FUELS & OILS
problems related to the filling process. The
pneumatic system was failing to reliably allow
any fluids to be pumped in. Some compartments
were also failing to cease filling at the correct
level, causing overfills. It was identified that
several floats had broken-off inside the tanks
due to the continuous sloshing around of
liquids, and the complex arrangement of
pneumatic lines was suffering wear and tear,
regularly failing. Banlaw’s simple ball valve,
level switch, and controller setup for each tank
removed the need for mechanical and
pneumatic parts inside the tanks which can be
prone to fail in this way. The Banlaw distributor
on site replaced the existing system with a bank
of FillSafe Power controllers with LED tank
status displays, all colour coded and located
adjacent to the service fluid fill points.
This new approach by Banlaw to use an
electronic solution for service truck filling and tank
safety has helped miners in Australia and the
Pacific overcome tank filling efficiency, safety, and
reliability concerns. The service trucks from these
projects do more work, more safely, and operators
know at a glance which fluid storages are full, and
which can be topped up. Banlaw’s FillSafe Power
is “a unique modular solution, suitable for all fluid
types, all flow rates, with integrated tank status
indicators at the fill point, and visual alarms just in
case anything goes wrong.”
Total Power, Inc covering all bases
Total Power, Inc. says it continues to provide
trusted fuel solutions for mining companies.
Staring with fuel treatment, TPx HD is a fully
synthetic fuel additive that is used by mining
companies to reduce fuel consumption, DPM, and
improve fleet readiness.
“The additive generates
savings by converting
waste into productivity;
reducing injector failure,
filter clogging, and black
smoke from diesel
equipment, turning these
problems into
opportunities. Also, Total
Power offers FMx fuel
management systems to
globally diverse
operations. Our goal is to
engineer solutions that
handle demanding
environmental challenges while being simple to
implement and operate. As these systems are
installed in remote facilities, they need to be
resilient in order to operate successfully.”
A system is currently being installed that will
remotely manage 36 Mgal/y of fuel, though a
network of 25 fuel stations in the Peruvian copper
belt. The system will track user ID using RFID,
includes touch screens for operators, and can
generate custom reports to a user anywhere they
have internet access. In addition to what FMx Fuel
Management can deliver to mining clients Total
Power has also started offing a ‘light’ alternative
for less complex facilities. “FMx ‘light’ will utilise
WiFi, satellite or 4G LTE (Verizon or AT&T) for
inventory management. Introducing FMx ‘light’ at
a lower price point simply expands the
possibilities for mine operators while maintaining
a focus on trustworthy data.”
The newest product from Total Power is Pit
Stop™, a fully integrated, modular, fuelling
Banlaw FillSafe™ Power Solution
n A simple pressureless tank filling solution that cannot be overridden. There is no way to overfill
tanks when the actuated valve is closed
n Bright LED indicators at the fill point show operators whether a tank is already full, or that it is able
to be filled
n A bank of controllers at the fill point ensures safe filling for any number of fluid types
n Systems can be engineered to cater for any flow and any fluid. It works perfectly for service fluids
at low fill rates and diesel fuel at very high/efficient flow rates
n Suitable for oils, coolant, AdBlue, diesel, and all other liquids
n Can be used with oil couplings, dry break refuelling equipment, camlocks and other fluid transfer
fittings of all makes
n Includes none of the mechanical parts or pneumatic components inside the tank, which often fail
from the rigors of day-to-day mine site operation
n Level switches have built-in redundancy and can be manufactured with up to five pre-set fill levels
which can be selected with a key switch
n Actuated valves are closed automatically at the appropriate fill level for each fluid storage,
stopping tanks from overfilling
n Ball valves are maintained in a closed position when not filling to avoid potential spills
n The FillSafe Power Controller has built-in visual alarm warnings should the system identify a
malfunction in any of the major system components
n Banlaw FillSafe™ Power is simple to install on site using standard Banlaw products and following
simple guidelines
Total Power has helped define the PSx
PitStop™ as a solution for large scale mining
clients to rethink their needs for standard fixed
site facilities
station. The modular and integrated design allows
the fuelling station to be quickly located (or
relocated) near production routes in order to
reduce empty travel time. “The fuelling station
integrates high capacity UL-142 double walled
storage tanks (21,000 gal for diesel & 1,000 gal for
oils), high speed pumps, large air compressors,
and a powerful 480v generator. Everything that
the station needs to operate is self-contained. The
station comes outfitted with swinging or roll-up
doors, LED lights, non-slip floor, and skidded so it
can operate safely, cleanly, reliably. It can be
scaled up or down to fit the requirements of any
company. Total Power is currently working on the
design and engineering for high altitude units that
will incorporate robotic fuelling arms.”
Filtration, the pill for cleanliness
External contamination of diesel fuel reduces filter
life, diminishes fuel life and can cause premature
fuel component failures. Failure to maintain good
housekeeping practices on fuel products will
eventually result in diesel engines encountering
problems caused by contamination that occurs in
the fuel distribution system. The main factors
associated with poor quality fuel are often related
to particulate and water contamination. The
original Caterpillar Diesel Fuel System Care advice
stated that: “90% of diesel troubles are due to dirt
or water in the fuel. For successful operation it is
necessary that these impurities be kept out of
fuel.”
This statement was chronicled in 1931 but
global fuel and lubricants major Total argues
remains as applicable today (if not more so) for
technologically advanced engines. “High Pressure
Common Rail (HPCR) fuel systems require even
more stringent fuel cleanliness levels. This is due
to the increased sensitivity of these systems to
small particulate contaminants especially under
very high pressures of up to 2,500 bar. The World
30 International Mining | JULY/AUGUST 2020