Cardillo Engineering Consulting

Pulverised Coal Injection Plant

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Operations manager during the final construction phase, commissioning and start up of the pulverised coal injection plant as part of a 15-year service agreement with BHP Steel Steelworks at Port Kembla NSW (Total capital $100M).

  • Prepared operator/maintainers for commissioning and start up including 3 weeks of training overseas;
  • Negotiated and sign off enterprise bargaining agreement (EBA) with 3 major unions (AMWU, ETU & AWU);
  • Carried out HAZOPS, CHAZOPs and detailed risk assessment of a hazardous gas plant – developed safe system of work;
  • Achieved 13 years no Lost Time Injuries (LTI’s)
  • Successful start up and achieved maximum injection rates in 40 days (25 days ahead of schedule).

Our Services

Years of Expertise
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Plant Maintenance

  • Develop maintenance plans & strategies for new and existing equipment;
  • Critical spares assessment and inventory management reviews;
  • Review equipment reliability;
  • Equipment life cycle management.
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Process Mapping

  • Process mapping of existing product & work flow;
  • Determine improvement opportunities or bottlenecks;
  • Identify risk points, inconsistencies, efficiencies & gaps in the process;
  • Develop prototypes and specifications for future development projects;
  • Determine process improvements in terms of cost, time, effort, safety etc.
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Risk Assessments

  • Facilitated HAZOP’s;
  • Facilitated CHAZOP’s;
  • Developing “Safe Systems of Work”.
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Readiness to Operate

  1. Develop all shift check lists/sheets;
  2. Develop and implement (test and train) all operational procedures;
  3. Develop operational checks and adjustments (eg belt scrapers, hopper skirt leakage, etc);
  4. Develop equipment troubleshooting skills and procedures;
  5. Establish site access and communications protocols;
  6. Develop operating protocols around emergency operations;
  7. Develop emergency response and tailings handling for major plant shutdowns – emergency storage options, emergency mobile stacker (THOR), trucking;
  8. Set up on-line self-paced refresher training, and
  9. Confirm suitability of all mobile equipment – move from lease to own as required;

Featured Work

We take pride in our work
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What Our Clients are Saying

Dont just take our word
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Sam Marciano – Mine Safety

When it comes to leadership, Walter is a paragon in the mining industry. His ability to communicate openly on all matters is exceptional and his leadership decision making is fair and equitable to both the human and organisational needs. Any industry that has Walter in a leadership role would benefit remarkably from his knowledge, wisdom and skills.

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Tim Gibson – WHSE Manager

Walter is an excellent engineer and great people person

WE CAN HELP BUILD YOUR PROJECT!

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