Newmont Refuelling Report April 2005
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1
BANLAW PIPELINE PTY LTD ABN: 88 062 044 071
Report on the Performance of Banlaw Pipeline Nozzles Refuelling CAT 793 Haul Trucks At the
Main Refuelling Bay
FOR
PT Newmont Nusa Tenggara April 2005 Submitted by: Paul Buckton – Operations & Technical Services Manager
“Hydrocarbon Management Specialists”
2
Refuelling Report 20th April 2005 This report was compiled to report on the operation of the new Banlaw Pipeline Refuelling Nozzle BPM800 onto Bay 1 at PTNNT main fuel bay as a trial on the 13th April 2005. The following observations were noted: Bay 1 – (New Banlaw Nozzle BPM800 H) Truck: #63 Cat 793C Flanged type receiver socket with Green Wiggins receiver. Flow rate at 560lpm nozzle handle was shaking and poppet / retainer rattle was audible. Truck #30 drove into bay 2 and commenced refuelling. The flow rate in bay 1 dropped to 360lpm and the nozzle vibration ceased. The nozzle shut off automatically when the tank was full with severe spillage from the remote mounted filter The new nozzle was dripping from the bleed hole in the end cap. Bay 2 – (old style Banlaw nozzle BAM800 H) Truck: #30 Welded type receiver socket with Wiggins receiver. Flow rate at 430lpm while refuelling at the same time as truck #63 in bay 1. Flow rate increased to 580lpm with refuelling at bay I was complete. Didn’t get to see the end of the refuelling but no evidence of spillage was noticed. Bay 1 – (New Banlaw Nozzle BPM800 H) Truck: #61 Cat 793C Flanged type receiver socket with Purple Wiggins receiver. Flow rate at 560 lpm nozzle handle was shaking and poppet / retainer rattle was audible. The flow rate slowly decreased to around 470 lpm then around 5 – 10 seconds later the nozzle shut off. No spillage was observed No sign of fuel dripping from bleed hole in back of the end cap Bay 2 – (old style Banlaw nozzle BAM800 H) Truck: #103 CAT 785B Welded type receiver socket with Wiggins receiver. Flow rate at 370 lpm while refuelling. Standard wiggins Vent. Auto shut off no spillage.
“Hydrocarbon Management Specialists”
3 Bay 1 – (New Banlaw Nozzle BPM800 H) Truck: #74 Cat 793C Flanged type receiver socket with Banlaw receiver. Flow rate began at 330 lpm after 175 litres flow rate increased to 580lpm. Orica truck began fuelling at bottom fuel bay and flow dropped to 435 lpm then after orica truck was full flow returned to 580lpm. Major spillage was observed. (see photo) No vibration audible during refuelling Bay 1 – (New Banlaw Nozzle BPM800 H) Truck: #22 Cat 793C Welded type receiver socket with plain Wiggins receiver. Flow rate began at 330 lpm after 175 litres flow rate increased to 560lpm. Standard Wiggins Vent ZV10 No spillage was observed. Automatic Nozzle shut off No vibration audible during refuelling Bay 1 – (New Banlaw Nozzle BPM800 H) Truck: #60 Cat 793C Welded type receiver socket with plain Wiggins receiver. Flow rate began at 330 lpm after 175 litres flow rate increased to 560lpm. Standard Wiggins Vent ZV10 No spillage was observed. Automatic Nozzle shut off No vibration audible during refuelling Bay 2 – (Banlaw Nozzle BAM800 H) Truck: #15 Cat 793C Welded type receiver socket with plain Wiggins receiver. Flow rate began at 330 lpm after 175 litres flow rate increased to 540lpm. Standard Wiggins Vent ZV10 No spillage was observed. Automatic Nozzle shut off No vibration audible during refuelling Bay 1 – (New Banlaw Nozzle BPM800 H) Truck: #26 Cat 793C Welded type receiver socket with plain Wiggins receiver. Flow rate began at 330 lpm after 175 litres flow rate increased to 560lpm. Standard Wiggins Vent ZV10 No spillage was observed. Automatic Nozzle shut off No vibration audible during refuelling
“Hydrocarbon Management Specialists”
4 Bay 2 – (Banlaw Nozzle BAM800 H) Truck: #09 Cat 793C Welded type receiver socket with plain Wiggins receiver. Flow rate began at 330 lpm after 175 litres flow rate increased to 560lpm. After 2700 litres had been delivered, Truck #58 connected up at Bay 1 and the flow rate dropped to 350lpm for the rest of the refuelling. Standard Wiggins Vent ZV10 No spillage was observed. Automatic Nozzle shut off No vibration audible during refuelling Bay 1 – (New Banlaw Nozzle BPM800 H) Truck: #58 Cat 793C Welded type receiver socket with plain Wiggins receiver. Flow rate recorded at 355 lpm while Truck #09 was refuelling in Bay 2 then flow rate increased to 560lpm. Standard Wiggins Vent ZV10 No spillage was observed. Automatic Nozzle shut off No vibration audible during refuelling Bay 1 – (New Banlaw Nozzle BPM800 H) Truck: #52 Cat 793C Welded type receiver socket with plain Wiggins receiver. Flow rate began at 330 lpm after 175 litres flow rate increased to 560lpm. Standard Wiggins Vent ZV10 No spillage was observed. Automatic Nozzle shut off No vibration audible during refuelling
“Hydrocarbon Management Specialists”
5 Conclusion: From the twelve refuellings that I observed it was obvious that all Trucks were not set up the same. Certain trucks while being refuelled showed evidence of vibration both visible and audible. The nozzle on some trucks was close to premature shut off while on others the nozzle wouldn’t shut off causing spillage. Upon investigation I found that all Haul trucks up to & including Truck # 60 had the Fuel Receiver screwed into a welded socket in the shell (see photo #1)
Photo #1 All trucks after Truck #60 had the Fuel Receiver screwed into a bolt on Flange in the shell (see photo #2).
Photo #2
“Hydrocarbon Management Specialists”
6
It appeared that the bolt on flange had something behind it creating a resistance to flow and hence an increase in pressure causing the Banlaw nozzle to shut off prematurely. Once back in Australia we obtained a Bolt on Flange assembly and found that it was an OEM CAT spec valve as per photo’s #3, 4, & 5.
Photo#3
Photo #4
Photo#5
“Hydrocarbon Management Specialists”
7 History & Problems: Apparently the problem of premature shut off of the Banlaw Nozzles has been occurring for some time on site. To overcome the problem of premature shut off the original spring in the Banlaw nozzle was changed to a heavy spring. This overcame the premature shut problem on the trucks fitted with the OEM CAT Spec valve but caused over pressurisation and in some cases spillage of all other Trucks. This over pressurisation could eventually lead to rupture of a fuel tank if this issue is not addressed. The OEM CAT spec valve is rated to a maximum flow of around 570lpm (150gpm). When one truck is refuelling the flow is around 570lpm, this increase in flow / pressure is causing the premature shut off problem that wasn’t occurring prior to receiving the additional CAT793 trucks to your original fleet. Solutions: There are a number of options to fix these inherent problems. 1. Install Banlaw AUS23L Receivers onto trucks fitted with CAT OEM valve & install Banlaw AUS23H receivers onto trucks fitted with no valve and leave nozzle set to existing setting. 2. Fit Banlaw Pipeline FillSafe electronic zero pressure system to all vehicles and set the Banlaw nozzle back to original spring setting. 3. Remove the OEM CAT Spec valve from all trucks fitted with this device and replace it with a flat flange complete with Receiver and set the Banlaw nozzle back to original setting 4. Fit OEM CAT Spec valve to Truck that don’t have it and leave the Banlaw nozzle at the higher setting.
“Hydrocarbon Management Specialists”
BANLAW PIPELINE PTY LTD ABN: 88 062 044 071
Report on the Performance of Banlaw Pipeline Nozzles Refuelling CAT 793 Haul Trucks At the
Main Refuelling Bay
FOR
PT Newmont Nusa Tenggara April 2005 Submitted by: Paul Buckton – Operations & Technical Services Manager
“Hydrocarbon Management Specialists”
2
Refuelling Report 20th April 2005 This report was compiled to report on the operation of the new Banlaw Pipeline Refuelling Nozzle BPM800 onto Bay 1 at PTNNT main fuel bay as a trial on the 13th April 2005. The following observations were noted: Bay 1 – (New Banlaw Nozzle BPM800 H) Truck: #63 Cat 793C Flanged type receiver socket with Green Wiggins receiver. Flow rate at 560lpm nozzle handle was shaking and poppet / retainer rattle was audible. Truck #30 drove into bay 2 and commenced refuelling. The flow rate in bay 1 dropped to 360lpm and the nozzle vibration ceased. The nozzle shut off automatically when the tank was full with severe spillage from the remote mounted filter The new nozzle was dripping from the bleed hole in the end cap. Bay 2 – (old style Banlaw nozzle BAM800 H) Truck: #30 Welded type receiver socket with Wiggins receiver. Flow rate at 430lpm while refuelling at the same time as truck #63 in bay 1. Flow rate increased to 580lpm with refuelling at bay I was complete. Didn’t get to see the end of the refuelling but no evidence of spillage was noticed. Bay 1 – (New Banlaw Nozzle BPM800 H) Truck: #61 Cat 793C Flanged type receiver socket with Purple Wiggins receiver. Flow rate at 560 lpm nozzle handle was shaking and poppet / retainer rattle was audible. The flow rate slowly decreased to around 470 lpm then around 5 – 10 seconds later the nozzle shut off. No spillage was observed No sign of fuel dripping from bleed hole in back of the end cap Bay 2 – (old style Banlaw nozzle BAM800 H) Truck: #103 CAT 785B Welded type receiver socket with Wiggins receiver. Flow rate at 370 lpm while refuelling. Standard wiggins Vent. Auto shut off no spillage.
“Hydrocarbon Management Specialists”
3 Bay 1 – (New Banlaw Nozzle BPM800 H) Truck: #74 Cat 793C Flanged type receiver socket with Banlaw receiver. Flow rate began at 330 lpm after 175 litres flow rate increased to 580lpm. Orica truck began fuelling at bottom fuel bay and flow dropped to 435 lpm then after orica truck was full flow returned to 580lpm. Major spillage was observed. (see photo) No vibration audible during refuelling Bay 1 – (New Banlaw Nozzle BPM800 H) Truck: #22 Cat 793C Welded type receiver socket with plain Wiggins receiver. Flow rate began at 330 lpm after 175 litres flow rate increased to 560lpm. Standard Wiggins Vent ZV10 No spillage was observed. Automatic Nozzle shut off No vibration audible during refuelling Bay 1 – (New Banlaw Nozzle BPM800 H) Truck: #60 Cat 793C Welded type receiver socket with plain Wiggins receiver. Flow rate began at 330 lpm after 175 litres flow rate increased to 560lpm. Standard Wiggins Vent ZV10 No spillage was observed. Automatic Nozzle shut off No vibration audible during refuelling Bay 2 – (Banlaw Nozzle BAM800 H) Truck: #15 Cat 793C Welded type receiver socket with plain Wiggins receiver. Flow rate began at 330 lpm after 175 litres flow rate increased to 540lpm. Standard Wiggins Vent ZV10 No spillage was observed. Automatic Nozzle shut off No vibration audible during refuelling Bay 1 – (New Banlaw Nozzle BPM800 H) Truck: #26 Cat 793C Welded type receiver socket with plain Wiggins receiver. Flow rate began at 330 lpm after 175 litres flow rate increased to 560lpm. Standard Wiggins Vent ZV10 No spillage was observed. Automatic Nozzle shut off No vibration audible during refuelling
“Hydrocarbon Management Specialists”
4 Bay 2 – (Banlaw Nozzle BAM800 H) Truck: #09 Cat 793C Welded type receiver socket with plain Wiggins receiver. Flow rate began at 330 lpm after 175 litres flow rate increased to 560lpm. After 2700 litres had been delivered, Truck #58 connected up at Bay 1 and the flow rate dropped to 350lpm for the rest of the refuelling. Standard Wiggins Vent ZV10 No spillage was observed. Automatic Nozzle shut off No vibration audible during refuelling Bay 1 – (New Banlaw Nozzle BPM800 H) Truck: #58 Cat 793C Welded type receiver socket with plain Wiggins receiver. Flow rate recorded at 355 lpm while Truck #09 was refuelling in Bay 2 then flow rate increased to 560lpm. Standard Wiggins Vent ZV10 No spillage was observed. Automatic Nozzle shut off No vibration audible during refuelling Bay 1 – (New Banlaw Nozzle BPM800 H) Truck: #52 Cat 793C Welded type receiver socket with plain Wiggins receiver. Flow rate began at 330 lpm after 175 litres flow rate increased to 560lpm. Standard Wiggins Vent ZV10 No spillage was observed. Automatic Nozzle shut off No vibration audible during refuelling
“Hydrocarbon Management Specialists”
5 Conclusion: From the twelve refuellings that I observed it was obvious that all Trucks were not set up the same. Certain trucks while being refuelled showed evidence of vibration both visible and audible. The nozzle on some trucks was close to premature shut off while on others the nozzle wouldn’t shut off causing spillage. Upon investigation I found that all Haul trucks up to & including Truck # 60 had the Fuel Receiver screwed into a welded socket in the shell (see photo #1)
Photo #1 All trucks after Truck #60 had the Fuel Receiver screwed into a bolt on Flange in the shell (see photo #2).
Photo #2
“Hydrocarbon Management Specialists”
6
It appeared that the bolt on flange had something behind it creating a resistance to flow and hence an increase in pressure causing the Banlaw nozzle to shut off prematurely. Once back in Australia we obtained a Bolt on Flange assembly and found that it was an OEM CAT spec valve as per photo’s #3, 4, & 5.
Photo#3
Photo #4
Photo#5
“Hydrocarbon Management Specialists”
7 History & Problems: Apparently the problem of premature shut off of the Banlaw Nozzles has been occurring for some time on site. To overcome the problem of premature shut off the original spring in the Banlaw nozzle was changed to a heavy spring. This overcame the premature shut problem on the trucks fitted with the OEM CAT Spec valve but caused over pressurisation and in some cases spillage of all other Trucks. This over pressurisation could eventually lead to rupture of a fuel tank if this issue is not addressed. The OEM CAT spec valve is rated to a maximum flow of around 570lpm (150gpm). When one truck is refuelling the flow is around 570lpm, this increase in flow / pressure is causing the premature shut off problem that wasn’t occurring prior to receiving the additional CAT793 trucks to your original fleet. Solutions: There are a number of options to fix these inherent problems. 1. Install Banlaw AUS23L Receivers onto trucks fitted with CAT OEM valve & install Banlaw AUS23H receivers onto trucks fitted with no valve and leave nozzle set to existing setting. 2. Fit Banlaw Pipeline FillSafe electronic zero pressure system to all vehicles and set the Banlaw nozzle back to original spring setting. 3. Remove the OEM CAT Spec valve from all trucks fitted with this device and replace it with a flat flange complete with Receiver and set the Banlaw nozzle back to original setting 4. Fit OEM CAT Spec valve to Truck that don’t have it and leave the Banlaw nozzle at the higher setting.
“Hydrocarbon Management Specialists”
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