Project Details
Introduction
Zeus Oil & Gas Pty Limited were proud to announce the completion of our first major Design & Construction project in 2009.
The completed facility was handed over to our client on 31st July 2009 within budget and exceeding the design criteria.
Our brief was for the Design and Construction of a world class facility to be used for the testing and approval of trade measurement flow meters used in the Petroleum, LPG and CNG market sector.
The scope was expanded during the period of construction to include the development and installation of a computerized control system to allow accurate control and reporting of the events undertaken in the testing of flow meters. The expansion bought the total value of the project to $3.85M.
Design & Construction
The design was managed in a co-operative manner with our client, involving them in every step of the process with ourselves and our specialist consultants including: – architect, civil, structural, hydraulic, electrical, HVAC and dangerous goods design specialists.
Project Images
Our client signed off on the design in August 2008 and construction commenced in September, the construction was managed in-house by our management team.
The site chosen by our client was at the Test Safe site on Londonderry Road, Londonderry, NSW. The site is typical clay flood plain area and the site had a creek running through it at some time in ancient past, we removed more than 1000 tonnes of soft clay and refilled the area with crushed sandstone to provide a suitable base for the building.
We installed a 30,000 litre double wall fiberglass underground tank for the storage of motor spirit and automotive diesel oil substitutes.
In conjunction with our client and consultants we chose to build a portal frame building standing on a raft slab.
We used pre-cast concrete walls from ground level to 4 metres high for temperature insulation, sound annuation and where necessary increased the thickness of the concrete walls to provide blast walls between hazardous and non-hazardous areas.
From 4 metres high to the roof we used colorbond cladding, insulated on the inside and with ventilators fitted in the walls and the roof to achieve a constant air flow through the building to maintain constant temperatures and to dissipate any accumulated vapours.
Control System
The computerized control system selected was Emerson Flow Boss© S600 Programmed Logic Controller.
Two controllers were installed to manage both liquid and gas flows, the actions of which are monitored and criteria variables can be changed using SCADA interactive PC’s
The facility is divided into four specific areas of testing:-
Bulk Flow – Meter Testing
We constructed fixed rig for testing bulk flow meters varying in size from 50 to 150NB., with the ability to calibrate flow rates from 7 to 4000 litres/minute using (non-flammable combustible) hydrocarbon based fluids that simulate the same kinematic viscosities of motor spirit and automotive diesel oil.
Typical bulk flow meters tested on this rig are those used at oil refineries, ships and marine terminals where large amounts custody transfers occur.
The test rig consists of an Emerson ballistic meter prover coupled to two EBSRAY V40 variable speed vane pumps where flow and pressure are controlled using Fisher control valves. All pipe work, valves and equipment are stainless steel.
Supply fluid for either a motor spirit or automotive diesel oil proving is pumped from underground storage tanks into an above ground stainless steel day tank which ensures that the pumps are fed with constant head and pressure and the fluid is maintained at a constant temperature during the proving process.
Driveway Flow Meter Testing and Pattern Approval
The National Measurement Institute undertakes pattern approval for fuel dispensing equipment imported into Australia; these typically consist of retail motor spirit and automotive diesel oil – pumps and dispensers.
Pattern approval involves rigorous testing of all aspects of the equipment for safety, usability and approving of the flow meters in such equipment.
We provided a test area for pattern approval which uses the same common equipment as used for bulk flow meter testing, we engineered out as many manual handling risks as possible and provided safety interlocks so that product exposure is minimized.
LPG – Flow Meter Testing
This fixed rig is for testing LPG flow meters varying in size from 25 to 100NB can, with the ability to calibrate flow rates from 5 to 2000 litres/minute using commercial grade Propane and Butane as test fluids.
Typical bulk flow meters tested on this rig are those used at gas platforms, ships, marine terminals and delivery vehicles where custody transfers occur.
The test rig we constructed consists of an Emerson ballistic meter prover coupled to EBSRAY V20 & V40 variable speed vane pumps and again flow and pressure are controlled using Fisher control valves.
All pipe work, valves and equipment are carbon steel designed and manufactured to AS4041-1998
The LPG is stored in two 5300 Litre above ground storage tanks and is protected with a fire deluge system
CNG Flow Meter Testing
The CNG system was existing at another location and transferred to this new location, we designed constructed the area to house this equipment and protected it with the fire deluge system.
CNG flow meter testing is achieved by comparing the amount of gas passed through the meter with the weight of gas in specific receiving bullets that are mounted on load cells.
The call for this type of testing is limited at the moment to Government bus fleets etc; but is sure to expand as the use of CNG becomes more common.
Occupational Work Health & Safety
All aspects of WH&S were monitored by our Management System which complies with the Building and Construction Industry Improvement Act 2005. No incidents or accidents occurred during the project.