Situation

The Esperance Grain Terminal is one of CBH Group’s four export terminals. It regularly receives more than 1,000,000
tonnes of grain direct from growers during harvest. CBH personnel identified several key improvements to
de-bottleneck the plant, increase export capacity, and improve the return on investment for the grain cooperative. The best way to implement those improvements was unknown, and there was a significant challenge to be ready for a brief shutdown period to implement the changes.

Solution

Aerison identified several key challenges including:

• The plant was built in the 1960s and the availability of accurate as-built information was variable.
• Access to and around the key equipment was restrictive within the brown fields, operating site.
• Completing the site works within a two-week shutdown would be challenging using a traditional, site assembled
  construction methodology.

Aerison personnel attended site to perform a laser scan survey of the plant. Our designers spent a week inspecting the plant and performing the scan, and this firsthand insight helped the design CAD modelling. Aerison recognised an opportunity to install a new access shaft to key equipment below ground level. This new access would allow conveyor modules to be installed during the shutdown, significantly reducing the onsite work hours, number of personnel, and risks.

The Capital Cost Estimate (CCE) was developed utilising Aerison’s experience in procurement, fabrication, on site construction, and implementing shutdowns. A Monte-Carlo range analysis was used to provide a probabilistic estimate and confirmed that the accuracy level was significantly better than the target.

Outcome

The Esperance Tonnes to Port project has progressed from the study and into detail design. CBH are confident that the increased export capacity will be achieved, and that the works will be delivered within the project budget and schedule. Should they choose to do so, CBH can rely on Aerison to deliver the works from this study and detail design, through the shutdown and construction execution, and into ongoing operations and maintenance.