Out with the Old, In with the New: A Weekend Fuel System Revolution for Cleanaway

Many industrial sites operate with equipment that has seen better days. When it comes to a critical asset like a fuel tank, relying on temporary fixes can create significant risks. An aging system with mismatched components can lead to unexpected failures and costly disruptions.

For a major operation like the Cleanaway depot in North Brisbane, reliability is essential. Their old diesel tank and its patchwork of systems posed a threat to operational uptime. They needed a modern solution without interrupting their busy weekday schedule. That's where GO Industrial came in.

The Problem: When Reliability Becomes a Risk

With older fuel tanks, the main challenge often isn't the tank itself, but the supporting systems such as pumps, electronics, and fuel management hardware. Continuous exposure to UV rays, weather, and general wear can cause these components to degrade.

Cleanaway's system was a clear example of this. It consisted of various fixes accumulated over years, making it inefficient and unreliable. Continuing with temporary repairs was no longer a practical solution. It was time for a complete overhaul to ensure dependable service for the next decade.

The Game Plan: A Full Depot Upgrade with Zero Downtime

Shutting down a busy depot, even for a day, can create significant logistical challenges. Cleanaway’s fleet needs to be ready to go first thing Monday morning. 

Our solution was a meticulously planned turnkey operation executed over a single weekend to ensure no disruption.

The mission covered every base:

• Decommissioning & Removal: We safely drained, cleaned, and removed the old tank and all its components.

• Site Prep & Installation: The area was prepared for the seamless installation of a new, state-of-the-art Con69 self-bunded diesel tank.

• Commissioning & Testing: We integrated a modern fuel management system, connecting all hardware and running extensive tests to ensure flawless operation.

• Supervised Handover: We oversaw the first fuel delivery into the new tank and provided a full handover to the Cleanaway team.

The Upgrade: A Closer Look at the Technology

This project was a significant investment in technology designed for longevity and performance in harsh Australian conditions.

At the core of the installation is the iFuel LITE Fuel Management System. This is a game-changer for fuel reconciliation and security. Operators simply scan a fob to authorise refuelling, and the system automatically tracks who takes fuel, when, and exactly how many litres. This eliminates manual logs and prevents fuel theft.

To support the FMS, we selected high-performance hardware:

• High-Flow Pumping: We opted for an electric Submersible Pump capable of delivering up to 300 LPM. These pumps are extremely reliable, offer great longevity, and don't take up additional space. This is paired with premium ZVA Nozzles, which are designed to handle the high flow rate, minimising vehicle downtime at the pump.

• Pinpoint Accuracy: For precise measurement, a Flomec Flow Meter was installed. This in-line Flow Meter provides extremely accurate dispensing data and features a pulse function that connects directly to the FMS, allowing for real-time tracking.

• Tank Monitoring & Safety: An OCIO Tank Gauge provides an accurate, continuous measurement of the fuel level inside the tank. Crucially, it also features high-level alarms to prevent dangerous and costly overfills.

The Result: Long-Term Peace of Mind

By Monday morning, it was business as usual for Cleanaway, but with a major difference. They now have a safe, compliant, and highly reliable fuelling system.

By proactively replacing the entire system, Cleanaway has eliminated the risk of unexpected breakdowns, improved operational efficiency, and enhanced safety. This represents a strategic move from reactive repairs to long-term reliability.

Is it time to review your fuel system? Don't wait for a costly failure. Contact the experts at GO Industrial today for a no-obligation consultation on a modern, turnkey solution for your site.