Introduction

The team at Hercules Group Pty Limited are proud to announce the completion of our first major Design & Construction project.

The completed facility was handed over to our client on 31st July 2009 within budget and exceeding the design criteria thanks to the hard work and dedication of all of our staff, sub-contractors and associates.

Since the handover date, our client has been undertaking commissioning and performance testing of the facility and any changes required have been minor.

Our brief was for the design and construction of a world-class facility to be used for the testing and approval of trade measurement flow meters used in the Petroleum, LPG and CNG market sector.

The scope was expanded during the period of construction to include the development and installation of a computerized control system to allow accurate control and reporting of the events undertaken in the testing of flow meters. The expansion bought the total value of the project to $3.85M.

Control System

The computerised control system selected was Emerson Flow Boss© S600 Programmed Logic Controller.

Two controllers were installed to manage both liquid and gas flows, the actions of which are monitored. Criteria variables can be changed using SCADA interactive PC’s 

The facility is divided into four specific areas of testing:-

Bulk Flow - Meter Testing

We constructed fixed rig for testing bulk flow meters varying in size from 50 to 150NB, with the ability to calibrate flow rates from 7 to 4000 litres/minute using (non-flammable combustible) hydrocarbon based fluids that simulate the same kinematic viscosities of motor spirit and automotive diesel oil. 

Typical bulk flow meters tested on this rig are those used at oil refineries, ships and marine terminals where large amount custody transfers occur.

The test rig consists of an Emerson ballistic meter prover coupled to two EBSRAY V40 variable speed vane pumps where flow and pressure are controlled using Fisher control valves. All pipe work, valves and equipment are stainless steel.

Supply fluid for either a motor spirit or automotive diesel oil proving is pumped from underground storage tanks into an above ground stainless steel day tank which ensures that the prover pumps are fed with constant head and pressure, and the fluid is maintained at a constant temperature during the proving process. 

Driveway Flow Meter Testing and Pattern Approval

The National Measurement Institute undertakes pattern approval for fuel dispensing equipment imported into Australia; these typically consist of retail motor spirit and automotive diesel oil  pumps and dispensers.

Pattern approval involves rigorous testing of all aspects of the equipment for safety, usability and approving of the flow meters in such equipment.

We provided a test area for pattern approval which uses the same common equipment as used for bulk flow meter testing, engineered out as many manual handling risks as possible and provided safety interlocks so that product exposure is minimized.

LPG – Flow Meter Testing

This fixed rig is for testing LPG flow meters varying in size from 25 to 100NB, with the ability to calibrate flow rates from 5 to 2000 litres/minute using commercial grade Propane and Butane as test fluids. 

Typical bulk flow meters tested on this rig are those used at gas platforms, ships, marine terminals and delivery vehicles where custody transfers occur.

Again, the test rig we constructed consists of an Emerson ballistic meter prover coupled to EBSRAY V20 & V40 variable speed vane pumps and again flow and pressure are controlled using Fisher control valves. All pipe work, valves and equipment are carbon steel designed and manufactured to AS4041-1998

The LPG is stored in two 5300 litre above-ground storage tanks and is protected with a fire deluge system

CNG Flow Meter Testing

The CNG system was existing at another location and transferred to this new location; we designed and constructed the area to house this equipment and protected it with the fire deluge system.

CNG flow meter testing is achieved by comparing the amount of gas passed through the meter with the weight of gas in specific receiving bullets that are mounted on load cells.

The call for this type of testing is limited at the moment to Government bus fleets etc; but is sure to expand as the use of CNG becomes more common.

Design & Construction

The design was managed in a co-operative manner with our client, involving them in every step of the process with ourselves and our specialist consultants including: architect, civil, structural, hydraulic, electrical, HVAC and dangerous goods design specialists. 

Our client signed off on the design in August 2008 and construction commenced in September, the construction was managed in-house by our management team including:
Andrew Nolan – Project Executive
Lawrence Smith – Project Manager
Ben Nielsen – Construction Manager

We undertook the majority of the construction work in-house using only specific subcontractors for tasks that were specialised or were cost effective, knowing that our quality control would be maintained.

The site chosen by our client was at the Test Safe site on Londonderry Road, Londonderry, NSW. The site is typical clay flood plain area and the site had a creek running through it at some time in ancient past; we removed more than 1000 tonnes of soft clay and refilled the area with crushed sandstone to provide a suitable base for the building.

We installed a 30,000 litre double-wall fiberglass underground tank for the storage of motor spirit and automotive diesel oil substitutes. 

In conjunction with our client and consultants we chose to build a portal frame building standing on a raft slab.

We used pre-cast concrete walls from ground level to 4 metres high for temperature insulation, sound annuation and where necessary increased the thickness of the concrete walls to provide blast walls between hazardous and non-hazardous areas.

From four metres high to the roof we used Colorbond cladding, insulated on the inside and with ventilators fitted in the walls and the roof to achieve a constant  air flow through the building to maintain constant temperatures and to dissipate any accumulated vapours

Excerpted from a letter the National Measurement Institute, Department of Innovation, Industry, Science and Research, dated 9th December 2009 (download letter in PDF, 539 KB):

"When executing its responsibilities as prime contractor and in its dealings with NMI, Hercules Group has at all times exemplified the utmost professionalism, integrity and an unwavering commitment to a quality outcome that went beyond the requirements of the contract..."

Excerpted from a letter from G.E. Shaw & Associates (ACT) Pty Limited, dated 13 July 2009 (download letter in PDF, 149 KB):

"We have been most impressed with HGPL’s willingness to walk the extra mile to get things done to tight schedules, their ready accommodation of client requirements for design changes, the clarity of their communications with us and with the client, and their indefatigable graciousness and good humour throughout the project..."