| Fast Facts: - Project: EPC project for 8” gas pipeline and associated facilities - Location: Pilbara Region, Western Australia - Client: Rio Tinto - Duration: Dec 2008 - Mar 2010 Overview: Rio Tinto operates an extensive power generation and distribution network providing power to mining and port operations in WA. A significant proportion of the power for this network was generated at the Cape Lambert and Dampier stations, however, these stations were at the end of their design life and needed to be retired from service and decommissioned. To replace the existing capacity and cater for the predicted increase in demand from the growing Pilbara mining, commercial and domestic sectors, a new gas-fired power station and interconnecting pipeline was required near Karratha.
Rio Tinto awarded OSD Pipelines the EPC contract for the 8” gas pipeline and associated facilities, known as the Yurralyi Maya Power Station Fuel Gas System. Scope of Work: OSD was engaged by Rio Tinto to design, supply, install and commission the 8” gas pipeline and associated facilities connecting the Dampier to Bunbury Natural gas Pipeline (DBNGP) to the Yurralyi Maya Power Station. The pipeline facilities included pipeline pigging systems, filtration, water bath heaters pressure regulation, and distribution piping to four gas turbine units. An inlet station was constructed adjacent to MLV7 on the DBNGP feeding gas to a conditioning station within the Yurralyi Maya Power Station compound. At the conditioning station, the gas passes through custom built filter coalescers to meet stringent minimum filtration levels. The gas is maintained within specified temperatures via Water Bath Heaters (fuelled via an off-take from the supply gas) and the extensive station pipe work (100m) is neatly fitted around the compound to ensure the highest safety standards are maintained whilst maximizing access and egress for the station operators. The gas is pressure regulated as per the load requirements of the Gas Turbines via a pressure regulation skid and finally odorized just prior to leaving the compound. Project Challenges: There were several major challenges associated with the Yurralyi Maya Power Station FGS project, including: - The project operated on an accelerated timeline. The intended decommissioning of the existing Cape Lambert and Dampier stations made it vital for OSD to complete the work on a very short timeframe whilst still ensuring all other project requirements were met.
- Communication between diverse stakeholders was another challenging aspect of the project. OSD was required to manage and interface between a number of different stakeholders, including the gas supplier, the power station operators, the power station owner, multi-tiered subcontractors, landholders, and government departments.
- As with most EPC projects, there was risk involved with ensuring Rio Tinto received a fault-free, turnkey project solution. OSD effectively managed all commercial, environmental, cultural, safety and other risk factors.
Outcome: The plant was handed over to Rio Tinto in March 2010. All major stakeholders were happy with the plant, the schedule and the budget.
The client was particularly impressed with the HSE outcomes. There were zero LTI hours recorded during the nearly 20,000 hours worked on site. Since the successful completion of the Yurralyi Maya Power Station FGS, OSD has been engaged to undertake further work in support of the Rio Tinto expansion program for the Pilbara Region.
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