Advisian Outer Harbour Fuel System Design
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Advisian Shell Cove Outer Harbour Fuel System Design Shell Cove Outer Harbour August 2018
Transcript of Advisian Outer Harbour Fuel System Design
Advisian
Shell Cove Outer Harbour Fuel System Design
Shell Cove Outer Harbour
August 2018
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Document Prepared By: Petrolink Engineering Pty Ltd. ABN: 96 155 909 498 4/31‐33 Jack Williams Drive PENRITH NSW 2750 T: (02) 4722 9775 F: (02) 4722 9774 E: W: petrolink.com.au
DOCUMENT CONTROL Document ID: 12020‐REP‐001
REV No Date Revision Details Author Verifier Approver
00 17/08/18 Original Report C. Henriksen B. Boné
01 23/08/18 Images Modified C. Henriksen B. Boné
© PETROLINK ENGINEERING Pty Ltd. All rights reserved. PETROLINK ENGINEERING has prepared this document for the sole use of the Client as per Scope of Works detailed within Job Number 11689 and for a specific purpose, each as expressly stated in the document. No other party should rely on this document without the prior written consent of PETROLINK ENGINEERING. PETROLINK ENGINEERING undertakes no duty, nor accepts any responsibility, to any third party who may rely upon or use this document. This document has been prepared based on the Client’s description of its requirements and PETROLINK ENGINEERING’s experience, having regard to assumptions that PETROLINK ENGINEERING can reasonably be expected to make in accordance with sound professional principles. PETROLINK ENGINEERING may also have relied upon information provided by the Client and other third parties to prepare this document, some of which may not have been verified. Subject to the above conditions, this document may be transmitted, reproduced or disseminated only in its entirety. The information contained within this document is CONFIDENTIAL and is intended only for the Client or Company addressed. Copying, distributing or review of this document is prohibited. In preparing this document PETROLINK ENGINEERING has relied upon data, analysis, surveys, plans, designs and other information provided by the Client, and other individuals and organisations referenced herein. Except as otherwise stated in this document, PETROLINK ENGINEERING has not verified the accuracy or completeness of such data, analysis, surveys, plans, designs and other information. This document does not proport to provide legal advice. Readers should engage professional legal advisers for this purpose.
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Contents 1.0 Executive Summary .............................................................................................................. 5
2.0 Introduction ......................................................................................................................... 6
3.0 Relevant Standards, Codes and Referenced Documents .................................................... 7
3.1 Relevant Australian Standards .................................................................................... 7
3.2 Relevant Australian/New Zealand Standards ............................................................. 7
3.3 Australian Legislation and Referenced Documents .................................................... 7
4.0 Fuel System Design .............................................................................................................. 8
4.1 Fuel Tanks ........................................................................................................................ 8
4.1.1 Filling of Fuel Tanks ................................................................................................. 11
4.1.2 Fuel Tank Vent Pipes ............................................................................................... 13
4.2 Fuel Pumping and Dispensing ........................................................................................ 14
4.2.1 Fuel Dispensers ....................................................................................................... 14
4.2.2 Fuel Pumps .............................................................................................................. 16
4.2.3 Fuel Pipelines .......................................................................................................... 17
4.3 Environmental ................................................................................................................ 19
4.3.1 Tank Pit Observation Well ...................................................................................... 19
4.3.2 Groundwater Monitoring Wells .............................................................................. 19
5.0 Application of SEPP 33 ....................................................................................................... 20
6.0 SEPP 33 – Relevant Tables and Figures .............................................................................. 22
6.1 SEPP 33 – Table 1: Screening Method to be Used ......................................................... 22
6.2 SEPP 33 – Table 2: Transportation Screening Thresholds ............................................. 23
6.3 SEPP 33 – Figure 4: Risk Screening Procedure ............................................................... 24
6.4 SEPP 33 – Figure 9: Class 3 PGII and 3 PGIII Flammable Liquids .................................... 25
7.0 Waste Management .......................................................................................................... 26
7.1 During Construction Phase ............................................................................................ 26
7.2 Fuel System in Operation ............................................................................................... 26
8.0 Traffic Management .......................................................................................................... 27
8.1 During Construction Phase ............................................................................................ 27
8.1.1 Tank Excavation ...................................................................................................... 27
8.1.2 Fuel Tank Delivery and Installation ......................................................................... 27
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8.2 Fuel System in Operation ............................................................................................... 27
Appendices ............................................................................................................................... 29
Drawing: 12020‐GA‐001 – Fuel System Layout .......................................................................
Drawing: 12020‐GA‐002 – Fuel Tanker Manoeuvring Path .....................................................
Drawing: 12020‐GA‐003 – Crane Lifting Plan ..........................................................................
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1.0 Executive Summary Petrolink Engineering Pty Ltd has been engaged by Advisian to advise on a suitable fully compliant design for a fuelling system for boats at the newly proposed marina at the Shell Cove Outer Harbour marina complex. The design will take into account the proximity of the fuel system to the water’s edge and be compliant with all relevant Regulations, Standards and Guidelines. The findings and recommendations of this report will be form part of the submission to Council for approval of the building of the fuelling system at the marina and incorporates a study for the requirements of the State Environmental Planning Policy No. 33 (SEPP33). Carsten Henriksen Engineering Manager Fuel Systems Engineer
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2.0 Introduction The Shell Cove Outer Harbour project is currently being developed by Frasers Property Australia under Shellharbour City Council Development Application 95/133. The project will incorporate a boat marina incorporating a fuelling system for boats. The proposed fuel system will comprise of underground fuel tanks for the storage of approx. 40,000 litres of diesel and 15,000 litres of premium unleaded petrol (PULP). Dispensing of fuel to the boats will be from a dedicated fuel and pump‐out pontoon which will incorporate two dual fuel dispensers mounted on purpose‐built marine‐grade stainless steel under‐pump sumps. The fuel pipelines between the underground tanks and the dispensers on the pontoon will be non‐corrodible, double‐walled HDPE piping as required by law.
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3.0 Relevant Standards, Codes and Referenced Documents
3.1 Relevant Australian Standards Reference Description
AS 1940:2004 The Storage and Handling of Flammable and Combustible Liquids
AS 2885.0:2008 Pipelines – Gas and Liquid Petroleum Part 0: General requirements
AS 2885.1:2012 Pipelines – Gas and Liquid Petroleum Part 1: Design and construction
AS 2885.3:2012 Pipelines – Gas and Liquid Petroleum Part 3: Operation and Maintenance
AS 2931:1999 Selection and Use of Emergency Procedure Guides for the Transport of Dangerous Goods
AS 3846:2005 The handling and transport of dangerous cargoes in port areas
AS 3962:2001 Guidelines for design of marinas
AS 4897:2008 The Design, Installation and Operation of Underground Petroleum Storage Tanks
AS 4977: 2008 Petroleum products – Pipeline, road tank compartment and underground tank identification
3.2 Relevant Australian/New Zealand Standards Reference Description
AS/NZS 2566.1:1998 Buried flexible pipelines ‐ Part 1. Structural design
AS/NZS 2566.2:2002 Buried flexible pipelines ‐ Part 2. Installation
AS/NZS 2885.5:2010 Pipelines – Gas and Liquid Petroleum Part 5: Field pressure testing
AS/NZS 60079 (series) Classification of Hazardous Areas
AS/NZS 60529:2004 Degrees of Protection provided by Enclosures
3.3 Australian Legislation and Referenced Documents Reference Description
Australian Dangerous Goods Code 7th Ed:2011
Australian Code for the Transport of Dangerous Goods by Road and Rail – 7th
Edition
EPA:1994 Environmental Protection Act 1994
EPP Water:1997 Environmental Protection Policies for Water 1997
Petroleum (SL) Act:1982 Petroleum (Submerged Lands) Act 1982
NOHSC:1015(2001) Storage and Handling of Workplace Dangerous Goods National Occupational Health & Safety Commission
UPSS Regulation 2008 Protection of the Environment Operations (Underground Petroleum Storage Systems) Regulation 2008, amended 2014
Water Act:2000 Water Act 2000
Applying SEPP 33 Hazardous and Offensive Development Application Guidelines NSW Government – Planning – January 2011
SEPP 33 Circular Planning and Assessment Guidelines for Hazardous Industry NSW Government – Planning – February 2011
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4.0 Fuel System Design
4.1 Fuel Tanks The fuel tanks for the Shell Cove Outer Harbour facility shall consist of one dual compartment underground double walled fibreglass tank and fabricated in accordance with AS 1692:2006. The fuel tank will have a total capacity of 55,000 litres, comprising of one 40,000 litre compartment for Diesel and one 15,000 litre compartment for Premium Unleaded Petrol (PULP). The underground fuel tank has an interstitial space (the gap between the inner and outer walls) which will be constantly monitored to detect any breach of either tank wall which could result in leakage of fuel into the environment. The underground fuel tank shall be installed in accordance with AS 4897:2008 and be located at least 2 metres from any boundaries as per AS 1940:2017 clause 5.12.4 and at a sufficient distance from the water’s edge so as to not require any additional safety precautions.
Installation of underground multi‐compartment fuel tank
(MacArthur Mazda, Campbelltown NSW, 2017) Approx. 120 m3 of soil will need to be removed during the excavation for the underground fuel tank.
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The excavated material for the tank installation is either re‐used on site or transported away for off‐site disposal together with the rest of the excavated material for other building works. Suitable excavated material would be reused within Precinct A (next to site) or elsewhere in the Shell Cove development. Any material not suitable for reuse would be placed in the Landscape Mound or disposed to an OEH licensed land fill facility. The tank cavity shall be lined with geo‐fabric to separate the back‐fill material from the surrounding soil prior to installing the tank. The back‐fill material around the tank cavity during tank installation will be self‐compacting 10‐20mm pea gravel or 10‐14mm crushed stone in accordance with the tank manufacturer’s installation manual.
Installation of geofabric in tank cavity prior to tank installation
(Kokomo Private Island Resort, Fiji, 2016)
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Typical profile view of tank installation
Note: The excavation is stepped for safety reasons
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4.1.1 Filling of Fuel Tanks Filling of the underground tank compartments will be via gravity fill from a fuel tanker parked in close vicinity to the tank. The tanker driver/operator will connect a fuel hose from the tank outlet into a port in a purpose‐built “spill safe box”. The spill safe box has a closed compartment designed to catch any spilt fuel and prevent any leaked fuel from entering the environment. A vapour recover point is fitted inside the safe spill box. The tanker driver connects a hose to this point to retract vapour from the fuel tank when delivering petrol as required for Vapour Recovery Stage 1 (VR1). Each tank compartment shall be fitted with an overfill protection valve in accordance with AS 4897:2008, clause 4.4.2 and the UPSS Regulation of 2008 (amended 2014) to reduce the possibility of the tank being overfilled. An automatic tank gauge system shall be installed to monitor the level of product in each tank compartment for wet stock inventory management. This will also be used by the tanker driver and operator during filling of the tanks to ensure the tanks are not overfilled as well as guarding against losses as part of inventory management. The fuel tanker will be parked in an area bunded by speed humps. The size and capacity of the bunded area shall be designed to capture the content of one tanker compartment (approx. 7,300 litres) in case of a fuel spill or valve failure. Any spilt fuel will be contained within the bunded area and will not be released into the environment including drains and waterways. A blind sump will be installed inside this bunded area to enable easy pump‐out of spills or retained stormwater. Safe Operating Procedures for Tanker Unloading and Clean‐Up will be implemented for all fuel deliveries to the site.
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Spill Safe Fill Box
PULP vent pipe fitted with Pressure‐vent for vapour recovery
Tanker unloading into underground fuel tank
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4.1.2 Fuel Tank Vent Pipes Each fuel tank compartment will be fitted with a vent pipe in accordance with AS 1940:2017 Section 5.4. The size of the vents will be such that pressure or vacuum resulting from filling, emptying, or atmospheric temperature change will not cause the maximum allowable stress for the tank to be exceeded. The vents will be installed to have a consistent fall back to tank at a slope of at least 1 in 100 and will terminate at least 4 metres above ground level and at least 4 metres laterally from any openings into any adjacent buildings, including vents and air conditioner inlets and heat flues and will furthermore be located away from any public thoroughfares for personal safety. The vent for the PULP is fitted with a pressure vacuum vent as part of the vapour recovery system. The proposed location for the vent pipes is at the northern wall of the adjacent office building. Exact location will be determined during installation to suit the façade of the wall and prevent vent pipes from obstructing any windows or other openings.
Proposed location for tank installation and vent pipes on site plan
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4.2 Fuel Pumping and Dispensing
4.2.1 Fuel Dispensers Fuel will be dispensed to water craft via two fuel dispensers located on the Fuel and Pump‐out Pontoon. One dispenser will be a dual high flow – low flow dispenser for diesel. The other will be a dual low flow dispenser for PULP. The fuel dispensers shall be models with marine‐grade stainless steel components and panels suitable for installation at a marina.
Fuel dispensers on marina (Anchorage Marina, Corlette NSW)
Each dispenser shall be mounted on a purpose‐built stainless‐steel under‐pump sump designed to catch any leaks from the dispenser internals as per AS 4897:2008 clause 4.4.1. The entry and exit for the fuel pipes into the under‐pump sump will be sealed with purpose‐made entry boots which seals around the pipes and prevents any leaked fuel from entering the environment. A canopy shall be installed above each fuel dispenser to protect these from the elements.
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Fuel dispensers on purpose‐built stainless‐steel under‐pump sumps
(Anchorage Marina, Corlette NSW & d’Albora, Akuna Bay NSW) The fuel dispensers and their installation shall comply with the requirements of AS 1940:2017 Section 7.5 and furthermore comply with AS/NZS 60079:10.1:2009 clause ZA.4.4.2.3 for the installation of a fuel bowser in a hazardous area on a wharf/jetty.
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4.2.2 Fuel Pumps A submersible fuel pump will be installed in the tank turret of each tank compartment to deliver the fuel to the fuel pontoon. Each submersible pump shall be fitted with leak detection monitoring as required per the Standards to detect a drop in pressure in the pipelines when the pump is idle as per AS4897:2008 Section 4.5.
Submersible fuel pump inside underground tank turret
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4.2.3 Fuel Pipelines The fuel pipelines between the fuel tank and the fuel pontoon will be flexible non‐corrodible, double‐walled HDPE fusion‐welded piping as per AS 4897:2008 and the UPSS Regulation of 2008 (amended). The interstitial space (the gap between the inner and outer pipes) is able to be monitored for signs of a compromise of either tank wall which could result in leakage of fuel into the environment.
Non‐corrodible HDPE pipework
Isolation valves for each fuel line will be installed in a valve box prior to the fuel pipes entering the Fuel and Pump‐out Pontoon as per AS 1940:2027 clause 7.5.3. The entry and exit for the fuel pipes into the valve box will be sealed with purpose‐made entry boots which seals around the pipes and prevents any leaked fuel from entering the environment.
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Isolation valves inside stainless‐steel valve box
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4.3 Environmental
4.3.1 Tank Pit Observation Well A tank pit observation well shall be installed in the tank excavation area in accordance with AS 4897:2008 clause 4.4.3. The tank pit excavation well shall be installed to intercept the tank excavation area in close proximity to the tank and shall terminate at least 150mm below the bottom of the tank but shall not penetrate the bottom of the tank excavation. The tank pit observation well shall be designed and installed so as to enable the presence of product vapour or free‐phase product in the tank excavation to be confirmed.
4.3.2 Groundwater Monitoring Wells Groundwater monitoring wells shall be installed in accordance with AS 4897:2008 clause 4.5.7 and the UPSS Regulation of 2008. Groundwater monitoring wells shall be located, installed and sampled appropriately and tested at least every six months for the presence of groundwater contamination from the underground petroleum system on the site. The number and locations of the groundwater monitoring wells shall be determined and designed by a qualified and experienced person. It is common to install at least three monitoring wells in locations to detect water flow into and off the site and to monitor if any contamination if migrating off the site. The attached site plan 12020‐GA‐001 indicates the proposed locations of the tank pit observation and three groundwater monitoring wells.
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5.0 Application of SEPP 33
Instrument:
Applying SEPP 33 Final 2011 Comment
1.2 The Policy SEPP 33 presents a systematic approach to planning and assessing proposals for potentially hazardous and offensive development for the purpose of industry or storage.
2.1 Does SEPP 33 Apply
Does the proposal require development consent or approval under Part 3A or Part 4 of the EP&A Act?
Is the proposal ‘potentially hazardous industry’?
Is the proposal ‘potentially offensive industry’?
Check lists and Risk Assessment as per the Guidelines will determine if SEPP 33 applies
7.1 How to Identify Potentially Hazardous Industry
List of all the hazardous materials used in the proposed development and the quantity of each present
Dangerous goods classification for each material
Mode of storage used
Distance of the stored material from the site boundary
Average number of annual and weekly road movements
Procedure for identifying potentially hazardous industry as outlined in Figure 4 Risk Screening Procedure 40,000 L Petrol, Class 3, PGII 15,000 L Diesel, Class C1 Equates to total of 55,000 L PGII as per SEPP 33 Clause 7.1 Underground fuel storage tanks 8 metres Estimate of one delivery per fortnight (26 deliveries annually)
Table 1: Screening Method to be Used For Class 3 PGII use Figure 9 Graph if quantity is greater than 5 tonnes
Notes to Table 1: Using the appropriate graph, plot the group total quantity against the distance from the nearest boundary. If the point lies below
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the screening threshold line, the proposed development is potentially hazardous. For Class 3 materials only, if storage is underground, the capacity of the tank should be divided by five prior to assessing it against the screening threshold.
Table 2: Transportation Screening Thresholds
For Class 3 PGII screening threshold is for vehicle movements greater than 750 annually or 45 weekly deliveries
Figure 9: Class 3PGII and 3PGIII Flammable Liquids Quantity (t) vs Distance (m) to establish if within Potentially Hazardous Region
Conversion of quantity for assessment: 55kL x 0.7t/m3 = 38.5 tonnes 38.5t/5 (under‐ground tank) = 7.7 tonnes
Result Graph (Figure 9) shows that quantity of 7.7 tonnes of PGII and PGIII is only in the Potentially Hazardous Region if placed within 4 metres of other uses.
CONCLUSION The fuel storage is in excess of 4 metres away from the boundary or any other buildings and is therefore not in the Potentially Hazardous Region as per the graph in Figure 9 (see Section 6.4) A Preliminary Hazard Analysis is therefore not required. The movements of fuel delivery trucks proposed is vastly below the Transportation Screening Threshold as per Table 2. SEPP 33 does therefore not apply.
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6.0 SEPP 33 – Relevant Tables and Figures
6.1 SEPP 33 – Table 1: Screening Method to be Used
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6.2 SEPP 33 – Table 2: Transportation Screening Thresholds
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6.3 SEPP 33 – Figure 4: Risk Screening Procedure
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6.4 SEPP 33 – Figure 9: Class 3 PGII and 3 PGIII Flammable Liquids
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7.0 Waste Management
7.1 During Construction Phase Excavation is required for the installation of underground fuel tank. The excavation shall be detailed to ensure only the minimum amount of soil is removed. The excavated material for the tank installation shall be either re‐used on site or transported away for off‐side disposal together with the rest of the excavated material for other building works. Suitable excavated material would be reused within Precinct A (next to site) or elsewhere in the Shell Cove development. Any material not suitable for reuse would be placed in the Landscape Mound or disposed to an OEH licensed land fill facility. Any acid sulfate soil excavated would be managed in accordance with the Contractor’s Acid Sulfate Soil Management Plan. It is envisaged that any acid sulfate soil would be neutralised prior to reuse, placement in the Landscape Mound or disposal to an OEH licensed land fill facility.
7.2 Fuel System in Operation The fuel system has been designed to not generate any additional waste which would require removal from site once the facility is operational. The road tanker delivering fuel to the underground fuel tank will be fully parked within a bunded area designed to catch the full volume of one road tanker compartment in case of a spill. The fuel installation includes a spill safe box for the fuel unloading. This spill safe box incorporates a compartment to catch any spilt fuel during the tanker unloading.
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8.0 Traffic Management
8.1 During Construction Phase
8.1.1 Tank Excavation The excavation for the underground tank will require the use of an excavator and trucks for the removal of soil. The trucks will travel on the road adjacent to the car park towards the boat ramp and enter the work site. Once the truck has been filled with soil from the tank excavation it will leave via the road leaving the site in the opposite direction. Wheel “bumps” will shake off excess dirt on truck at exit point to limit the amount of loose dirt falling of on the roads.
8.1.2 Fuel Tank Delivery and Installation The fuel tank will be delivered to site by a 19‐metre semi‐trailer and offloaded using a crane. The semi‐trailer with the tank will reverse into the area and park alongside the tank excavation hole. The crane will lift off the tank from the semi‐trailer which will then leave the site in a forward direction. Drawing 12020‐GA‐003 shows the proposed location for the crane and semi‐trailer delivering the underground fuel tank. The area marked “Bunded Fuelling Area” on the site plans will be fenced off during the excavation and tank installation for protection of the public and other people working in the area.
8.2 Fuel System in Operation The owners of the site estimates one fuel delivery by road tanker once every fortnight. Fuel will be delivered to the site by a 19‐metre‐long semi‐trailer fuel tanker. The road tanker will travel along the road towards the boat ramp and make a right‐hand turn prior to entering the boat ramp area. The tanker will then reverse past the office building and into the bunded fuelling area and park in the bunded tanker parking area. The operator of the fuel facility must be on hand to guide and direct the tanker driver and prevent other personnel and passers‐by from entering the tanker’s path during manoeuvring.
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Once the fuel delivery has been completed, the tanker will leave the fuelling area in a forward direction and leave the site via the established roadways. The proposed vehicle path of the fuel tanker is shown on attached drawing 12020‐GA‐002 for fuel delivery to the underground fuel tank.
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Appendices
Drawing: 12020‐GA‐001 – Fuel System Layout
Drawing: 12020‐GA‐002 – Fuel Tanker Manoeuvring Path
Drawing: 12020‐GA‐003 – Crane Lifting Plan
