FillSafe Zero

Banlaw’s mechanical tank overfill protection systems help mining, construction, and rail companies that need to refuel diesel-powered machines efficiently and safely. They achieve this by avoiding productivity loss from underfills, overfills, and tank damage while delivering substantially higher flow rates under normal operating conditions.

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Prevent fires on mine sites! Take ownership of maintenance

Due to a series of recent fires on mine sites, we’ve decided to focus this article specifically on the fire risk associated with using fuels and oils in an industrial setting. Banlaw team members spend well over 100,000 hours a year designing, building and maintaining dry break fuel systems, processes, and infrastructure. Our service teams spend the majority of their hours on site, auditing fleets and facilities, training operators, delivering preventative maintenance, or analysing the data that’s been captured on mine sites to find improvements. We’ve seen pretty much every conceivable way that a fire can be caused in a fuel facility or on mobile plant. Below is what we’ve learned about avoiding fires over the last 37 years.

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Tank Overfill Prevention – Are your tanks spill free?

Are your generators, vehicles, plant equipment or stationary tanks overfilling? There are numerous ways to manage the risk of tank overfill, and in this blog article, we’ll lay out some of the most common, along with the pros and cons of each. Your first question is probably ‘Why should I care?’, and you’d be asking the right question. It all comes down to risk; what is going to happen in each specific situation if an overfill occurs? Does your current risk management program consider the variables of each application, specifically those variables which may determine a hazard? The ALARP principal is often used in the regulation or safety-critical systems, and requires that residual risk is reduced “as low as reasonably practicable”. If you overfill a small storage tank used for water, it may be that plants will get watered, and ‘people could get wet’.
With liquid hydrocarbons, it’s often more of an issue. Soil and water become contaminated, tanks are ruptured, critical machines burn down, explosions occur; people can die.

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How Banlaw has helped Indonesia’s premier coal mine

International Mining magazine visited the Kaltim Prima Coal mining complex in Indonesia in late 2015, to see how such a large operation manages its huge fleet of machines over an extensive area. Kaltim Prima Coal (KPC) is the world’s largest single producer and exporter of thermal coal, as well as largest single coal mining complex in Asia. ‘Back in 2008 the fuel accounting system at KPC was still highly manual, yet local teams were expected to manage inwards deliveries of some 3 million litres of diesel, which were arriving by barge every couple of days. This product was being hauled 16 km by tanker trucks and pipeline to the ROM storage area. From the ROM area, the diesel was used to fill haul trucks and large service trucks which would operate at refuelling locations within the pit. Pretty much everything was hand written, while contractors on the site also had to acquire the fuel they needed via a paper-based system. These factors caused significant difficulty in terms of reconciling around 1.6 million litres per day.

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Refuelling Faster than Formula One

Fuel is the number one consumable expense for most heavy industrial operations and fleets. Inefficient refuelling wastes significant time and money. Formula One fans are currently waiting for the FIA to confirm whether in-race refuelling will be allowed once more. While Bernie Ecclestone and some drivers are all for it, there are also safety and cost considerations. When refuelling was last introduced to F1 in 1984, the pit lane went from being somewhere to stop with a problem, to the place where competitive advantage is achieved. On this highly visible stage races were won with a combination of high speed refuelling hardware, a well-trained team, and optimised processes.

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