making project delivery within budget achievable and greatly reducing the risk of downtime,” says Macnab.
He adds that WorleyParsons was able to use the integrated project platform model to show the customer how the project could be executed quicker and more cost-effectively.

“The success of our integrated project platform is a watershed moment for WorleyParsons as we continue to embrace technology to move forward, increasing our levels of confidence and accuracy and offering cost-effective and competitive design products to our customers,” says Macnab.

Henry Jonker, General Manager, Mining Minerals and Chemicals for WorleyParsons RSA adds that while the integrated 5-D model played a major role in WorleyParsons being awarded the contract, overall the  customer was also very impressed with their one-team approach to ensure clear, efficient lines of communication and ultimately successful and timeous project delivery.

This is the second project for WorleyParsons at the Bafokeng Rasimone Platinum Mine concentrator as the project delivery company was previously contracted to provide detailed design, procurement, construction management, commissioning and project management for the Styldrift Merensky Phase 1 Mine Project. The 100 ktpm Merensky concentrator upgrade will provide BRPM the ability to treat all future Merensky reef production from BRPM and Styldrift.