Case Study – Specialised Pipe Racks – Lubricant Plant Expansion

SPECIALISED PIPE RACKS, NEW SOUTH WALES

LUBRICANT PLANT EXPANSION

CLIENT: FUCHS LUBRICANTS

YEAR: 2017

SECTOR: INDUSTRIAL

WORLD CLASS FACILITY TFG Group proudly completed the Greenfield mechanical installation expansion for Fuchs Lubricants in Beresfield, New South Wales. The 12-month installation project included nine kilometres of 304 stainless steel sanitary grade tube, one kilometre of stainless steel pipe, multiple tanks and the specialised fabrication of a blending platform and pipe racks to move specialised oils around the 25,000 metered squared factory. PIPE RACKS AND BEND PANELS Austline Fabrication’s engineering team completed 3D drawings, then designed, fabricated and installed the 35 tonne specialised blending platform and pipe racks for the Lubricant Plant. The racks were designed for 40 percent extra capacity with future expansion. The platform is over 40 meters long and three tiers high and was flat packed, transported, assembled and installed by the Foodline Projects team on site in Beresfield. 40 tonnes of steel were used in the fabrication of the pipe racks and platform. Austline also fabricated in their Perth Workshop a 6m x 4.5m blending platform complete with a stair access platform. It also included two extensive flow boards incorporating 46 ports and swing boards, combined with the fabrication and welding of additive hoppers. These were transported to site in Beresfield and installed by the Foodline team. Both platform and flow boards include full drip tray protection for cleanliness and safety of operators. SAFETY RECORD TFG Group reached another project milestone in quality and safety with 12 months or 26,000 hours MTI and LTI free. This is a testament to the dedicated project team on completing the specialised installation of pipework, tanks and all equipment within budget and on time.

Case Study – Lubricant Plant Expansion – Fuchs Lubricants

LUBRICANT PLANT EXPANSION, BERESFIELD, NSW

MECHANICAL INSTALLATION EXPANSION

CLIENT: FUCHS LUBRICANTS

YEAR: 2016-2017

SECTOR: INDUSTRIAL

WORLD CLASS FACILITY Foodline Projects proudly completed the Greenfield mechanical installation expansion for Fuchs Lubricants in Beresfield, New South Wales. The 12-month installation project included nine kilometres of 304 stainless steel sanitary grade tube, one kilometre of stainless steel pipe, multiple tanks and the specialised fabrication of a blending platform and pipe racks to move specialised oils around the 25,000 metered squared factory. DESIGN & INSTALLATION After receiving the process design and P&ID’s from Fuchs, Foodline mechanically designed and installed the pipe routes and pipe racks which increased production capacity from 30 to 90 million litres. Foodline was integral in the success of the project through designing and incorporating 3D models of the pipe routes and racks which improved efficiency within the facility. Foodline also completed the piping and installation to the unique loading arm, which was aptly nicknamed “Optimus Prime”. PIPE RACKS FABRICATION Austline Fabrication’s engineering team designed and completed 3D drawings of the 35-tonne blending platform and pipe racks, which were fabricated in Austline’s workshop and then installed onsite at the plant. The racks were designed with 40 percent extra capacity for future expansion in mind and the platform which is over 40 meters long and three tiers high was flat packed, transported, assembled and then expertly installed on site in Beresfield. SAFETY RECORD Foodline reached another project milestone in quality and safety with 12 months or 26,000 hours MTI and LTI free. This is a testament to the dedicated project team on completing the specialised installation of pipework, tanks and all equipment within budget and on time.
Project Ninja

Case Study – Mechanical Installation – Project Ninja, Wetherill Park

PROJECT NINJA, WETHERILL PARK, NSW

MECHANICAL INSTALLATION

CLIENT: PROCESS PARTNERS

YEAR: 2017

SECTOR: DAIRY

PROCESS PARTNERS    Foodline Projects was awarded the mechanical installation of three new flavoured milk lines and three new fillers. Foodline was engaged as one of the lead contractors through Process Partners, who designed and engineered the Lion Flavoured Milk Upgrade at the Wetherill Park Site in New South Wales. This is Lion’s largest dairy project in Australia and is currently in validation stage. OVERALL SCOPE Process Partners engaged Foodline to install all process equipment, pipework and services at the Wetherill Park Site. The 10-month project included the mechanical installation of two new tanker bays, one new sugar intake bay and upgrading the RIS area by installing a 160-valve manifold and two milk coolers. Foodline personnel fabricated and installed the new Raw CIP & PFS systems including the intake components. Foodline also installed 9 batching tanks, 9 PFS tanks and 3 batch lines. SPECIALISED INSTALLATION Due to the limited access on site, Foodline successfully lifted each tank through the mezzanine level (wall plug) within the PFS area to complete this installation. Agitators and sanitisers were expertly installed in the PSF area coupled with three TFG fabricated and installed pasteuriser skids. Foodline also installed two TFG fabricated pre-heater and thermaliser skids in the components room. In addition, Foodline fabricated and installed all hygienic stainless-steel platforms, along with two specialised fabricated scalloped platforms of 30m and 22m, installed uniquely alongside the batching tanks in the PFS Area. ZERO HARM Lion and Process Partners were ecstatic with the result of zero LTI’s and MTI’s on site. Foodline tradesmen installed a total of 12km of pipework; 8km of 316 process pipework and 4km of 316 services pipework including stainless and carbon steel. Foodline was proudly involved in every process area in the plant from Raw Storage Intake Components to the Pasteurizer Room and onwards to connections in Filling and Packing. The project was delivered on time and within budget, using aseptic welding equipment and mix proof valves to deliver the best quality installation of dairy equipment and process pipework  
project ninja wetherill park

Case Study – Powder Handling System – Project Ninja, Wetherill Park

PROJECT NINJA, WETHERILL PARK, NSW

POWDER HANDLING SYSTEM

CLIENT: FRESCO SYSTEMS AUSTRALASIA / ENVIRONMENTAL PRODUCTS INTERNATIONAL

YEAR: 2017

SECTOR: DAIRY

FRESCO SYSTEMS AUSTRALIA    Fresco Systems Australasia were engaged by Lion who awarded Foodline Projects the contract to complete the installation of a three-stage powder handling system. Mounted on load cells this allows three products to be weighed simultaneously and disperses product effectively. Foodline successfully installed all components required for this service. The stainless steel process pipework, hoppers, platforms and conduits were expertly installed to the powder and bag handling systems using dairy standard sanitary welding and R22 electrical standard. Foodline tradesmen also installed the central vacuum system and pump to enable the environment to be controlled and powder free for stringent safety requirements of handling powder. ENVIRONMENTAL PRODUCTS INTERNATIONAL Foodline installed its first RO plant within the dairy industry at the Wetherill Park site for Environmental Products International. Two separate RO skids and one free issue chemical skid were skilfully installed. All services of steam, condensate and glycol, together with all process pipework lines were successfully installed by the Foodline team within the timeframe and with the highest quality of workmanship MULTI FACETED APPROACH    Foodline successfully installed the three-stage powder handling system for Fresco Systems Australasia and the RO Skids for Environmental Products International. Together with installing the process pipework in every process area of the Wetherill Park plant, from Raw Storage Intake Components to the Pasteurizer Room and onwards to the connections for Filling and Packing.  
mechanical piping installation csl pharmaceutical

Case Study – Formulation & Mechanical Piping Installation – CSL Broadmeadows

CSL BROADMEADOWS, VICTORIA

FORMULATION & MECHANICAL PIPING INSTALLATION

CLIENT: CSL BEHRING

YEAR: 2017

SECTOR: PHARMACEUTICAL

PROJECT SCOPE    Foodline Projects was engaged to complete the pipework and mechanical installation to increase production of the formulation area in the existing CSL plant. The Biotechnology manufacturing facility required substantial upgrades to all clean rooms and due to the increased demand for plasma, the project was expedited from the original timeline. Foodline upgraded the process piping and process service piping to the formulation, bulk purification, sterile filtration and sub fraction sterile plants to ensure the plant was efficient with production. SPECIALISED INSTALLATION A 14-strong specialised welding team ensured the project was completed in the very tight timeframe. All pre-spooling fabrication was carried out prior to the 2-week shutdown where final ties-ins to existing process and service pipework was completed. Orbital welding was performed to an exceptionally high standard together with borescoping to inspect all internal welds. All tradesman completed and passed daily weld tests inclusive of all NDT competencies. QUALITY ASSURANCE    Full traceability was mandatory for all fittings and weld maps, coupled with qualifications and drawing updates to CSL standards and QA requirements. Foodline complied and submitted a Quality Assurance Manual including quality plan, material and test certificates, welding procedures and qualifications, weld mapping, as-built isometric drawings and installation checklists. All welds were documented to ASME BPE 2014 Bioprocessing Equipment Standard. INNOVATION & COMPETITIVE SOLUTIONS   Foodline personnel have been highly commended on the installation of the addition of the new IgLAB IV Bulk Formulation and Ultra filtration which forms part of the overall bulk process of the CSL Broadmeadows facility. The timeline and scope of works required Foodline to meet and achieve stringent deadlines within the production schedules. Foodline supplied orbital welders and an onsite qualified QA personnel throughout the project to ensure all aspects were successfully achieved with a 100% safety record.
civmec reclaimer buckets

Case Study – Civmec RC3 Reclaimer Buckets – Port Kembla Coal Terminal

PORT KEMBLA COAL TERMINAL, NEW SOUTH WALES

CIVMEC RC3 RECLAIMER BUCKETS

CLIENT: CIVMEC

YEAR: 2016

SECTOR: MINING

SCOPE OF WORKS    Austline Fabrications were awarded the fabrication of 15 reclaimer buckets for the Port Kembla Coal Terminal in Wollongong, New South Wales. The design and fabrication required Austline to design an initial ‘jig’ to ensure consistency of build tolerance across all buckets. The tight timeframe of delivery required the universal fit as critical in the fabrication process. Throughout the fabrication process extensive MDR and ITP requirements were supplied to ensure all quality assurances and specifications were achieved. PROJECT TIMELINE Austline’s competitive and timely quotation enabled awarding and lodging of QA documentation and weld quality documents to proceed with the fabrication. The design and fabrication of the ‘jig’ enabled precise assembly, welding and machining of the initial bucket. The trial fit to ‘wheel’ was completed and the supply of the remaining reclaimer buckets were fabricated and delivered on time. INNOVATION & TECHNICALITIES    The buckets were fabricated with 3CR12 Sandvik proprietary material, a high wear capacity and to AS1554 Standards for all welding and testing. In house line bore machining to +/-0.1mm on mounting pin locations was completed with precision, coupled with extensive dissimilar materials fabrication for each reclaimer bucket. TRANSPORTATION   Austline designed, then fabricated from the initial assembly procedures and followed this process closely with essential stabilising frames to allow for easy transportation, assembly and final site installation.
  • 1
  • 2
  • 4