Cairns, Queensland, Australia
James gained his experience as a mechanical engineer and project manager in the mining and mineral processing industries through his employment with international mining companies across a variety of resources including underground coal, iron ore and bauxite. After graduating from the University of Queensland in 2001 with an Honours degree in mechanical engineering, James completed an engineering graduate program at Rio Tinto’s Hamersley Iron Mine where he was responsible for the reliability and failure analysis of the heavy mobile equipment fleet across six sites and involved in the specification and procurement of replacement heavy vehicles. Transferring to Rio Tinto’s Comalco operation in Weipa in 2004 saw him gain extensive operational experience while working in a variety of roles ranging from project engineer to major plant shutdown coordinator. During this period he managed several significant engineering projects from justification though to capital handover. In his role as shutdown coordinator he was responsible for all aspects of planning and execution of major shutdowns across the fixed plant operations including the railway system, beneficiation plants and port facilities. In 2009, after identifying a business opportunity, James started FNQ Engineering, and as the Principal and Manager he has gained valuable insights into the world of private enterprise. His extensive experience in the engineering and project management field has ensured FNQ Engineering has been a successful engineering consultancy now in its 4th year of operation. James provides project management, engineering certification and technical support to a number of organisations in Weipa, including Rio Tinto, local contracting companies, Government agencies, Weipa Town Authority and surrounding Aboriginal communities.
James started FNQ Engineering after identifying a requirement in Weipa for a local engineering consultancy. FNQ Engineering now employs two people and provides engineering services to Rio Tinto Alcan, Weipa Town Authority, local contracting companies, Government agencies and surrounding Aboriginal communities. As manager of FNQ Engineering, James provides project management services for numerous small to medium sized projects in the region from concept and justification through to capital handover. He has broadened his field of expertise to include projects and operational assistance outside the mining sector, including four $1M+ road rehabilitation and reseal projects completed for Rio Tinto, structural designs for North Queensland Bulk Ports Corporation including lead lights and wharf extensions and numerous engineering certifications for private and industrial building developments. James has provided engineering and technical support to the Weipa Town Authority’s Planning and Infrastructure team to facilitate the upgrade and maintenance of major town assets including roads, water, and sewerage. He worked with community groups to secure a number of Government grants for new infrastructure for the Town of Weipa including a skate park and a recreational facility. He has also acted in several operational capacities for the Weipa Town Authority including the development and management of the Weipa Cemetery.
James was responsible for all aspects of the planning and execution of major plant shutdowns on Rio Tinto Alcan’s Weipa site. During the planning stages James was in continual liaison with equipment suppliers, design and construction contractors and the site maintenance teams to ensure all critical tasks were identified for each shutdown. He was involved in the preparation of the schedule to maximise the utilisation of scarce resources and in producing a final schedule and budget estimates for management approval. He was also responsible for the preparation of job packs, engagement of resources, and defining the roles and responsibilities of the teams conducting the work. A total of six successful plant shutdowns were executed while James was coordinator, each ranging in length from 5 to 15 days long and employing 80+ contractors each, all within budget, on schedule and without injury or incident. The shutdowns he coordinated include three major Beneficiation plant shuts on two different plants; two ship loader shutdowns on two different ship loaders including the complete replacement of long travel rails; and the complete rebuild of the Lorim Point AF11 Apron Feeder and truck dump bridge repair and reline.
James conducted the planning and execution of several large plant maintenance activities including the overhaul of the Lorim Point SL2 ship loader long travel drive assemblies, which included a full motor and gearbox retrofit and replacement of all wheels, bull and pinion gears. Responsible for the design and installation of jacking frame assemblies to safely raise and support the 165 tonne ship loader for travel bogie assembly refurbishment. James was responsible for general engineering and technical support of the work being conducted in the main workshop. He commissioned a new CNC plasma cutter for the main workshop and performed the programming of the CNC lathe and plasma cutter.
Initiated an oil cleanliness campaign across the mobile equipment fleet and bulk oil storage facilities. Site contact for hydrocarbons and worked closely with the supplier on a number of projects and was instrumental in the switchover to environmentally friendly oil in sensitive areas of the site such as SL2 ship loader on the Lorim Point wharf. Decreased wear rates in C5/C7 transfer chute by 85%. Developed a concept chute design, calculated ore flows and conducted 3D modeling of the chute. Project was awarded a Rio Tinto “Bravo” for significant improvement to safety. Managed the design, purchase and installation of a personnel and equipment lift to service a seven story Beneficiation Plant. Project included the design of footings, supports and tie-in to existing structure and walkways.
Responsible for monthly availability and utilisation reports for the HME fleet across six sites. Conducted RCA investigations on major component failures in conjunction with the equipment manufacturer and processed any resulting warranty claims. Implemented a program to identify failed / bypassing cylinders on the hydraulic shovel fleet prior to the warranty period expiring. Delivered a number of safety improvements to the heavy mobile equipment fleet including significant work on fire related risks; facilitated risk assessments on each type of mobile equipment across the mine sites and developed a fire suppression standard. Worked on oil analysis and oil specifications for mobile following a number of failures related to incorrect oil specification due to high ambient temperatures and oil contamination in the 994 loaders. Coordinated a fuel additive trial to investigate potential fuel savings in haul trucks and prepared and delivered a presentation to senior management.
Completed the engineering design, drafting and safe operating procedures for Long Wall Removal Equipment including a roof stay for long wall chocks and a rolling equipment platform for heavy air tools. Coordinated the removal, refurbishment and installation of a bore pump & vent fan. Prepared scope and tender documents for a new sump pump installation. Project managed the concrete and pipework installation.