Viva Energy
Bulk Lubrication Facility
Nqpetro is proud to announce the successful delivery of the Viva Lubrication Facility in Karratha, Western Australia.
Location: Karratha, Western Australia
Service: Supply & Install of Bulk Lubrication Facility
Client: Viva Energy
Design & Planning: 9 Months
Construction: 7 Months
Project Manager
Shaun Yancazos
Storage Capacity
0
Million
Flow Rate
0
L/pm
Stainless Steel Pipe
0
km
Bulk Lubrication Facility - Viva Energy
Project Overiew
Lubricant Storage
- 10 × F.E.S. Grande 200 kL Tanks
- 4 × F.E.S. Grande 100 kL Tanks
Providing over 2.4 million litres of secure lubricant storage, fully interconnected by AS 1657-compliant walkways, stairways, and tank-top access systems, with more than 1.2 kilometres of seamless stainless-steel pipework welded to AS 4041 standards.
Central Bund Area
- 10 × Ebsray HD400 gear pumps
- FRP mesh walkways and handrails
- 1-tonne gantry crane system
- 10 × stainless-steel filter vessels
- 10 x flow switches with interlocks for no flow conditions
- 10 x pressure transmitters integrated with VSDs
Lubricant Loading Containers
Straddle carrier used to load lubricant containers onto the unloading area.
4,500 m² of heavy-duty hardstand laid, providing long-term stability for trucks and machinery.
100,000 kL Interceptor Tank System
A large oily water separator system capable of handling up to 12,000 L/min.
Designed to capture and treat contaminated water before it leaves the site.
Unloading Area
6 × Ebsray HD400 gear pumps
(up to 1,000 L/min)
Remote start/stop stations at each pump, with potentiometer control for local motor speed and flow rate adjustment.
Tanktop Access Area
- Enclosed with handrails and kick plates
- Filtered breather PV vent assemblies
- ATG probes
- Independent high-level switches
- Thermal relief valves
Loading Gantry
- 1 × Liquip 4-arm loading gantry
- 1 × Liquip 6-arm loading gantry
- 10 × LC IQR digital meters
- Cantilevered refuelling canopy
- 2 local control stations, deadman systems and RM140 overfill monitors
Switchroom
The custom-designed switchroom houses the facility’s MCC and provides full control of electrical systems. The installation includes:
- 16 × WEG CFW variable-speed drives
- 2 × EVO550 ATG consoles with 14 tank probes
- Alarm and annunciator panels for system status and fault indication
- A changeover switch providing mains and generator power supply functionality
Bulk Lubrication Facility - Viva Energy
Project Scope
This landmark installation was developed to support the Pilbara’s mining and industrial sectors with secure, high-volume, and sustainable lubricant storage and distribution capabilities.
The new facility delivers over 2.4 million litres of hydrocarbon storage capacity through 14 fully integrated tanks, achieving flow rates of up to 1,000 litres per minute across ten different lubricant products. The project was delivered over a 16-month program, including 9 months of design and planning followed by 7 months of construction, and was completed on time and within budget.
Bulk Lubrication Facility - Viva Energy
Mechanical Scope
The facility was designed to centralise the storage, blending, and transfer of multiple lubricant grades essential to mining operations.
Mechanical scope included:
- 10 × 200 kL and 4 × 100 kL F.E.S. Grande hydrocarbon storage tanks, interconnected via AS1657-compliant walkways, stairways, and tank-top access systems.
- Filtered dual-trap breather PV vent assemblies to ensure product integrity.
- 10 × stainless-steel filter vessels manufactured locally in Perth.
- 16 × Ebsray HD400 gear pumps delivering up to 1,000 L/min across ten lubricant types.
- Liquip LBM800 bottom-loading arms, LC IQR digital meters, and pneumatic flow controls.
- Over 1.2 km of seamless 316 SS pipework, welded to AS4041 with NDT and full traceability.
Bulk Lubrication Facility - Viva Energy
Electrical and Control Systems
Power and control are managed from a custom-built switchroom housing the facility’s MCC.
The electrical installation includes:
- Custom built switchboard, supplying power and controls to all equipment and sub-boards
- Variable-speed drives for all lubricant transfer pumps
- Annunciator panel for system status and fault indication
- Dual EVO550 ATG consoles providing remote level and temperature readings
- Local control panels, deadman systems and RM140 overfill monitors at each loading gantry
- Remote start/stop stations for unloading pumps, with potentiometers for control of pump speed
- Instrumentation including flow switches, pressure transmitters and independent high level sensors
- Earthing grid
Bulk Lubrication Facility - Viva Energy
Structural Works
The structural scope of the project was designed to support safe, efficient, and compliant operations across the entire facility.
Key elements included:
Key elements included:
- Dual loading gantries and custom pump skids enabling streamlined and secure tanker operations.
- A cantilevered refuelling canopy providing full weather protection for operators.
- FRP mesh walkways and handrails ensuring safe and compliant access across elevated areas.
- A central 1-tonne gantry crane system allowing for easy maintenance and equipment handling.
- Design compliant with the cyclonic conditions experienced in Karratha
- Pipe support structures, providing support to over 1.2km of 316 SS pipework
Bulk Lubrication Facility - Viva Energy
Civil and Environmental Works
All civil works were delivered to meet strict environmental and safety standards, ensuring long-term durability and compliance.
Key components included:
Key components included:
- Bulk earthworks and compaction for tank bunds, driveways, and crossovers.
- Reinforced concrete bund walls with full containment and isolation valves.
- A 12,000 L/min oily water separator system designed to capture and treat contaminated water before discharge.
- 4,500 m² of heavy-duty hardstand providing stable access and operational longevity for heavy vehicles and equipment.
- Concrete drainage systems connected to spillceptors for effective hydrocarbon containment and site protection.
Bulk Lubrication Facility - Viva Energy
Project Outcome
Delivering this project in the Pilbara’s extreme climate and remote location presented several challenges, including repeated cyclone activity, complex stainless-steel fabrication, and global procurement constraints.
Through careful planning, collaboration, and a strong on-site safety culture, the project team successfully delivered all milestones without compromise to quality or schedule.
The completed facility enables Viva Energy to supply lubricants directly to the Pilbara region, reducing road transport from Perth by up to 70 percent.
This significant reduction improves supply-chain efficiency, reduces emissions, and enhances service reliability for customers throughout the region.
Nqpetro is proud to have delivered this world-class project — reinforcing our capability and reputation as a national leader in hydrocarbon infrastructure, design, and construction.
View Our
Gallery
Fuel Storage Made Simple
self-bunded tanks
F.E.S. Self-Bunded Tanks are designed for secure, compliant, and reliable fuel storage across industries. Our team’s in-house fabrication capabilities mean we can deliver custom fuel storage solutions, from tailored dispensing systems to site-specific configurations — ensuring every tank meets your operational needs.
Partner with Nqpetro
Contact us now for expert advice, fast solutions, and nationwide support from Australia’s leader in hydrocarbon solutions.
