InterGroup has successfully delivered an extensive manual industrial tank cleaning programme at Channel Infrastructure’s Marsden Point facility, demonstrating advanced technical capabilities and exceptional safety performance. The project, which commenced in June 2022, formed a critical component of the site’s transition from a refinery to a terminal storage facility.
Project Scope and Execution
Channel Infrastructure, formerly known as Refining NZ, appointed InterGroup to provide specialized tank cleaning services during the decommissioning phase of the facility’s transformation. The scope encompassed approximately 40 tanks previously used to store crude oil, finished fuel products, and other hazardous substances. With certain tanks designated for different product service roles in the terminal configuration, the project was structured into two groups aligned with varying priority levels and the terminal transition schedule.
Ryan Naidu, area manager, led the project execution, supported by InterGroup’s Northern Industrial Operations and Administration teams along with the company’s National Compliance Management division. The collaborative approach enabled comprehensive planning, programming, and delivery of operations that met the client’s requirements for timeline, cost, and overall project outcomes.
Exceptional Safety and Environmental Performance
InterGroup achieved remarkable health, safety, and environmental results throughout the project duration. The company completed 45,000 manhours without a single safety incident, while maintaining zero spillages and loss of containment—a critical achievement given Channel Infrastructure’s stringent “No Spill” culture and elevated safety standards.
The company’s existing presence at the refinery provided significant advantages, bringing established familiarity with the client’s systems and procedures. This experience proved essential in successfully executing multi-disciplined work packages within an extremely high-risk operational environment. Strong performance was achieved through expertly designed methodologies and strategic minimization of manned entry operations through deployment of robotic systems.
Technical Delivery and Methods
InterGroup’s specialised team performed sludge removal and detailed cleaning across 33 hydrocarbon tanks, including nine large-diameter floating roof crude tanks. These operations required confined space man entry procedures utilizing breathing apparatus and extensive health and safety planning protocols. Cleaning standards ranged from Class II to Class IV levels of cleanliness, determined by each tank’s intended repurposing requirements. The team removed approximately 4,000 cubic meters of sludge from crude tanks over the project duration.
Tank cleaning operations were executed through multiple methodologies tailored to specific conditions. These included manual cleaning techniques, magnetic cleaning utilizing InterGroup’s Verti Drive magnetic tank cleaning robot, and for heavy sludge-intensive crude oil tanks, deployment of the company’s Gerotto Zone 0 robotic tank cleaning system.
Navigating Complex Operational Challenges
The project team encountered numerous operational challenges requiring adaptive management approaches. Frequent modifications to the tank availability schedule, driven by the evolving terminal transition plan, necessitated continuous adjustments to project management, planning, and delivery timelines. InterGroup maintained regular and transparent communication with Channel Infrastructure to integrate these changes effectively. The company’s agile operational approach and strong client relationships enabled continuity of work within required timeframes despite necessary schedule modifications.
Integration of the Gerotto robotic technology presented an additional challenge, as the team had no prior operational experience with the system. Recognising the substantial benefits the technology offered, InterGroup invested significant resources in training appropriate personnel on optimal robot operation. This investment transformed the initial challenge into a realised opportunity for enhanced project delivery.
Innovation Through Advanced Technology
InterGroup demonstrated its commitment to technological innovation by introducing the Gerotto Lombrico robotic system to New Zealand for the first time. While widely utilized for de-sludging and cleaning crude tanks at refineries throughout Western Europe, the technology had not previously been deployed in New Zealand operations.
The remotely operated crawler system is designed and certified to operate in explosive atmospheres where risk is continuous. The unit fits through standard 24-inch manways and can be deployed immediately upon manway cover removal, significantly reducing required manpower and tank cleaning duration. The technology provides substantial health, safety, and environmental benefits by eliminating personnel exposure to toxic waste and removing the need for nitrogen blankets or tank venting procedures.
The Zone 0-rated unit features a low-pressure, low-volume jet nozzle system that introduces diluted cutter stock to agitate and fluidize sludge. This capability enables efficient vacuum extraction through the system, with fluidized sludge removed from tanks via the ATC head using high-capacity 3A vacuum trucks.
Technical Problem-Solving Capability
InterGroup’s technical expertise and problem-solving capabilities were particularly evident during work on tank T04, a crude tank conversion to Jet-A1 fuel specification. This operation required a first-of-its-kind solution to achieve complete internal shell cleaning without resulting jet fuel contamination. Despite the complex technical requirements, the industrial team delivered work meeting required quality standards within the committed cost parameters and schedule.
The Marsden Point project exemplifies InterGroup’s capacity to manage large-scale, technically complex industrial cleaning operations while maintaining exceptional safety and environmental performance standards. The successful completion positions the company as a leader in introducing innovative technology solutions to the New Zealand industrial services market while delivering tangible value to clients navigating significant operational transitions.
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