General Manager | Principal Mechanical Engineer
BE (Hons), GradDipEM, AdvDipPM, AdvDipLM, MIEAust
Qualifications:
- Bachelor of Mechanical Engineering (Honours)
- Graduate Diploma of Engineering Management
- Advanced Diploma of Project Management
- Advanced Diploma of Leadership and Management (SADILP Program)
- HAZOP Leader Training
- Hazardous Area Classification (HAC)
- Cert IV Leadership and Management Training
- Structural Steel Design (AS4100)
- Construction White Card
- Confined Space, Working at Heights, High-Risk WP License
Professional Summary:
Daniel Halls is Ingenia’s General Manager and Principal Mechanical Engineer, with more than 14 years of hands-on experience delivering technically complex, safety-critical engineering projects across Australia. With a core focus on materials handling systems, mechanical design, risk assessments, and project management, Daniel leads multi-disciplinary teams in the successful execution of projects across the industrial, construction, mining, and food and beverage sectors.
Daniel has a proven track record in the integration of complex mechanical systems—designing and managing assets such as bulk storage silos, pressure vessels, elevated tanks, pipelines, machine components, and automated handling equipment. His design leadership covers both new installations and major plant upgrades, ensuring efficient system layouts, compliance with Australian and international standards, and alignment with broader operational goals.
His meticulous approach to engineering design—particularly in Finite Element Analysis (FEA), structural mechanics, and detailed mechanical engineering—has resulted in safe, robust, and efficient project execution that consistently exceeds client expectations.
He is highly experienced in applying standards such as AS1657 (Fixed platforms), (AS1210 (Pressure Vessels), AS1170 (Structural Actions), AS3990 (Mechanical Equipment), AS4100 (Steel Structures), AS4024 (Machine Safety), AS2304 (Fire Tanks), and Hazardous Area Classification. Daniel’s strength lies in bringing these technical requirements together with project constraints—budget, schedule, safety, and operational continuity—ensuring holistic, risk-aware solutions that stand up to real-world conditions.
As a qualified HAZOP facilitator, Daniel has led numerous HAZOP’s, risk assessments and Safety in Design (SID) workshops across a range of industries. His work has included complex scenarios such as diesel power stations, flood gates, burner management systems, and material diversion systems. His experience also extends to Reliability Centred Maintenance (RCM) and forensic engineering, supporting clients in improving long-term asset performance and safety.
Beyond technical delivery, Daniel is known for his approachable leadership style and strong communication skills. He builds lasting relationships with clients by aligning engineering outcomes with business objectives—whether it’s improving plant efficiency, increasing throughput, or reducing safety and compliance risk.
Key Skills and Expertise:
- Leader in mechanical engineering across industrial, materials handling, construction, and food & beverage sectors (Principal Mechanical Engineer)
- Collaborative problem-solver with excellent technical and client-facing communication skills
- Project and contract management with a focus on high-quality delivery
- Subcontractor management and Governance
- Facilitation of HAZOP studies, risk assessments, and Safety in Design (SID) processes
- Expertise in Finite Element Analysis (FEA), structural design, and solid mechanics
- Materials engineering, manufacturing processes, and Reliability Centred Maintenance (RCM)
- Hazardous Area Classification (HAC)
- Strong background in pressure vessel, tank design and pipeline design to Australian Standards (AS1210, AS2885, AS3788, AS4041, AS4343) and International standards API 650 & API 620.
- Knowledgeable in Engineering Management & Professional Practice
- Proficient in production line layout
- Square and round fire tank design (AS2304)
- Experience in machine design including AS4024 machine audits
- Fixed platforms, walkways, stairways and ladders Auditing (AS1657)
- Forensic Engineering
Projects & Experience:
Daniel has played a key role in the successful delivery of many major engineering projects across Australia. His work includes high-value developments in the mining, materials handling, and industrial sectors, as well as plant and equipment upgrades to new and existing facilities.
Education, Certifications, and Memberships
- Bachelor of Mechanical Engineering (Honours), Adelaide University
- Professional Member of Engineers Australia
- Graduate Diploma of Engineering Management
- Advanced Diploma of Leadership and Management (SADILP Program)
- Advanced Diploma of Project Management
- HAZOP Leader Training
- Hazardous Area Classification (HAC)
- Structural Steel Design (AS4100)
- Construction White Card
- Confined Space
- Working at Heights
- High-Risk WP License
Silos and Hopper Design
Daniel has extensive experience designing and managing silos, bins and hopper design in compliance with Australian and European Standards, including:
- 1000t Silo Design
- Fringe Materials Silos
- Aggregate Bins and Hoppers
- Tundish Design
- Flow improvements and upgrades
- Material sampling and diversion
Pressure Vessel, Tanks, and Pipeline Design
Daniel has extensive experience designing and managing pressure vessels, tanks, and pipelines in compliance with Australian standards, including:
- Elevated Water Tank Design
- Vertical and horizontal pressure vessels (AS1210)
- Pig Launchers and Receivers (AS2885)
- Chiller pipework (AS2885)
- Transport pressure vessels (AS1210)
- Ethanol and hot oil pipelines, flexibility analysis (AS2885)
- Numerous industrial storage tanks (AS1210, AS2304, API 650 & API 620)
- Numerous industrial bins and silos (AS1210, AS3774, AS3990, AS4100)
HAZOP Facilitation
Daniel has facilitated over 40 HAZOP and Risk studies across various projects, ensuring comprehensive risk management and safety compliance. Key projects include:
- Lime Chip HAZOP
- Malting Plant HAZOP
- Wastewater Pump Station HAZOP
- Multiple Gas Burner / Burner Management System (BMS) HAZOPs
- Diesel Power Station HAZOP
- Silo and Process HAZOPs
- Flood Gate HAZOP
- Large Silo HAZOP
- Pumping System HAZOP
- Blending System HAZOP
With a proven track record of delivering complex projects on time and within budget, Daniel combines his mechanical engineering expertise with strong project management capabilities, ensuring every project meets the highest standards of safety, quality, and efficiency.
