1. On-site performance
Typical symptoms on site
- The generator set is operating normally, but the day tank cannot cover one shift, so the site has to arrange refueling frequently.
- The large fuel tank was placed in a convenient location, but the generator set was on the other side, so temporary fuel hoses, fuel drums, and vehicles had to be moved back and forth.
- During the rainy season, if mountain roads or construction roads are affected, supply trucks cannot come in, and the generator can only reduce the load or shut down and wait.
- The positions of campsites, production lines and crews were constantly adjusted, but the fuel tanks and refueling routes were not re-planned accordingly.
2. Risk causes
Root cause in the power-system design
Many projects treat the generator as the core of the power-supply plan, but treat fuel tanks, refueling routes, and refueling frequency as minor site details. During true continuous operation, these details decide whether the generator set can keep producing power.
Refueling in remote mine sites is affected by roads, weather, slopes, vehicle turning space, night duty, and safety management. Generator-set capacity may be enough, but if fuel cannot reach the set, the power will still be interrupted.
Long-term continuous operation requires runtime autonomy planning. The daily fuel tank is too small, the large fuel tank is too far away from the unit, the refueling frequency is too high, or there is no backup route, the site will always be led by fuel dispatch.
3. Scope of influence
Production, fuel, maintenance, safety and environmental risks all grow
- The generator set stopped not because of a fault, but because no fuel was available. The production line, dewatering, lighting, and communications are still affected.
- Temporary refueling occupies people and vehicles, and refueling at night or on rainy days will also increase management and safety risks.
- Unstable supply will force the site to reduce load in advance, stagger production, or maintain key equipment, disrupting the production rhythm.
- If the fuel tank and route are changed later, it is often necessary to rearrange the foundation, rainproofing, anti-seepage, oil pipes, enclosures and vehicle channels.
4. How to avoid before construction
What to confirm before procurement or expansion
- Determine the daily fuel tank, large fuel tank, refueling truck path, turning space, oil unloading position and personnel duty mode simultaneously during unit layout.
- Estimate fuel range based on continuous operating hours and worst-case refueling conditions. Do not only arrange refueling based on normal weather and smooth roads.
- Design the refueling route around rainy-season access, mountain roads, construction roads, camp location, and production-area safety, so fuel trucks do not pass through high-risk or congested zones.
- Reserve fuel safety margins and emergency refueling plans for critical power loads to ensure that drainage, communications, lighting, and necessary production can be maintained when replenishment is delayed.
5. On-site confirmation information
Site information needed for an engineering review
- Site layout showing the generator set, day tank, large fuel tank, camp, production area, and access road.
- Planned continuous operating hours, estimated daily diesel consumption, and minimum acceptable fuel endurance.
- Types of refueling vehicles, road conditions, rainy season traffic conditions, refueling locations and nighttime refueling restrictions.
- Existing fuel tank capacity, oil pipe direction, rainproof and anti-seepage measures, and records of shutdowns or load reductions caused by refueling in the past.
