BHP Iron Ore – Yandi Mine 500,000 L Fuel Farm Installation, Control & Monitoring
Client: BHPIO (BHP Iron Ore)
Location: Yandi Mine, Pilbara, Western Australia
Project Period: 2014
Project Type: Capital Project – Industrial Process & Fuel Infrastructure
System Scope: Bulk Fuel Storage, Distribution, Control & Monitoring
Role: Head Contractor – Program Director
Strategic Objective
Yandi Mine is a cornerstone asset within BHP Iron Ore’s Pilbara operations, where fuel availability directly underpins mining, haulage, and processing continuity.
To support operational scale and reliability, BHPIO required a new 500,000‑litre fuel farm capable of providing secure bulk storage, controlled distribution, and real‑time operational visibility—while meeting strict environmental, safety, and governance standards.
The strategic objective was to design, install, and commission a state‑of‑the‑art fuel farm system that strengthened operational resilience, reduced environmental exposure, and integrated seamlessly into the site’s control environment—without interrupting live mining operations.
The Challenge / Need
Bulk fuel systems represent a high‑consequence operational node in large‑scale mining environments.
The Yandi project needed to address:
- High‑volume fuel storage and distribution under continuous demand
- Limited real‑time visibility of fuel inventory and transfer events
- Environmental and safety risks associated with large‑scale hydrocarbon storage
- Integration of modern control systems into existing site infrastructure
- Delivery within a live operating mine with zero tolerance for downtime
Any failure in sequencing, commissioning, or environmental control would have had immediate operational and reputational impact.
Project Scope
The engagement encompassed end‑to‑end system leadership, including:
- Site assessment and operational needs analysis
- Engineering design of a 500,000 L fuel storage and distribution system
- Installation of tanks, distribution pipework, and associated infrastructure
- Deployment of SCADA‑based control and monitoring systems
- Integration of environmental protection and fail‑safe mechanisms
- Phased construction, commissioning, and operational handover
- Development of technical documentation and workforce training
Our Approach
A risk‑led, operational‑first delivery model was applied—recognising that fuel infrastructure must perform invisibly and reliably under continuous load.
Key elements included:
- Whole‑System Assessment: Identification of capacity, control, and compliance requirements
- Operational Alignment: Close collaboration with BHPIO operations, maintenance, and safety teams
- Modular Infrastructure Design: Fuel storage and distribution systems designed to reduce installation risk and support scalability
- SCADA Integration: Real‑time monitoring, inventory tracking, and automated control of fuel movements
- Environmental Protection by Design: Engineering of spill‑prevention, overfill protection, and emergency shutdown mechanisms
- Operational Enablement: Structured training and documentation to support long‑term reliability
The emphasis throughout was on predictable system behaviour, not just asset installation.
Complexity & Risk
The project sat at the intersection of several high‑risk considerations:
- Live mine operations with zero tolerance for fuel disruption
- Hazardous material handling and environmental exposure
- Integration of new control systems into existing operational platforms
- Tight delivery windows aligned to production schedules
- Strict regulatory, safety, and corporate governance requirements
These risks were mitigated through disciplined planning, conservative sequencing, and continuous safety governance.
Solution & Key Deliverables
The project delivered:
- Installation of 500,000‑litre fuel storage tanks with high‑capacity distribution systems
- Advanced SCADA‑based monitoring and control for real‑time fuel visibility
- Automated inventory management and distribution oversight
- Integrated safety and compliance systems to prevent leaks, overflows, and losses
- Fail‑safe emergency shutdown and containment mechanisms
- Comprehensive technical documentation and staff training
- Fully commissioned systems ready for sustained operation
Delivery Team
Design
- 1 × Lead Solutions Engineer
- 4 × Solutions Integrators / Designers
- 1 × Process & Control Implementation Engineer
Construction
- 1 × Project Manager
- 1 × Construction Engineer
- 1 × Contracts Manager
- 1 × Quality Manager
- 1 × Safety Manager
- MEP fabrication and installation contractor
- Mechanical systems fabrication contractor
- Tanks and tanking contractor
- 7 × Functional suppliers
- Electrical contractor
Delivery & Safety Performance
The project was completed with:
- ~26,000 work hours
- Zero Lost Time Injuries (LTI)
- One First Aid Incident (FAI)
This reflects disciplined safety leadership within a high‑risk industrial environment.
Outcome
The upgraded fuel farm:
- Delivered reliable bulk fuel storage and distribution capability
- Enabled real‑time monitoring and control of fuel assets
- Strengthened environmental compliance and spill‑prevention assurance
- Integrated seamlessly into Yandi’s operational control environment
- Was delivered on time and within approved scope and budget
- Maintained uninterrupted mining operations throughout execution
BHPIO gained a robust, future‑ready fuel infrastructure platform aligned with Yandi’s operational scale and governance expectations.
Why This Matters
This project reinforces a recurring capability across Murray’s mining portfolio:
- Ownership of high‑consequence infrastructure nodes
- Delivery within live production environments
- Automation and control applied as risk‑reduction tools
- Safety and environmental assurance embedded by design
Fuel systems are invisible when they work—and immediately disruptive when they do not.
This engagement ensured reliability, compliance, and control without operational compromise.
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