Project
LPG to Natural Gas Site Conversion
Client
Confidential
Location
Goldfields, WA
Sector
Industrial / Mining
Nature of project
Fuel Source Conversion & Full Gas System Upgrade
Project Background
The client approached Kalgas Energy Services to manage a complete site transition from LPG to Natural Gas. Their existing LPG infrastructure had become increasingly inefficient and costly to operate, with growing safety, compliance, and scalability concerns. The business required a future-proof solution that could meet long-term operational demands while reducing costs.
The client sought a comprehensive, future-proof energy solution that would not only reduce operational expenses but also ensure long-term reliability and adherence to stringent industry standards.
As part of Kalgas’s expertise in fuel source conversion, system automation, and compliance engineering, the project was scoped as a full turnkey delivery. We managed every aspect from decommissioning through to final commissioning and integration.
Scope of Work
Kalgas Energy Services undertook a meticulous, multi-phase project, encompassing the following areas.
Full Decommissioning of Existing LPG Infrastructure
Kalgas undertook the safe purging, dismantling, and removal of all legacy LPG storage tanks, pipework, vaporisers, and associated control systems.
Comprehensive Natural Gas System Design
We tailored the engineering of a new natural gas delivery system, meticulously designed to meet the site’s current energy demands. It was engineered with capacity for anticipated future expansion as well. This included detailed flow analysis, pressure regulation, and sizing of all components.
Engineering of Advanced Combustion Management Systems
We further integrated state-of-the-art burner technology and sophisticated combustion controls. This helped optimise fuel efficiency and process stability across the client’s industrial appliances.
Deployment of Industrial-Grade Safety Protocols
To achieve this, Kalgas undertook installation of robust safety systems, including comprehensive emergency shutdown (ESD) capabilities and fail-safe redundancies. This included gas detection systems, pressure relief valves, and interlocks to prevent hazardous conditions.
Professional-Grade Piping and Valve Configuration
Our work also included fabrication, installation, and pressure testing of natural gas pipework and valve configurations. This critical component of the project adhered to the highest safety and material standards, enhancing system longevity and operational integrity.
Leveraging In-House Inventory
A significant portion (90%) of the installed equipment, including advanced burner technology and control components, was sourced from Kalgas’s extensive inventory of premium industrial solutions, ensuring rapid deployment and access to the latest advancements in gas systems.
What We Achieved
The successful conversion project delivered substantial and measurable benefits to the client
This project showcases our ability to deliver turnkey gas infrastructure solutions that align with modern energy standards. From SCADA integration to high-efficiency natural gas delivery, the site now benefits from safer, smarter, and more cost-effective operations.
Reduction in Fuel Costs
Achieved through the superior energy efficiency of natural gas and optimised combustion management, leading to tangible operational savings.
Enhanced Operational Stability and Production Reliability
The new, robust natural gas system provided consistent and reliable energy supply, minimising interruptions and ensuring smoother production processes.
Profound Improvement in Site Safety and Regulatory Compliance
The upgraded infrastructure and adherence to the latest Australian gas regulations provided peace of mind and ensured the client’s operations met all legal and industry safety benchmarks.
Future-Proofed Energy Infrastructure
The new system was designed with scalability in mind, allowing for seamless capacity expansion to accommodate future growth and evolving energy demands without major overhauls.
Minimal Operational Downtime
Kalgas’s comprehensive turnkey approach and efficient mobilization capabilities ensured the conversion was executed with minimal disruption to the client’s critical operations.
PROFESSIONAL
Our team is highly trained and experienced to get the job done on time and budget.
SAFE
Safety is our number one priority on all work we undertake to ensure the safety of clients and staff.
QUALITY SERVICE
Guaranteed to provide high quality workmanship and documentation every time.
RELIABLE
Peace of mind knowing we’ll be on site when you need us there.