FUELS AND OILS
is a heavy vehicle dispensing skid, self-bunded,
with two pumps (duty/standby configuration)
and two-stage filtration integrated into the skid.
There is also a dispense metering skid, self-
bunded, with flow meter and FMS control
valves. This skid is located adjacent to a
Banlaw-manufactured loading arm. Dry Break
Auto ID dispensing nozzles make a direct
electronic ID connection due to Auto ID
technology being integrated inside of the
refuelling hardware. This allows for process
automation and industry best diesel flow rates
for an expected fleet of 67 heavy vehicles.
The Fuel Management System itself has five
Fuel Management Controllers providing local
user interface, fluid security, collecting
temperature compensated flow data, and
triggering the activation of pumps and valves.
Flow and temperature-compensated fluid
measurements are captured throughout the site
to enable industry-best reconciliation accuracy.
PLC-controlled automated stock rotation
capabilities have been deployed to minimise
fluid degradation within both storage facilities.
Two 6 m Motor Control Centre (MCC) platforms
provide powered-hardware control for the
facilities and all Banlaw systems have been
configured to interface with the site control
network, allowing control room visibility and
interaction with pumps, alarms, tank levels, and
PLC systems (SCADA). Banlaw’s ResTrack RMS
(Resource Management System) is the
overarching software for enterprise reporting,
and the configuration of all fluid storages,
moves, and access for fuel-consuming assets.
Go-live support includes Banlaw presence on
site for the period directly after system
activation. Banlaw technicians focus on the
training of users to enable safe fuelling and
fluid-management processes, establishing
accurate FMS reporting, and ensuring all
systems are functioning correctly.
The Service Level Agreement covers ongoing
remote services support to reconciliation
accuracy, identifies continuous improvement
opportunities, and ensures software
maintenance is conducted in a timely manner.
Site visits are conducted quarterly. During these
visits, meter calibration services (using NMI-
certified master meters) are performed to
ensure the reconciliation target of >99.5%
accuracy is achieved. These visits also focus on
safety checks, and improvement plans aiming to
deliver cost reductions, and efficiency gains.
There were some environmental challenges
to address. The area of operation is prone to
cyclones, and therefore all structures need to be
cyclone-rated. This was of particular importance
for the Motor Control Centres (MCCs), due to the
large platforms (around 6 m in length). Also
during the ‘wet season’, humidity remains
38 International Mining | JULY 2018
above 85% for months on end, and rainfall per
year exceeds 2 m for the work site. Besides
influencing in which months deployment of the
fuel management project would be possible,
these local conditions mean that tropics-rated
(very high humidity) electrical motors needed to
be used to ensure reliable long-term operation
of equipment. During the ‘dry season’ there are
some months with average rainfall of just 1 mm,
and humidity averages 61%. For this reason,
both storage and dispensing functions include
particulate dust controls.
Finally, bauxite, the resource being mined,
has significant corrosive properties. Tanks,
pipework, skid frames and more have been
specially treated to make them resilient to
constant exposure to the minerals it contains.
“Large and long-term resource projects such
as Amrun, engender a great deal of attention
and also concern from the public and
government. Governance and visibility is critical
for all stakeh