Storage Terminal Expansion

In 2020 DIALOG Fitzroy were awarded an EPC contract to construct a fuel storage tank terminal expansion development at Port Botany in Sydney, Australia.   

DIALOG Fitzroy’s scope of work for this project included:

  • All civils - Site preparation, tank foundations, concrete bund walls, sumps and lining, roads and pavements, including kerbs and car parks, stormwater and drainage, potable water and structural and equipment slabs, plinths, foundations and grouting;
  • Tanks - Design fabrication and construction of three (3) x 35,000m³ (working volume) steel storage tanks, including all fittings and peripherals; and inspection, testing, pre-commissioning and commissioning of the tanks (including hydro test);
  • Structural, mechanical and piping scope including - detailed design for the procurement, fabrication and construction of all transfer lines, valve manifold, tank inlet/outlet piping, tank recirculation piping and pump station piping, stormwater management for the site and oily water management, compressed air reticulation and utility connections, potable water supply and distribution including safety showers, firewater piping;
  • An underground road crossing to connect the new site to the existing terminal and jetty
  • Painting, insulation, inspection, testing and commissioning of all piping;
  • E&I including - all B4A electrical and instrumentation including switchroom, management of and procurement of new Ausgrid packaged substation including design and provision of associated civil works and all cabling, B4A automation systems involving Vopak-specified suppliers and including PLC, SAAB, Tankmaster, Motor Operated Valves, ESD system, CCTV, Access Controls, Fire Indicator Control Panel systems; sufficient automation engineering to complete the powering up of automation devices, point-to-point testing and pre-commissioning to achieve Practical Completion.

DIALOG Fitzroy Solution

COVID lockdowns occurred just as ground was broken in March 2020 but fortunately the bulk of our team were on site at that point.  The pandemic, tight project duration, some terrible weather and very restricted site access made for interesting times in what was essentially a relatively straight forward project. 

In total we lost 35 days during the build due to extreme weather, at one point the whole site was under half a metre of water for a week and it took two days to clean up and get the site back to a workable condition.  To add to the headaches, the NSW government shut down the whole of the Sydney area from 18th to 31st July as COVID took hold in the state.

DIALOG Fitzroy employed some innovative methods for this project including the installation of a steel sheet-piled bund wall around the site, just the second time this method had been used in Australia. 

We had to undertake a comprehensive lighting study in order to gain compliance with air traffic control requirements for the nearby Sydney Airport.  This was well worth the effort as the site is brilliantly lit up, with no shadows thrown anywhere. 

Despite all of the issues and with the outstanding efforts of our subcontractors, practical completion was achieved on 17th September 2021, which allowed our client to begin their pre-commissioning and testing works. That whole process went very smoothly, with no problems found on any of the systems tested and calibrated.