Fuel management solutions provider AFS Group has been awarded the contract to supply its fuel monitoring technologies and expertise to BHP Billiton’s Douglas-Middelburg optimisation (DMO) project.

AFS Group has been the approved fuel management contractor at all of BHP’s collieries since 2004 when an efficient fuel management solution was required to moni-tor and control the significant volumes of fuel and lubricants used by the various plant vehicles and other equipment at the DMO project site, as well as at BHP’s other sites.

“We oversee the entire fuel and lubricant process, from ordering bulk deliveries to dis-pensing to the mine’s various vehicles and equipment. 
“This way, we can account for every drop of fuel on the mine,” says AFS Group GM Pradil Maharaj.

The company reports that, prior to AFS’s involvement at BHP’s Khutala, Klipspruit and Middleburg Mine Services collieries, the coal export giant was using a manual system, which proved unsuccessful. 
However, the company adds that, with the implementation of AFS’s technology, the man-agement of fuel has improved.

The company cites as an exmple BHP’s Middleburg Mine Services site, the largest coal producer in the group – there was a slight meter vari-ance of 0,01% in fixed sites and less than 0,06% on mobile sites over a period of one month, a vast contrast to the industry standard of 0,5%. 
BHP Billiton contracts manager Tilly Bird reports that it is through the use of AFS technology that its audit results have greatly improved – this is especially important as fuel counts as the mine’s highest spend commodity.

AFS reports that all bulk fuel storage tanks on the mines are fitted with a probe, which acts as an electronic dipstick. 
These are connected to a tank levelling system which records tank levels as well as deliveries made. 
Further, the system not only detects leaks and water presence in the tanks, but is also equipped with alarms to indicate the delivery limit, the low-level limit and overfill.

To ensure that only appro-priately authorised vehicles receive the required fuel and lubricants, AFS has fitted all the mine’s vehicles with identification devices which, when detected by a reader attached to the nozzle on the home base fuelling point, automatically identify each vehicle. 
Only once the vehicle has been identified and authorised for refuelling will the pump switch on.

During the refuelling pro-cess, data such as the vehicle’s odometer reading, the date and time of the transaction, the fuel type and transaction volume are accurately and automati-cally recorded. 
In addition, the identification devices on the mining vehicles calculate and store engine hour or odometer readings in order to calculate fuel consumption.


Further, because there are a number of items of plant that cannot be moved, the mobile bowsers that supply these with fuel are also fitted with this technology. 
This ensures that all fuel transferred is accounted for and that the transaction is recorded. 
All transactions and tank levels for each site are down-loaded and recorded on a daily basis by an AFS information services analyst.
 Once processed, the data is measured against meter readings to ensure that all transactions are accounted 
for and a report is sent to the mine. 
This includes details such as meter movement, transactions and variance, and from this information, a monthly over-view is then created. 
These reports also reconcile what was ordered and what was actually delivered. 
AFS also provides 24-hour on-site support to ensure the seamless operation of its services.