Execution Strategy:  

Design, Fabrication and Logistics  

• Developed 3‑D models and isometrics to ensure perfect alignment once re‑assembled.  
• Completed factory‑acceptance testing (FAT) for instrumentation loops, MCC wiring and PLC I/O.  

• Disassembled the skid package into six road‑freight modules under Main Roads WA limits.  

• Coordinated heavy haulage and permits for the multi‑day journey from Perth to Exmouth.  
  
  

Installation and Mechanical Tie‑In  

• Re‑erected all skids on reinforced plinths with zero cumulative alignment error.  

• Completed NATA‑certified hydrostatic pressure testing.  

• Integrated PLC and SCADA controls into the facility’s existing DCS with hot‑cutover.  
  
  

Commissioning and Optimisation  

• Flushed, purged and started up each skid in stages prior to live fluid introduction.  

• Tuned PID loops and verified fail‑safe shutdown sequences to meet SIL‑2.  

• Trained operators and handed over full O&M documentation.  
  
  

Project Challenges and Solutions  

Remote Regional Location  

• Modular design allowed 95 % of fabrication and testing in Perth, reducing site time and weather delays.  
  
  

Harsh Coastal Environment  

• Hot‑dip galvanised frames and 316 SS instrumentation protect against salt spray and cyclonic winds.  
  
  

Compressed Schedule  

• Pre‑task SIMOPs workshops and 24/7 split‑shift roster kept critical path on track during 12‑day outage window.  
  
  

Integration with Existing DCS  

• Used shadow PLC testing and phased I/O migration to maintain >98 % plant availability. 
   

Client Response  

The client commended our ability to deliver a turnkey package in a logistically challenging region while maintaining zero harm and zero unplanned downtime. The six‑part skid hit nameplate capacity on the first pass and reduced pump power draw by 7 %.  

For more information about our projects, visit: MECS Group Projects