Jeff Carey

The Electronically Controlled Pneumatic Braking (ECPB) is the key enabler for introducing longer, heavier trains, increasing the trains to be loaded from 38-40 tonne axle loading and increasing rake length from 124 to 132 wagons. In total 4,567 wagons required retrofitting upgrading to ECBP. This was done at Boodarie workshop which contained three parallel roads allowing for three independent and concurrent processes consisting of Shunting, Welding and assembly in a ‘Pit-Stop’ style methodology.($120M AUD)

The 291km Bridge Project consisted of a new water crossing, incorporating reinforced precast concrete box culverts installed parallel to the existing NML 291km bridge. The track was realigned over the new culverts and then connected back into the existing NML track. The Project delivered an engineered solution that complied with current Australian Standards and mitigated the risks identified by the stakeholders. The Project complied with Health and Safety (HS) Project target of zero harm and an environmental target of nil net effect. It was managed so no unplanned impact on production occurred and met the WAIO standard specification of 50 years design life.($8m AUD)

The Ballast and Track Remediation (BTR) Project has remediated 180km of mainline track, including 18 turnouts between Port Hedland and Newman. The BTR Project was established to life extend the existing track that was constructed in the late 1960s and to allow increased tonnage output. BTR imported a ballast cleaner (RM80) from Europe and has successfully carried out full track bed remediation works including turnout remediation. The project involved managing 160+ personnel in a remote area. ($300M AUD).

Project description: $300M Major Port expansion at the Geraldton Port Authority including:. • Relocation and upgrading of existing electrical circuits • A twin-car rotary dumper (or train unloader), which is also capable of bottom dumping • A 297m long storage facility with a capacity of 255,000t to house stockpiles of magnetite concentrate and hematite DSO delivered to port • In feed conveyor and out loading conveyor circuit • A dedicated Berth 7 and ship loader which can accommodate Panamax vessels (loaded to approximately 60,000t).

Duties: • Maintain a comprehensive understanding of the project and provide advice to the Project Manager. • Internal Liaison and Communication with Iluka management and staff. • Manage project risk assessment. • Represent and ensure the Iluka’s interests are met. • Provide the key contact and communication channel between the clients & Iluka • Provide input into design development including recommendation on drawing acceptability to the Project Manager. • Provide input into the preparation of project budgets • Preparation of Scopes of Works & associated tender documentation. • Tender assessment. • Estimating, and running various awarded jobs from procurement of materials through to planning and site installation • Coordinate Site Meetings • Issue and Manage Site Instructions. Analyse and provide recommendations on applications for Extension of Time and subsequent delay costs if applicable • Maintain comprehensive daily records

Duties: • Manage and organise the shutdown/ Project teams varying from small shutdowns to larger site specific projects. Frequently requested by Iluka resources, to join their team as a supervisor on their major, multi-million dollar major planned outages. • Attend post shutdown meetings with clients to ensure all client’s need were met satisfactory, both internal and external. • Ensuring that all personnel operate in a safe and effective manner while complying with time and budget constraints to the client’s satisfaction. • Build and Maintain relationships with new clients to ensure continuity of work is achieved. • Estimating, and running various awarded jobs from procurement of materials through to planning and site installation. Duties include organising parts to be fabricated in workshop and machine shop, ensuring the availability of manning resources, reviewing job tasks and allocating the appropriate resources. • Warman 14/12 pumps and other various smaller Warman pump complete overhaul/ refurbishment. • Develop improvements to Iluka Eneabba Scrubber drive assemblies. Introduce these improvements, for longer plant liability. Research and development of Iluka Kiln cooler ID fan’s for reliability improvements • Travel both nationally and internationally to carry out kiln servicing duties including Kiln Tyre and Trunnion machining, Girth Gear alignment, Pinion Gear alignment, Inclination checks, Surveying of Kiln layout and Kiln tracking. • General plant maintenance, and fitting duties including but not limited to machining duties, welding & fabrication, hydraulic and pneumatic installation & troubleshooting. Gear box repair/installation, conveyor repairs • Condition monitoring and Laser Aligning

Duties: • Coordinate personnel and equipment movements for site shutdowns and plant maintenance at both BHP Finnican Island and Nelson Point. • Build and Maintain relationships with new clients to ensure continuity of work is achieved • Attend post shutdown meetings with clients to ensure all client’s need were met satisfactory, both internal and external. • Estimating, and running various awarded projects from procurement of materials through to planning and site installation. Duties include organising parts to be fabricated in workshop and machine shop, ensuring the availability of manning resources, reviewing job tasks and allocating the appropriate resource, Producing close out reports to the client and ensuring all timekeeping paperwork and invoices are completed • Pump reconditioning and fitting duties • Welding & Fabrication • Overhaul and recondition to bring back to specification large industrial sized gearboxes using Horizontal boring machine. • Fabrication repairs and site installations of Conveyor head, tail, take-up and snub pulleys. • Gearbox repairs and alignment and general machining duties • Carry out shaft alignment on typical pump-motor setups using laser alignment techniques. Perform spindle alignment on a machine using laser optical spindle alignment techniques and conduct pulley alignment on a belt-driven system using laser emitter and reflector techniques • Condition monitoring of Gear boxes with BHP to prevent plant failure and to plan equipment change outs during planned outages.

Duties: • General machining duties • Welding & Fabrication • Line boring & Laser aligning duties, traveling to and Covering the entire Pilbara region • Build and Maintain relationships with new clients to ensure continuity of work is achieved • Line boring machining, including re boring of holes on dozers, backhoes, and front end loaders. Additionally boring repairs to areas such as backhoe and track hoe buckets, articulating joints, wheel loader arm pin-holes, and hinge points in tilt bed trailers, and steering axle sleeves in heavy duty fork trucks as well as dump body locating pin hole and chassis locating pins. machine faces, PCD's and bores ranging from 40mm to 400mm • Flange facing of high pressure vessels on the BHP Billiton HBI project.

Duties: • General machining duties • Welding & Fabrication • Shutdown & Project work • Line Boring • Build and Maintain relationships with new clients to ensure continuity of work is achieved. • Attend post shutdown meetings with clients to ensure all client’s need were met satisfactory, both internal and external. • Coordinate personnel and equipment movements for site shutdowns and plant maintenance at both Iluka plants located in Geraldton as well as Iluka’s miming area located at Eneabba. • Estimating, and running various awarded jobs from procurement of materials through to planning and site installation. • Organising parts to be fabricated in workshop and machine shop, ensuring these items are completed on time and under budget. • Apprenticeship completed