Gas Projects

ARROW ENERGY / CPECC WDS JV

Daandine Epansion Project - Central Gas Processing Facility

• Structural Mechanical and Piping
• Electrical and Instrumentation
• Pre-Commissioning / Commissioning
• Inlet Seperator

QCLNG / THIESS

GAS FIELD COMPRESSOR STATIONS

• Matilda John FCS
• Kate FCS
• McNulty FCS
• Ross FCS

APA GROUP

QLD COMPRESSOR STATION 4

• APA – Scraper Station 4 Upgrade

QUEENSLAND GAS COMPANY

• Supply, Fabrication & Installatsion of 40 Gas Compression Facilities 2006-2010

DDEXP

Scope: Structural, Mechanical and Piping

Location: Dalby, Surat Basin QLD

Value: $10.5 Million Incl.

  

IN BRIEF

Contracted by CPECC WDS Joint Venture (JV) in 2015 to complete the installation of civil, structural, mechanical, piping, electrical and instrumentation scope of works for the three compressor expansion of the Arrow Energy Daandine Central Gas Processing Facility (CGPF) near Dalby in Queensland.

Pipemech worked with CPECC WDS JV in the lead up to site mobilisation to finalise the scope of work and installation methodology which included a complex, time constrained plant shut down to tie in the three new compressor installations.

CUSTOMER BENEFITS

Upon contract award Pipemech quickly mobilised its experienced management, supervisory and labour teams to undertake a rapid ramp up to full production and efficiency at the CGPF site initially managing and driving the completion of the civil works in order to allow SMP and E&I works to commence.

Pipemech further assisted Clough Amec JV (CAJV) with the inspection and reporting of progress on the overseas fabrication packages.

Pipemech were able to develop and successfully implement a methodology that took account of the restricted site working area and weight of the new compressors using a heavy lift ‘lock and lift’ system.

As part of the SMP and associated shut down planning Pipemech assessed and provided options for the most cost and schedule effective means of undertaking hydro testing of the works to CAJV and Arrow Energy.

Pipemech successfully completed the SMP elements of scope required on time during the CGPF shut down, allowing Arrow Energy to reintroduce gas to the plant as planned with all works being performed in compliance with the Arrow Energy isolation permitting requirements. The scope of work completed during the shutdown included;

• Tie in piping connections (both mechanical and welded) of compressors and vendor equipment;
• Hydrostatic testing and drying of piping systems;
• Coordination of all Non Destructive Examination: and
• Night shift work providing 24 hour operations.

Following the completion of the CGPF shutdown, Pipemech’s team moved into the completion and pre-commissioning phase of works at the CGPF which was heavily reliant on the Pipemech in-house developed innovative weld traceability software package.

Pipemech have also been able to assist CPECC WDS JV with completion of discrete scope on the Production Facilities / Gathering elements of the project in addition to undertaking the procurement of materials, plant and suppliers to ensure a successful project outcome for Arrow Energy.

TECHNICAL FEATURES

• Receipt and installation of three x Ariel JGC/6 compressors and coolers
  • Main Skid – 120T;
  • Wing Skid #1 – 20T;
  • Wing Skid #2 – 19T;
  • Process Gas Air Cooler – 25T;
  • Engine Air Cooler – 14T;
• Receipt and installation of Scrubber, TEG, Glycol, Oil, Fuel Gas, LP Flare, Water Processing and Compressed Air vendor skid packages;
• Installation of interconnecting process pipework, valves and piping supports;
• Installation of new gas coalescer;
• Erection of two x compressor buildings and gantry cranes;
• Preparation and submission of project execution and handover documentation;
• Hydrostatic testing and drying of piping systems: and
• Management of the Completions process and plan for MC, PC and SOF for the work.

DDEXP

Scope: Electrical and Instrumentation

Location: Dalby, Surat Basin QLD

Value: $10.5 Million Incl.

IN BRIEF

Pipemech’s experienced E&I team complimented by their E&I QA/QC team executed an Arrow Energy’s planned shutdown of the CGPF for the expansion and tie in of three x Ariel JGC/6 reciprocating compressors, one x TEG Generation package, TEG contactor tower, glycol filter, fuel gas and buffer vessel, inlet coalescer, oil filter, inlet separation boot and production facility flow lines. Following the shutdown, the team completed installation of the E&I Scope of Work for the new compressor packages including hazardous area auditing, UCP and MCC installations.

CUSTOMER BENEFITS

Pipemech’s E&I leadership team including experienced Electrical Engineers, worked closely with the client to create work methodologies for the safe execution and tie in to existing electrical infrastructure given the operating plant conditions.

Pipemech’s E&I QA/QC team conducted all MCC testing, hazardous area inspections, instrument inspections, cable tests, earth grid tests and following all testing, Pipemech’s E&I Engineers produced all as build documentation to complete the handover dossiers.

E&I TECHNICAL FEATURES

• Modifications to existing MCC-001;
• Installation of new MCC-002;
• Installation of power, control and fibre optic cabling to on-skid junction boxes for the three new compressors, TEG, Glycol, Fuel and Oil vendor supplied packages;
• Re-assembly of compressor packages including the installation of unit control panels and two x MCC’s to each package;
• Installation of instrumentation, electric motors and associated pumps for the produced water transfer package;
• Modifications to Braemar one and two metering stations;
• Relocation and re-verification to the moisture analyser;
• Plant instrumentation and calibrations;
• Installation of new flame detectors and plant emergency sirens;
• New VSD’s for TEG package;
• Installation of local control stations;
• Modifications to existing plan lighting and installation of new plant lighting;
• Plant earthing;
• Cable ladder: and
• Underground cabling.

E&I QA/QC FEATURES

• Compilation of all test packs and inspection test records: and
• Completions Management System population.

E&I ENGINEERING FEATURES

• Work Methodology/Work pack preparation: and
• Inspection Test Plan.

DDEXP

Scope: Inlet Seperator

Location: Dalby, Surat Basin QLD

Value: $0.5 Million Incl

IN BRIEF

Based on the Pipemech teams' knowledge and experience in pipeline installation and deep excavations in confined/restricted areas on operational sites, CPECC WDS JV requested Pipemech’s assistance with the installation methodology, risk management, estimating and installation supervision of the Daandine Central Gas Processing Facility (CGPF) gas inlet separator pipe.

Pipemech developed and assessed seven separate options and estimated two of these prior to finalising the agreement of EPC Clough Amec JV (CAJV) and Arrow Energy for the selected installation methodology.

CUSTOMER BENEFITS

Pipemech’s experience and input into this project allowed for the safe, on time and under budget installation of this complex element of work within a live gas facility.

Consideration to the proximity of existing live gas infrastructure, as close as 1.4m to the proposed new pipe, underground electrical cables at the edge of the excavation, and installation of the inlet pipe under the CGPF Flare line, was given to the safe methodologies and risk management.

Procedures employed prior to and during installation by Pipemech.

Pipemech proposed the installation of the pipe within a 4.7m deep trench, straight walled on one side to avoid impacting existing infrastructure and one bench on the opposite side to allow for personnel access to the side of the trench. This trench arrangement combined with the use of a large trench box at the gathering tie in under the CGPF Flare line, accurate excavation and flowable bedding and padding allowed for the elimination of the entry of personnel into the trench until within safe depths.

Vacuum excavation and use of zero slew excavators was employed to minimise the risk of live infrastructure strikes during the excavation of the trench.

Using a 50t crane and 11m spreader bar Pipemech was able to ensure the pipe was lifted in an approved manner and installed at exactly the correct position for the gathering and CGPF tie ins.

TECHNICAL FEATURES

• 20m long, 5T, 100mm dia. HDPE pipe with 600 and 315mm dia. risers and 80mm dia. drain line, 5m height when fabricated;
• 28m long 4.7m deep excavation for inlet separator pipe;
• 25m long gathering tie in trench;
• Pre installation fabrication of risers, drain line and gathering tie in: and
• Excavation through fill, clay and rock.

DDEXP

Scope: Pre Commissioning / Commissioning

Location: Dalby, Surat Basin QLD

Value: $10.5 Million Incl.

IN BRIEF

Pipemech’s pre-commissioning team were tasked with delivering each system ready for start-up once mechanical completion was accepted by the client.

The scope included electrical energisation of new and existing equipment; instrumentation loop checks; PLCDCS integration; motor bumping; alignments, and first fills of all equipment/vessels; oil flushing, and nitrogen/helium leak testing.

Commissioning/Start-up assistance to the Arrow Operations team was also part of the scope to bring the plant back online upon completion of the shutdown, and also assist with start-up of the new TEG, and three compressor packages in addition too, 22 wells in the gathering network.

CUSTOMER BENEFITS

Pipemech’s pre-commissioning teams’ prior experience in compression and plant equipment was a valuable asset to the client project team, by way of population of the completions management system to ensure all testing of PLC logic, instrumentation and equipment was completed to ensure a seamless transition into commissioning.

The Pipemech pre-commissioning team also completed pre-commissioning of Arrows gathering network of 22 well heads across three well pads, including providing assistance to the Arrow/Clough Amec Joint Venture operations to commission and start-up the well.

TECHNICAL FEATURES

• Cause and Effect Testing;
• Functional Instrument Loop Testing;
• Allen Bradley PLC Modbus Mapping;
• Emerson PLC and Delta V HMI Modbus Mapping;
• MCC Energisation;
• Three x CAT 3612 Coupled with an Ariel JGC/6 4 stage reciprocating compressor commissioning, full function testing including cooler fan, alternator, MCC and PLC functional testing;
• Flare control panel commissioning;
• TEG Dehydration package commissioning;
• Equipment oil flushing;
• Plant Leak Testing using a nitrogen with a 1% helium mix;
• Motor bump testing;
• Motor coupling alignments: and
• First fills of TEG glycol, compressor lubricator and crankcase oil, CAT engine coolant, and greasing of all equipment.

DDEXP

Scope: Pre Commissioning / Commissioning

Location: Dalby, Surat Basin QLD

Value: $0.5 Million Incl.

  

IN BRIEF

Pipemech’s experienced Civil, SMP, E&I and Quality teams were tasked with the complete installation and pre-commissioning of 22 well head skids, six gas generators and three remote terminal unit MCC’s on three well pads for the expansion of the Arrow Energy Daandine Production Facilities.

The scope included civil works, mechanical skid installation, interconnecting pipework, electrical and instrumentation installation, pre-commissioning, vendor/commissioning support, and all associated completions and QA/QC.

CUSTOMER BENEFITS

Working closely with our client, Pipemech was able to safely complete the works, managing labour and supervision across multiple work fronts, including the Central Gas Processing Facility expansion and Production Facilities scope mitigating several scope increases and emergent works to maintain schedule for both discrete project elements.

Pipemech’s experienced team was able to provide a complete solution, encompassing all works, and associated support functions required to leave the well pads in a state fit for purpose ready for the introduction of hydrocarbons.

TECHNICAL FEATURES

• Installation of 22 well head skids;
• Installation of six gas generators;
• Installation of three remote terminal unit MCC’s;
• Fit-out of three low point drain pipework assemblies and associated fuel gas skid;
• Civil works including trenching; pad preparation; backfill; compaction; skid footing, and fencing;
• Installation of interconnecting process pipework, valves and piping supports including welding and mechanical fittings;
• Installation of power and control of electrical and instrumentation components, including cable ladder, earthing and underground services;
• Non Destructive examination and hydrostatic testing of pipework;
• SMP QA/QC including welding inspection, flange management and skid installation to project specifications;
• E&I QA/QC including EEHA inspections, HA Audit, instrument inspections, earth grid testing and cable test;
• Functional instrument loop testing and TRU testing;
• Preparation and submission of project execution and handover documentation: and
• Management of the Completions process and plan for the MC, PC and SOF for the work.

Matilda John FCS

Project: Matilda John Coal Seam Gas Field Compressor Station

Location: QGC Tenements, Central Fields, Surat Basin QLD

Value: $9.1 million

In Brief:

Commissioned by QGC in 2013 to carry out the complete structural, mechanical and piping installation of a 2 train Field Compressor Station in the Central Fields of the QGC tenements. The successful construction of this plant led to the award of three further FCS sites, two in the Central Field and one in the Northern Fields to date.

Customer Benefits:

Our company’s ability to mobilise highly skilled site management and supervisory teams experienced in a number of similar construction designs, combined with an extensive database of trade personnel, enabled a smooth construction process right from initiation through to the award of mechanical completion. We delivered to the client a product of the highest quality within schedule, enabling the client to meet critical commissioning deadlines for the Central Fields while maintaining ZERO Loss Time Injuries.

Pipemech’s commitment to maintaining flexibility with our clients contracting strategies meant that we were able to convert this contract from Lump Sum to Cost Reimbursable having already completed 90% of the scope. This conversion allowed for a 30% cost saving to the client on the original contract works value.

Pipemech’s extensive resources have allowed us to further supply ongoing labour support for the pre-commissioning and commissioning phases of this project outside the contract scope helping our client to achieve their critical deadlines.

Technical Features:

• Two x 20 MMSCFD Compressors;
• One x 18mVA Transformer, 1 x 1mVA Transformer;
• Utility Air, Nitrogen and Metering Skids;
• One x Flare;
• ~ 100T Structural Steel;
• ~ 2000LM of pipework;
• Three x Electrical & Instrumentation Switchrooms;
• Flange Management;
• Hydro Testing Pack Creation: and
• Quality Assurance and Completions including the creation of Inspection Test Report and Procedures allowing streamlined, single discipline walk-downs and sign offs.

 

Kate FCS

Project: Kate Coal Seam Gas Field Compressor Station

Location: QGC Tenements, Central Fields, Surat Basin QLD

Value: $7.5 million

In Brief:

On the successful completion of Matilda John Field Compressor Station, Pipemech was commissioned by QGC in 2013 to carry out the complete structural, mechanical and piping installation of the three 3 train Kate Field Compressor Station located in the Central Fields of the QGC tenements.

Customer Benefits:

Taking lessons learnt from the construction of the Matilda John Field Compressor Station, Pipemech was able to mobilise quickly and move a complete management team directly to Kate to carry out site establishment works.

Pipemech’s ability to mobilise highly skilled site management and supervisory teams experienced in a number of similar construction designs, combined with an extensive database of trade personnel, enabled us to build on the construction efficiencies using an experienced SMP team delivering a further 20% total cost saving on the Matilda John FCS price to the client.

Mechanical Completion for Pipemech’s scope is scheduled to be achieved in May 2014, two months ahead of the client schedule.

Technical Features:

• Three x 20 MMSCFD Compressors;
• One x 18mVA Transformer, 1 x 1mVA Transformer;
• Utility Air, Nitrogen and Metering Skids;
• One x Flare;
• ~100T Structural Steel;
• ~2000LM of pipework;
• Three x Electrical & Instrumentation Switchrooms;
• Flange Management;
• Hydro Testing Pack Creation: and
• Quality Assurance and Completions including the creation of Inspection Test Report and Procedures allowing streamlined, single discipline walk-downs and sign offs.

 

McNulty FCS

Project: McNulty Coal Seam Gas Field Compressor Station

Location: QGC Tenements, Central Fields, Surat Basin QLD

Value: $7.5 million

In Brief:

On the successful completion of Matilda John Field Compressor Station, Pipemech was commissioned by QGC in 2013 to carry out the complete structural, mechanical and piping installation of the four train McNulty Field Compressor Station located in the Central Fields of the QGC tenements.

Customer Benefits:

Taking lessons learnt from the construction of the Matilda John and Kate Field Compressor Stations, Pipemech was able to mobilise quickly and move a complete management team directly to McNulty to carry out site establishment works.

Pipemech’s ability to mobilise highly skilled site management and supervisory teams experienced in a number of similar construction designs, combined with an extensive database of trade personnel, enabled us to build on the construction efficiencies using an experienced SMP team delivering a further 20% total cost saving on the Matilda John FCS price to the client.

Technical Features:

• Four x 20 MMSCFD Compressors;
• One x 18mVA Transformer, 1 x 1mVA Transformer;
• Utility Air, Nitrogen and Metering Skids;
• One x Flare;
• ~100T Structural Steel;
• ~2000LM of pipework;
• Three x Electrical & Instrumentation Switchrooms;
• Flange Management;
• Hydro Testing Pack Creation: and
• Quality Assurance and Completions including the creation of Inspection Test Report and Procedures allowing streamlined, single discipline walk-downs and sign offs.

 

Ross FCS

Project: Ross Coal Seam Gas Field Compressor Station

Location: QGC Tenements, Northern Fields, Surat Basin QLD

Value: $7.5 million

In Brief:

On the successful completion of Matilda John Field Compressor Station, Pipemech was commissioned by QGC in early 2014 to carry out the complete structural, mechanical and piping installation of the four train Ross Field Compressor Station located in the Northern Fields of the QGC tenements.

Customer Benefits:

Taking lessons learnt from the construction of the Matilda John, Kate and McNulty Field Compressor Stations, Pipemech was able to mobilise quickly and move a complete management team directly to Ross to carry out site establishment works.

With a steady man power ramp up in alignment with the progressing civil construction schedule, Pipemech have been able to build on the construction efficiencies using an experienced SMP team and ensuring only the highest quality of workmanship.

Technical Features:

• Four x 20 MMSCFD Compressors;
• One x 18mVA Transformer, 1 x 1mVA Transformer;
• Utility Air, Nitrogen and Metering Skids;
• One x Flare;
• ~200T Structural Steel;
• ~2600LM of pipework;
• 3 x Electrical and Instrumentation Switchrooms;

• Flange Management;
• Hydro Testing Pack Creation: and
• Quality Assurance and Completions including the creation of Inspection Test Report and Procedures allowing streamlined, single discipline walk-downs and sign offs.

 

APA – QLD Compressor Station Unit 4

Project: QLD Compressor Station Unit 4 Upgrade

Location: Charleville QLD

Value: $5.8 million

In Brief:

Commissioned by APA Group in 2013 to deliver a Scraper Station Unit Upgrade including Earthworks, Civil Works, Steelwork, Piping Demolition, Piping Installation, Electrical and Instrumentation Removal and Installation Works allowing for a bi-directional flow capacity.

Customer Benefits:

Under the capable direction of Pipemech’s Project Management team, trades and labour personnel worked diligently within a tight schedule to ensure APA Group’s Eastern Haul Project delivered a successful outcome within the planned duration of the shutdown. This project was conducted onsite some 95 km from Charleville amid extreme summer temperatures.

The company rolled out comprehensive safety management protocols and strategies to alleviate the risk of heat stress and fatigue, resulting in no recordable injuries during the project.

Integral to the seamless delivery of construction works during the shutdown, Pipemech ensured a transparent interface between its team and other stakeholders involved in the project. Pipemech’s electrical and instrumentation subcontractor was strategically scheduled with planned pipe fabrication, field weld placement and spool installation to minimise the time spent onsite during the shutdown.

The combination of Pipemech’s planning, systems and staff underpin its ability to deliver a successful outcome whilst maximising value for money for the client.

Technical Features:

• Modify existing facility to allow bi-directional flow capability from the Cooper Basin to Gladstone;
• Remove redundant and install new pipe supports and structural steel;
• Excavation and reinstatement of bulk earthworks;
• Remove redundant piping and control valve systems and replace;
• Cathodic protection, electrical and instrumentation supply and installation;
• Remove and relocate cathodic protection hut;
• Pre-shutdown and shutdown scope planning and installation;
• Prepare and utilise all construction execution plans, assisting in development of Plant Isolation Procedure/s:
• Offsite fabrication of heavy wall pipe spooling:
• Offsite construction of precast concrete footings;
• Hydro test pack creation and hydro test completions: and
• NDT, QA system provision and completion of compliant MDR.

 

Queensland Gas Company

Project: Supply, fabrication & installation of 40 gas compressions and associated infrastructure - 2006 to 2010

Location: Surat Basin, QLD

Value: $30 million

In Brief:

Commissioned by Queensland Gas Company (QGC) to undertake early field development works at the Berwyndale, Kenya and Codie Gasfields, located within the Surat Basin area of Queensland.

Contract works commenced in 2006 and continued until 2010 and comprised the supply, and fabrication of structural steelwork, pipe spooling, supply of miscellaneous items and the installation, testing and commissioning of Field Compressor Stations (FCS) and Central Processing Plants (CPP) external fabricators.

Customer Benefits:

Being contracted to supply, and fabricate the structural steel component from our Workshop in Brisbane, delivery was fast-tracked and coordinated with the site installation schedule. This offered the client a seamless, cost effective and time efficient transition from fabrication offsite to installation on-site.

This freed up the client’s procurement team from involvement and minimised the risk inherent in coordinating timeframes when dealing with external fabricators. The deployment of a professional management team, complemented by highly skilled trades personnel, and by offering direct interface between fabrication, and installation units. All projects were delivered on time and on budget.

Technical Features:

Scope of Works – on-site installation of structural steel, mechanical items and pipe work, and pipe spool fabrication

Locations -

Field Compressor Stations

• Berwyndale South FCS FO1;
• Nangram FCS FO3;
• Codie FCS FO4: and
• Kenya FCS FO2.

Central Processing Plants

• Berwyndale CPP PO1: and
• Kenya CPP PO2.

Brown field works:

• Sales Gas Skids SO1 and SO2: and
• Personnel – site management, supervisory and engineering tradespersons, riggers, scaffolders and TA’s.