Fuel Tank Installation

This case study highlights a 2025 fuel tank installation carried out for an NHS Trust in the north of England. The site housed four large heavy fuel oil tanks that required decommissioning and removing from site for disposal. The existing tank farm then required demolishing to allow a new compound to be constructed. Once completed, a new 25,000 litre bunded fuel tank was installed, along with a new pump system and all required telemetry.

Scope and Delivery:

Following a successful tender process, the following works were undertaken:

• Firstly, undertake an initial consultation with stakeholders to discuss project requirements and design.
• Commission architect and structural engineer to design the new fueling compound and ensure adequacy of proposed concrete pads.
• Submit drawings, safe system of work and lifting plans to the client for approval, make the required F10 submission and generate project schedule.
• Attend pre-start meeting with the Trust to finalise details prior to mobilisation.
• Set up a site compound with suitable fencing, signage and welfare.
• Supply and commission a temporary steam boiler to reduce the viscocity of the existing heavy fuel oil.
• Uplift and dispose of waste heavy fuel oil, clean 4 x 100,000 litre tanks to gas free standards in preparation for removal.
• Prepare, cut and lift the redundant heavy fuel oil tanks for disposal.
• Conduct ground scanning and structural surveys ahead of bund demolition and compound construction.
• Demolish the existing brick bund structure, tank pads and slab, then conduct ground contamination testing and validation.
• Install a new fuel compound with reinforced concrete pads, compound lighting, palisade style fencing, HGV gate and line marking.
• Supply and deliver a new 25,000 litre bunded fuel storage tank with lockable full height cabinet, offset fill point, fuel recirculation unit, filters, alarms, gauge with BMS relays and overfill prevention.
• Installation of duplex standby gear pumps, stainless steel pipework including a new fill point, flow and return lines from the tank to pumps and pumps to boilers, including pressure testing of the entire system.
• Commissioning of the new system in collaberation with the Trust’s facilities team.
• Demobilising from site, ensuring that all work areas have been left clean and tidy.
• Finally, handover of all documentation in an O&M manual including waste notes, drawings, certificates, operating procedures and safety information.

Challenges & Mitigations:

This fuel tank installation project posed a number of challenges due to the setting and requirements from the client to maintain existing services. Our in-house project team were able to successfully navigate all difficulties to ensure a safe, compliant and efficient outcome. Below are some of the challenges faced and the control measures used to overcome.

Hospital site constraints &  manitenance of critical services.

• Close co-ordination with hospital estates and A&E, phased shutdown windows, contingency plans and out of hours working allowances.

Restricted space and access.

• Detailed logistics and plant selection, staged removal and delivery, suitably designed work compound with gated access.

Health, Safety & Environmental compliance.

• Use of in-house safety specialists, method statements, risk & COSHH assessments, lift planning, asbestos surveys, licensed waste handling and disposal.

Continuity of heating supply with temporary storage provisions and phased tie-in to avoid boiler downtime.

• Alignment with existing infrastructure, thorough survey, adaptation of pipe routing, flexible connection designs with suitable isolations.

The Result.

In conclusion of the above listed works, our client was presented with a new fuel compound that meets and exceeds fuel storage regulations. The legacy heavy fuel oil tanks were safely decommissioned, with over 90% of the waste produced on site being recycled, helping the client to meet their sustainability goals.

Should you have any fuel tank installation questions or requirements, please do not hesitate to get in touch with our team by emailing [email protected] or by calling 01132635163. If you would like to read any of our other case studies, please click here.

If you would like to read any information regarding the safe storage of flammable liquids in tanks, you can download free guidance from the HSE website here.