BMA Goonyella Riverside Mine – Fuel Farm Upgrade, Control & Monitoring Systems
Client: BMA (BHP Mitsubishi Alliance)
Location: Goonyella Riverside Mine, Queensland, Australia
Project Period: 2013
Project Type: Capital Project – Industrial Process Infrastructure
System Scope: Fuel Storage, Distribution, Control & Monitoring
Role: Head Contractor – Program Director
Strategic Objective
Goonyella Riverside is a large‑scale, high‑throughput metallurgical coal operation within the BMA portfolio, where fuel availability underpins every production activity—from mobile equipment to fixed plant operations.
The existing fuel infrastructure required modernisation to support increasing operational demand, improve environmental assurance, and provide real‑time visibility of fuel inventory and distribution.
The strategic objective was to design, install, and commission an upgraded fuel storage, control, and monitoring system that enhanced operational reliability, strengthened environmental protection, and integrated seamlessly into the mine’s broader control environment—without interrupting production.
The Challenge / Need
Fuel systems represent a high‑consequence risk node in mining operations.
The project needed to address:
- Ageing fuel infrastructure not aligned with current operational scale
- Limited real‑time visibility of fuel inventory and distribution
- Environmental risk associated with spills, losses, and containment failure
- Integration of modern control systems with legacy infrastructure
- Delivery within a live mining environment with zero tolerance for disruption
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:
- Comprehensive site audit of existing fuel infrastructure
- Engineering design of upgraded fuel storage and distribution systems
- Installation of modern monitoring and control platforms
- Integration with site SCADA systems
- Environmental protection and spill‑prevention measures
- Phased construction, commissioning, and operational handover
- Development of operational manuals 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 demand.
Key elements included:
- Whole‑System Assessment: Identification of capacity, control, and compliance gaps
- Phased Implementation Planning: Sequencing works to protect uninterrupted mining operations
- Operational Alignment: Close collaboration with BMA operations, maintenance, and safety teams
- SCADA Integration: Deployment of real‑time monitoring and automated control for fuel inventory and distribution
- Environmental Safeguards: Engineering of fail‑safe systems to prevent spills and fuel loss
- Operational Enablement: Structured training and documentation to support long‑term reliability
The emphasis throughout was on predictable system behaviour, not just infrastructure replacement.
Complexity & Risk
The project sat at the intersection of several high‑risk considerations:
- Live mine operations with no tolerance for downtime
- Hazardous material handling and environmental exposure
- Integration of modern control systems into legacy assets
- Tight delivery timeframes within an active production schedule
- Strict regulatory and safety compliance requirements
These risks were mitigated through disciplined planning, conservative sequencing, and continuous safety governance.
Solution & Key Deliverables
The project delivered:
- Upgraded fuel storage and distribution infrastructure
- Advanced SCADA‑based monitoring and control systems
- Automated inventory tracking and distribution oversight
- Integrated spill‑prevention and environmental protection mechanisms
- Comprehensive operational manuals and staff training
- Full commissioning and compliant handover
All systems were validated under live operating conditions prior to final handover.
Delivery & Safety Performance
The project was completed with:
- ~26,000 work hours
- Zero Lost Time Injuries (LTI)
- One First Aid Incident (FAI)
This outcome reflected disciplined safety leadership within a high‑risk operational environment.
Outcome
The upgraded fuel farm:
- Delivered robust, real‑time control and monitoring capability
- Enhanced operational visibility and fuel management efficiency
- Strengthened environmental compliance and spill‑prevention assurance
- Integrated seamlessly into site control systems
- Was delivered on time and within approved scope and budget
- Maintained uninterrupted mining operations throughout execution
BMA gained a future‑ready fuel infrastructure platform aligned with operational scale and compliance expectations.
Why This Matters
This project demonstrates a consistent capability across Murray’s mining portfolio:
- Ownership of high‑consequence infrastructure nodes
- Delivery within live production environments
- Integration of automation and control 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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