Enhancing Operational Safety: Fuel Tanks Overhaul
Project Overview
One of the largest providers of commercial explosives and blasting systems to the mining industry approached Fuelfix to inspect and repair two of their self-bunded tanks at the Mount Thorley Warkworth Mine.
Originally the brief was to replace old pipework and perform upgrades on the dispensing outlet of a 105,000L fuel tank and replace the defective flowmeter of a 30,000L diesel tank.
While assessing the site and equipment, Fuelfix was able to determine that both fuel tanks required a 10 Year Inspections.
The customer asked Fuelfix to provide a solution to ensure compliance with legislative requirements and return the self-bunded tanks to their former glory without impacting their operations.
The diesel tanks were not performing well and causing safety issues on site with their configuration being non-compliant with the evolving standards and operational requirements. Additionally, the tank’s location within a hazardous area at the AN facility within the mine posed significant challenges, including the inability to perform hot work.
Considering the fuel tank’s critical role in Low Vehicle and Heavy Vehicle refuelling activities, ensuring a smooth continuity of the operations during the inspection and upgrade of their existing fuel tanks was crucial. The key to success for the client was to get a fast turnaround on completion, minimise operational costs and downtime and avoid the need to manage contractor activities within a hazardous zone.
Fuelfix’s approach to the project at Mount Thorley Warkworth Mine was characterised by meticulous planning, proactive problem-solving, and a commitment to delivering exceptional results while prioritising safety and efficiency.
Through collaborative discussions and thorough assessments, we devised a comprehensive solution that addressed not only the immediate compliance issues but also identified opportunities for improvement.
During the development of the scope, it was identified that exchange tanks were required to keep the site operational during the inspection process.
By strategically scheduling the 10-Year Inspections to coincide with necessary repairs, we’ve minimised downtime and disruption to the site’s operations, delivering a cost-effective and quality solution. The tanks were removed from the hazardous zone, and we were able to perform the work within our depot, avoiding the need for the client to manage contractors performing high-risk work on their site and allowing us to control the project within our depot, meaning no site mobilisation and a faster turnaround with reduced costs.
The Project was split into 3 x sections:
- 10-Year Inspection with a 95,000L and 20,000L exchange fuel tanks provided allowing for Heavy Vehicle and Light Vehicle refuelling.
- Upgrade of tank pipework and dispensing outlets on 105,000L fuel tank and replacement of the flowmeter on the 30,000L diesel tank. Blast & respray of both tanks.
- Demobilise redundant pipework from facility.
By implementing this solution, the site didn't experience downtime during the inspection process and the client’s team was able to access fuel needed for operations in a safe and succinct manner, reducing environmental, personal and operating risks relating to refuelling.
The tanks returned compliant and ready for operation with enhanced safety and efficiency, aligning seamlessly with the client's operational objectives to operate in accordance with Australian and industry standards and maximise equipment up-time and fuel efficiency.
This collaboration highlights Fuelfix's commitment to delivering tailored diesel tanks solutions that address clients' unique challenges while prioritising safety, compliance, and operational efficiency. By leveraging strategic planning and expertise, Fuelfix not only resolved immediate issues but also contributed to long-term asset reliability and performance.
Keep an uninterrupted fuel supply
Whether you’re operating a mine, overseeing a construction project, or managing a large transport operation, it’s important you have a team of specialists available to manage your fuel facility repairs and maintenance.
Here at Fuelfix, we believe an integrated approach of regular inspections and prompt attention to necessary repairs reduces cost, eliminates downtime, enhances safety and protects the environment. Once we’ve installed your fuel tanks and fuel management systems, we can also keep them in top condition. System’s agnostic, we are the ideal specialists for your fuel equipment service needs, whether you bought fuel equipment from us or elsewhere. Our team are strategically located around Australia ready to respond rapidly and keep your fuel supply as uninterrupted as possible.
Contact Fuelfix and Tanks2Go today for flexible energy and emissions solutions to manage current fuel consumption and transition to green energy solutions.
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