Assessment and Repair of Caustic Soda Rail Tanker Fleet

LOCATION

Bunbury, WA

INDUSTRY

Chemical (Transport)

VALUE

Over $1 Million

Scope of Work

The Rail Tanker fleet had been operating for some time with limited maintenance due to operational constraints and our client required us to make an assessment of what maintenance work needed to be carried out to extend the fleet’s working life while replacement options were investigated.

Initially a detailed condition survey of all twenty-eight Tankers in the fleet was carried out. This was done parallel with a design conformity review to ensure the Tankers and subsequent repairs were compliant with all applicable current engineering standards, transport codes and government regulations. From these surveys APMS worked closely with our client to prepare and prioritise individual remediation plans for each Tanker.

Project Resourcing

The project team included:

Project Management
Quality Management
Mechanical Design Engineer
Project Supervision
Boilermaking and Coded Welding Personnel
Subcontracts – chemical cleaning, post weld heat treatment, NDT, surface treatment.

Fabrication

The Tankers are 1.9m diameter x 15.5m long, with a capacity of 43,000 litres and weigh 19 tonnes each. Their material of construction is carbon steel. Having established the scope of work repair work is now being carried out. This includes nozzle replacement, shell overlay, internal repairs, handrail/platform remediation and the introduction of new safety features. The project involves material procurement, chemical cleaning the Tankers internally, carrying out the repairs, NDT, post weld heat treatment, hydrotesting, surface treatment and delivery of the completed Tankers back to the rail yard. All work complies with AS1210 and AS7520 (Railway Rolling Stock) and WHS and Dangerous Goods Acts and Regulations. Welding is to AS3992.

Project Achievements

Zero recordable incidents or accidents throughout the duration of the project.
Ensuring compliance with all applicable current engineering standards, transport codes and government regulations.
Extensive interaction with our client to define repair workscope and ensure timely resolution of numerous technical issues.
Development of long term remediation plan for the Tanker fleet.

Key Activities

The success of the project was dependant on the successful execution of the following activities:

Condition survey of all Tankers in the fleet.
Engineering conformance checks to AS1210, AS1200, AS7520.2 (Rolling Stock), WHOS Act 2020, Dangerous Goods Act 2004, ADG.
Material procurement for identified repairs.
Coded Tungsten Inert Gas (TIG) and Flux Cored Arc (FCAW) welding to AS3992.
Post weld heat treatment of Tanker.
Successful NDT (100% RT, PT and UT) and hydrotesting.
Surface treatment of Tankers (including complaint signage)
100% material and weld traceability.