Train V LNG Jetty Expansion

PROJECT DETAILS:

Location: NorthWest Shelf, Western Australia

Contract Value: A$120 million (2005)

Contract Period: December 2005 - March 2007

Safety Statistics: Manhours: 344,440 LTIFR: 0

CLIENT: Woodside Energy LtdScope of Work:The $120 million Train V LNG Jetty Expansion project, completed by the Harbourworks Clough Joint Venture (HCJV, now BAM Clough) in 2007, involved the construction of a 150 metre long jetty extension to Woodside’s existing LNG export marine terminal, at Withnell Bay near Dampier, Western Australia. This brownfields project provided an additional berth loading facility for LNG export tankers with a capacity up to 145,000 cubic metres.

Despite being located in an area frequently visited by cyclones, HCJV delivered the project on schedule, within budget and with an impeccable safety record of zero lost time injuries for the project. Extensive precautions were taken prior to commencement of project through the development of staff and equipment evacuation procedures for cyclonic conditions.

Additionally the existing LNG jetty (Woodside Phase II), which was built earlier by HCJV, remained fully operational throughout the construction phase.

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Key Aspects

9 Self Performed

9 Construction at in an operational LNG export facility requiring unobstructed access.

9 Project site in cyclone area

Project Highlights

9 Excellent Safety Performance - Zero Lost Time Incidents

9 Project completed on schedule

9 Added scope to reinforce existing material offloading facility.

9 Existing facilities fully operational during construction.

9 Crane installed on breasting dolphin for sea condition independent craneage.

9 Prefabricated concrete structures reduced labour installation requirements.

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Key project components included:

• A six-span 170 metre long approach trestle consisting of five two-pile bends and one, four-pile anchor bent

• Tie in works to the existing loading platform

• Four breasting dolphins and four mooring dolphins connected by seven catwalks with a length of up to 71 metres. The four breasting dolphins have five piles and the four mooring dolphins feature three piles each.

• Installation of pre-assembled units supplied by the client;

• Navigational aids and buoys; and

• Upgrade and reinforcement of a material offloading facility for landing the Train V modules.

The loading platform is a 40 metre x 27 metre concrete main deck, supporting a steel-framed concrete roadway upper deck. The substructure is made of in-situ concrete-filled pre-cast pile caps and trough headstock beams. Pre-cast deck slabs and in-situ concrete topping complete the deck.

Piling and drilling operations utilised hydraulically operated piling templates that were designed and constructed to withhold the forces of the piles, the large hydraulic piling hammer, and the reversed circulation drill. To maintain the schedule, pile drilling was performed during the night shift.

Tie-in works at the existing trestle were executed in a planned three-day shutdown of the existing LNG berth and involved installation of a pre-assembled steel unit for the piping tie-ins.

To reduce labour installation requirements and meet the schedule, the 30 metre long access trestle units were fabricated off site in Perth and transported 1,800 kilometres over land to the site. The 120 tonne modules were then shipped via the Material Offloading Facility to the jetty for installation by the crane barge.