Case Study: Oil Tank Replacement Project for a Government Organisation

Project Overview

Our company was tasked with the successful removal of two aged oil tanks and the installation of new, state-of-the-art bunded steel oil tanks for a government facility. This complex project spanned several weeks and involved several phases, from decommissioning and safe disposal of the old tanks to the installation and testing of new fuel storage systems. The goal was to ensure that the new tanks complied with current regulations, improved operational safety, and met the energy demands of the building, while minimizing disruption to ongoing operations.

This case study provides a comprehensive look into how our professional oil tank services team handled the project, the technologies involved, and how we navigated various logistical and technical challenges.

Phase 1: Decommissioning of Old Oil Tanks

Disconnecting the Tanks and Fuel Transfer

On the first day we began by disconnecting one of the old oil tanks. Given the age of the tanks, there was a high risk of sludge buildup at the bottom of the tank. This required careful management to avoid contaminating the transferred fuel. Using intermediate bulk containers (IBCs), we transferred fuel from the decommissioned tank to the second tank. To ensure only high-quality fuel was transferred, the fuel was pumped through an advanced filtration system, removing any sludge or particulates. This ensured that the fuel remaining in the second tank was clean and usable.

Technologies Used:

IBC Containers: For temporary fuel storage and transfer.
Filtration System: To filter out impurities from the fuel.

Tank Removal

Then the physical removal of the old tanks was handled. A Hiab lorry, operated by Welman Transport, was used to safely lift and transport the tanks to a scrapyard. To minimize on-site waste, a skip was delivered by Smyth Recycling, enabling us to dispose of any non-fuel waste, including old components and materials from the tanks.

Technologies Used:

Hiab Lorry: For heavy lifting and transportation of the tanks.
Skip Services: For recycling and waste disposal.

Phase 2: Site Preparation for New Tanks

Structural Modifications and Surface Preparation

On the third day a demolition expert, arrived on-site to begin taking down the supporting pillars from the previous installation. This was followed by the surface preparation work two days later , during which the ground was leveled in preparation for the installation of the new tanks. A key challenge here was ensuring that the removal of the old pillars did not compromise the structural integrity of the area where the new tanks were to be placed.

We also needed to assess the underlying concrete beneath the fiberglass bund after its removal. This was crucial because the condition of the concrete would determine whether additional concrete laying was necessary. Another area of focus was the underground fuel lines, which needed to be tested to ensure they were still safe for use with the new tanks.

Technologies Used:

Concrete Assessment Tools: To determine the quality of the existing concrete.
Heavy Machinery: For breaking up old concrete and leveling the ground.

Phase 3: Installation of New Oil Tanks

Delivery and Positioning

The new oil tanks were delivered to the site a week later . These 15,000-liter steel tanks were designed to meet modern standards for oil storage, ensuring both environmental safety and operational efficiency. A lorry was used to lift the tanks into position, with precision placement ensuring the tanks were securely set in the prepared space.

Installation Process

A day later our engineers returned to transfer the remaining fuel from the temporary IBCs to the new tanks and complete the installation process. The fuel was filtered once again before being pumped into the new tanks to ensure its quality.

Over the course of five working days, our team installed:

New piping that connected the tanks to the building’s existing boiler system.
Fuel boxes and non-return valves, ensuring that fuel could only flow in one direction and preventing any backflow into the system.
Filler pipes, to facilitate future refueling operations.
Bund alarms and overfill devices, to alert the system in case of potential leaks or overflows, enhancing safety protocols.

Our team also installed a protection barrier in front of the fuel line outside the bund area to safeguard the system from external damage. This barrier was securely bolted into the tarmac, ensuring it would withstand the stresses of the environment.

Technologies Used:

Non-Return Valves and Overfill Devices: For safety and operational efficiency.
Bund Alarms: To monitor the tanks and prevent spills.
Protection Barriers: For securing fuel lines and protecting the system from damage.

Phase 4: Testing and Commissioning

Fuel Line and System Testing

Before the tanks could be fully operational, a critical step was to test the underground fuel line, ensuring there were no leaks or compromises in the system. Our engineers performed pressure tests on the lines and confirmed that they were fully functional.

Additionally, we offered the client a choice between electrically powered gauges and battery-operated systems for monitoring tank levels and bund alarms. After discussions with the client, we advised that while electrically powered systems were more reliable in the long term, battery-operated systems required periodic maintenance to replace batteries, which could prove costly and inefficient.

Technologies Used:

Pressure Testing Tools: For underground fuel line testing.
Electrical and Battery-Powered Monitoring Systems: For bund alarms and fuel level tracking.

Phase 5: Final Decommissioning and Site Cleanup

After successfully commissioning the new tanks, we decommissioned the remaining old systems, including removing fuel gauges, dismantling pipework, and clearing out any remaining components. During this phase, we cleaned the bund from the old tank to meet environmental standards. Any remaining sludge or waste fuel was properly disposed of, with up to 1,000 liters of sludge handled in accordance with waste management regulations.

The job was completed with a final site cleanup, ensuring that all old materials, waste, and equipment were cleared from the location.

Technologies Used:

Pressure Washers: For bund cleaning.
Waste Management Systems: For safe disposal of fuel and sludge.

Conclusion

This project involved a wide range of technologies and processes to ensure the successful decommissioning of the old oil tanks and installation of new, compliant systems. Our team coordinated multiple phases, working closely with subcontractors and suppliers to ensure a smooth and efficient operation. Despite the challenges, we successfully delivered a modern fuel storage system that enhances both the safety and operational efficiency of the government organization’s facilities.

With meticulous attention to detail and a strong focus on safety, the new tanks are expected to serve the client for many years to come, providing both reliable fuel storage and peace of mind.