QCLNG, APLNG & GLNG Hazardous Area Inspections


Project Overview

The Curtis Island LNG processing plants mark one of the last stops in a long journey for QLD natural gas, prior to export. Fed by a 540km underground pipeline running through Queensland’s Surat Basin region, CSG will be converted to liquefied natural gas for export in a world first, which is earmarked to thrust Australia into the top two LNG exporters globally. Fully operational, it is estimated that annual LNG production capacity will be around 9 million metrics tons for APLNG, 7.8 million metric tons for GLNG and around 8.5 million metric tons for QCLNG.

Each LNG plant consists of two LNG processing trains. Each train uses six large refrigerant compression units with built-in chillers to cool the gas to minus 162 degrees Celsius, using propane, ethylene and methane as refrigerants. At this temperature the natural gas liquefies, at which point it takes up just 1/600th of its original volume.

Scope of Work

EnerMech was selected by GE Oil and Gas, to provide Electrical Equipment Hazardous Area Inspections for the massive gas compression systems on QCLNG, APLNG and GLNG, located on Queensland’s Curtis Island.

The enormity of this project is clearly evident once the complexity of the systems are closely evaluated, with each refrigerant compression units comprising gas turbines, centrifugal compressors and generators, resulting in approximately 3,600 EEHA devices which require detailed inspection and approximately 3,000 cable tests on each train. When all six trains are accounted for there is a total of 21,600 detailed inspections and over 18,000 cable tests.

EnerMech’s brief included the following key areas:

1. Identify, manage and resource the non-compliances and rectification of non-compliances as per Australian Standards AS/NZS 60079 on the EEHA equipment in the gas compression systems on QCLNG, APLNG & GLNG projects on Curtis Island.

2. Manage and resource the testing of the cables that have been supplied by GE Oil & Gas to the QCLNG, APLNG & GLNG projects on Curtis Island.

3. Manage and resource the EEHA inspections once the rectification work and cable tests had been completed.

Solution

EnerMech assembled a formidable workforce of dedicated experts in the field of Hazardous Area Inspections including six EEHA Supervisors, two Completion & QA Supervisors, two Engineers and 52 EEHA Inspectors/ Electricians.

The 62 person team was distributed between both the QCLNG, APLNG & GLNG sites and maintain a high level of client visibility with weekly reporting updates on all projects including:

1. Percentage completed works for the project.

2. Works completed for the fiscal week.

3. Health Safety Environment report.

4. Detailed reports for non-compliances and estimated hours to complete rectification works.

5. Updated cost to complete.

6. Updated expected materials for site for both EnerMech EnerMech and GE supplied goods.

7. Updated issues register for the client.

Achievements to date

The EnerMech team has so far completed tens of thousands of hours work safely and effectively. Our expertise in this area is evidenced by the fact that the EnerMech team has been able to improve the schedule of completions, while also remaining on budget across a project of such significant proportions.

High Voltage transformers at plant site