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Fuel consumption is at the heart of all transport and mining industries. Likewise so too is the maintenance of this infrastructure. Fuel systems servicing and maintenance is critical to any modern rail, fleet, mining or port operation and there is no company better placed to manage this for you than Banlaw. Banlaw has been established since 1980 and are the “Pioneers in Unified Fuel Management”. Operating as specialists in refuelling and other fluid transfers, Banlaw offer an onsite fuel system maintenance capability unlike any competing solution globally.

Banlaw has a dedicated Research and Development team that are committed to continuous improvement of our products and services in order to maintain our industry leading position. Our team can also work on specific projects to solve your particular refuelling or hydrocarbon management issues. For example, we have worked with Pacific National – a large freight loco operator in Australia – to develop our unique in-line refuelling coupling to overcome concerns they had regarding their fluid couplings used within In Line Refuelling systems, commonly used on longer haul journeys.

Our LubeCentral range of couplings is designed to fill and evacuate a wide range of fluids. This helps all heavy industries, including mining and rail businesses that want to service key equipment cleanly, and quickly. LubeCentral products have been specifically created for the job. They avoid contamination and cross-contamination of fluids, and maximise flow rates due to engineering design focused on optimising the fluid path.

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.

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.

Banlaw’s fluid evacuation couplings transform waste fluid removal practices. Using just one Coupling, service teams can connect to all the Banlaw Flush Face receivers from size 1 to size 11. Waste products are evacuated using a vacuum rather than gravity to reduce fluid removal times.

Service Truck Fuel Management System

The following is an excerpt from the Austmine webinar ‘Predictive Maintenance and Life of Asset’, which was aired to Australian Mining, Equipment, Technology, and Services organisations (METS) in August 2016. The presenter; João Silveirinha, is Banlaw’s Group Engineering & Development Manager. João’s background is innovation in engineering across a range of industries; more recently Energy, Oil & Gas, and Mining. On a day to day basis João is involved in planning around Functional Safety, Machine Safety and Explosive Atmospheres. His team leverage many of the key International Standards that form the guidelines for safe and innovative practices across numerous heavy industries. João is originally from Portugal, and is now based out of Newcastle in Australia.

Modern engines and plant equipment are designed to offer increased efficiency, reduced emissions and longer service intervals. As a result, they are also more sensitive to fuel and oil contaminants. In particular, higher fuel pressures within engines to achieve a more complete combustion lead to closer tolerances, causing even smaller particles to have an effect on the life and performance of fuel system components. Modern ULSDs and biodiesels also pose an increased risk of water (moisture) retention and microbial contamination, which left undetected and untreated, can seriously degrade the quality of the fuel, and introduce other problems including reduced fuel filter life and accelerated corrosion of tanks, pipes and other metal components.