Their requirement was for a tank to store waste water from a food processing plant.
Situation: The process required storage of the water for it to be treated. In the past tanks storing this water built up sludge rapidly—during holding time most of the sediment would drop out—a time consuming, expensive job to periodically shut the system down to de-sludge the tanks.
You need a pump to get the water from your tank to your tap or reticulation. If you didn’t have a Pump You would need a tank stand 23 metres high to equal the pressure of just a small pressure pump.
Solution: Two tanks with sloping floors going to a central 150mm floor suction point. The installation of mixing nozzles in 4 locations around the tank and the installation of a circulation pump. The operation of the system provides continual mixing of the water in the tanks and continual agitation of sediments that did settle out down to the central scour suction outlet.
Outcome: With this system there is no build up of sludge and no need to enter the tank other than for scheduled inspection of the tank liner.
The first project is via Steelfab supply to Lycopodium Engineering for client Lion Ore for the Black Swan Nickel Project 80km north of Kalgoorlie.
Situation: The client’s initial request was for a 1.2 megalitre (1,200kL) tank for storage of raw water and a 550kL tank for storage of potable water.
They required design and construction with options for dimensions that would fit with their plant design. The request was for recommended solutions and the reasoning behind those recommendations.
We were instructed to recommend materials that would fit within a stated budget and cater for the required design life.
Solution: Our solution was for the preferred standard diameter and height for the project of 19.95m diameter and 4.3m high being 1344kL-—allowing for the required effective capacity if 1200kL. The requirement for this tank was to be open top allowing for possible wind conditions that could affect the tank’s structure when empty.
The final design was for a Zinc Coated Steel panel (galvanised) for life expectancy for the shell, and a .8mm PVC membrane UV stabilized for the required design life.
Result: We made recommendations for the preferred diameter and height for the project potable tank to be 12.35m diameter and 4.6m high allowing for the required effective capacity of 500kL. The requirement for this tank was for roofed construction to prevent contamination of the water stored being potable water. The offer of materials was accepted and the contract awarded.
Roche Mining – Granny Smith : Water Truck Fill Station
Situation: The initial enquiry was for a 50kL tank on a 12m tower to provide water pressure to fill water carts at the Granny Smith mine. 50kL water trucks were taking around 40 minutes to fill. Additional equipment was required to complete the important tasks of dust suppression around the site. This system was required to speed to fill time and reduce standing time of the trucks.
Solution: We made the point that a tower based system would not be cost-effective for them. The solution offered was for them to push up a 4m high bund and pour an eight metre square concrete pad on top of it. We would then construct a 10m high x 5.2m diameter tank on the concrete pad with a truck fill gantry connected to the base. We calculated that when the tank was full, the top 2m of the tank contained the required 50kL with the original requirement of 12m of head pressure. The truck fill gantry in 400NB pipe would allow adequate flow to fill the tanks and a shorter time.
The proposal and costings were submitted to the client with full General Arrangement drawings for their consideration.
Result: The cost of the system was substantially lower than their original budget. The final result was the placement of an order for the original system on the earth bund as well as a second tank and gantry to be installed on the side of a waste dump for pressure.
Once the systems were installed and commissioned the water trucks were able to be filled in 4-6 minutes instead of the previous 30-40 minutes Financially, the client later confirmed that the entire system paid for itself in less than 12 months—they were able to complete the same overall watering regime with one less water truck. The reduction in equipment hire was enough to cover the cost of the system.
CSR Readymix : Chilled Water Storage Tanks
Situation: The client required a tank to store chilled water for their concrete batch plant at Dampier Port for the new port upgrade project. Chilled water (3-4˚C) is required for batching concrete to maintain a predetermined temperature at delivery to the site. Concrete supplied at more than .5˚C over the pre-determined temperature is rejected, therefore the possibility for substantial losses is high.
Solution: In discussion with one of our Associate Companies, Control and Thermal Engineering, the option of externally cladding the tanks was suggested. This would be a costly exercise and time consuming. Given the short life expectancy of the plant—for the construction period of the project—the option of externally cladding the tanks with “Aeroflex Rubber” was chosen. The panel design of the Steelfab range of tanks made the fitting of the “Aeroflex Rubber” a simple process-—providing a perfect solution to the project requirement.
This flexibility of thinking and design allowed for a product that could be dismantled and re-assembled at another plant if required. Steelfab were able to offer this re-location service if required.
Result: The result was the purchase, manufacture and installation of the tank for the project and the on-site application of the Aeroflex rubber to the external surface of the tanks.
The final product provided adequate insulation to allow for the water to be chilled and held at 3-4˚C for the batching process.
Steelfab have since supplied two other projects of a similar nature with the same successful outcomes.
UAE, Dubai – World Islands : Water Supply Project
Situation: This project required the design, supply and installation of potable water storage tanks for the new World Islands project. A product suitable for site assembly with minimal infrastructure requirements by way of mechanical equipment was stipulated.
Solution: It was necessary for the dimensions of the tanks design to reduce the footprint area and keep the height down to the required levels. As always the Steelfab design allows for shipping and transporting of materials to remote and inaccessible sites—components are then bolted together to form the shell of the tank.
Result: Steelfab’s core competencies in design, production, delivery and installation is exemplified in this case: due to the urgent nature of the contract the tanks were airfreighted from Australia to the UAE and delivered onsite to the installation supervisor within ten days of the order being placed. The two 250kL tanks were efficiently installed within three and half days of receiving the materials.
The suitability of the product for the project was noted by the client—with future projects directly resulting from our ability to design to unique and specific project requirements—rather than expecting our clients to select from pre-determined standard sizes and templated solutions. Our flexible approach in all areas of our business is the key to our clients satisfaction.
