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.

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.

Milk processing skids

Case Study – Milk Processing Skids – Project Ninja

PROJECT NINJA, NEW SOUTH WALES

MILK PROCESSING SKIDS

CLIENT: PROCESS PARTNERS

YEAR: 2016

SECTOR: FOOD & BEVERAGE

SCOPE OF WORKS   

Austline Fabrications was engaged to supply, manufacture and install three mounted and fully assembled pasteuriser skids as part of the Lion flavoured milk upgrade in New South Wales. In addition, Austline was awarded the fabrication of a thermaliser skid, two CIP skids and preheaters of which all were fabricated, delivered and installed to the Lion owned Wetherill Park facility.

SPECIALISED FABRICATION

All skids were fabricated in Austline’s purpose built workshop in Western Australia by experienced tradesmen to achieve the project time frame. All fabricated skids and items utilised 316L stainless steel tube and aseptic grade valves.

ENGINEERING  

Austline were issued 3D model drawings and produced working/fabrication drawings for their stainless steel fabricators. This ensured the skids were complete with plate heat exchangers, Hipex shell and tube heat exchangers, high flow pumps, Balance tanks (fabricated to sanitary grade), S/S control panel supports, inline micro filtration strainers, automated mix proof aseptic valves, instrumentation, airlines, electrical conduits and 36 meters of holding tube.

DELIVERY  

From receipt of drawings and equipment, the skids were delivered to site within a six week timeframe. The skids arrived fully assembled and this enabled connection on site to minimise installation and testing time at the Wetherill Park Dairy.

Case Study – Stainless Steel Ducting – Curtin University

CURTIN UNIVERSITY, BENTLEY CAMPUS PERTH

STAINLESS STEEL DUCTING

CLIENT: ENVAR PTY LTD

YEAR: 2016

SECTOR: COMMERCIAL

NEW TECHNOLOGY   

Building 304 will provide custom research facilities dedicated to the Centre for Crop and Disease. Situated on the eastern side of Curtin’s Bentley campus; the four-story building will feature three levels of highly specialised laboratories.

SCOPE OF WORKS

Austline Fabrications was awarded the contract to supply, fabricate and install all associated stainless steel ductwork and decontamination lines for the custom research facilities by lead contractor Envar Group. Austline successfully designed, fabricated and installed all deliverables. Austline also assisted with final testing before the handover to the client.

PRE-WORKS & COMPETITIVE SOLUTIONS  

A comprehensive pre site measure to existing floor and ceiling penetrations allowed Austline to customise and pre fabricate with precision in our Perth based factory. The pre-fabricated lobster back elbows, t- junctions and all spooling were then installed on site by experienced tradesmen with specialised cushion head install engaging purge welding techniques. Working with Envar on the design of the cushion head allowed for cost effective fabrication. Austline’s opportunity to maximise off site fabrication of large bore spools was integral in the success of the projects timeline.

QUALITY – SANITARY GRADE  

This facility demanded each environment within the building to have a specific controlled atmosphere. The ductwork required Austline fabricators and installers to utilise sanitary grade purge welding to all stainless steel spools and fabricated items to ensure air purification of individual rooms and spaces in the laboratory. Passivation of all welds also ensured successful final testing of the system. This dedicated research building provides truly world-class contemporary facilities and will be the catalyst in attracting globally recognised crop and disease management scholars to Curtin University.

crown towers stainless steel

Case Study – Architectural Stainless Steel – Crown Towers

CROWN TOWERS, WESTERN AUSTRALIA

ARCHITECTURAL STAINLESS STEEL FEATURES

CLIENT: BROOKFIELD MULTIPLEX

YEAR: 2016

SECTOR: COMMERCIAL

WORLD CLASS ESTABLISHMENT  

Austline Fabrications were awarded the specialised architectural and intricate stainless steel fabrication and installation of Perth’s newest and most luxurious hotel, overlooking the Swan River. Setting a new standard in Western Australia, Crown Towers feature 500 guest rooms, suites and villas, restaurants, bars, a ballroom, business centre, resort pool and world class spa facilities.

SPECIALISED FABRICATION

Austline fabricated in our custom-built workshop visually outstanding stainless steel porthole windows, flashings, balustrading, TV surrounds and stainless features. These components are purposefully showcased throughout the custom designed interiors and exteriors of the hotel.

THE PORTHOLE

To fabricate the high-end window dressings, Austline imported the exotic champagne/rose gold stainless steel. Situated adjacent to The Waiting Room Bar, both windows were custom fit to reflect the opulence of the Crown Towers through there seamless and intricate appearance and purpose.

HIGH QUALITY OUTCOME

After completing extensive site measurements and liaising with our client, Austline installed all fabricated components on site. The visually impressive and architecturally inspired result showcases the outstanding fabrication and installation of stainless steel and its versatility within the commercial sector.

cookers bulk oil

Case Study – Relocation & Expansion – Cookers Bulk Oil

COOKERS BULK OIL SYSTEMS, WESTERN AUSTRALIA

RELOCATION & EXPANSION

CLIENT: COOKERS BULK OIL SYSTEMS

YEAR: 2016

SECTOR: FOOD & BEVERAGE

PROJECT SCOPE  

Austline Fabrications is pleased to have assisted Cookers Bulk Oil Systems in their commitment to innovation in providing their clients with fresh oil solutions and sustainable management of bulk oils. Austline collaborated with Cookers for a three month project to install and upgrade the capacity of the tanks for bulk oils handling in their Perth plant.

EXPERIENCE & EXPERTISE

Our specialised process pipe tradesman fitted and installed four new tanks to increase the capacity to six fresh oil tanks while also doubling the capacity of an existing waste oil tank. Austline installed the tanks and associated pipework to increase the filtration from a stage one filter to a three stage micro filtration process. In addition, at Cookers new facility the capacity increased from 90,000 litres to 300,000 litres. Austline were integral in doubling the waste oil capabilities from 30,000 litres to 60,000 litres.

INNOVATION

Austline designed, fabricated and installed two valve manifold systems, allowing efficient transfer of product between tanks to the trucks for the loading and unloading process. In addition to this specialised fabrication Austline sourced, fabricated and installed with precision the two swivel truck systems which increases operational efficiency in the transfer of oils.

Fabrication allowances were made for future expansion of two new fresh oil tanks through the manifold system at the facility.

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