Karratha Gas Plant

Karratha Gas Plant is one of the most advanced, integrated gas production systems in the world, where LNG, domestic gas, condensate and LPG is produced. It is an integral onshore element of the North West Shelf (NWS) Project’s facilities which constitute Australia’s largest oil and gas development.

The Karratha Gas Plant facilities include five LNG processing trains, two domestic gas trains, six condensate stabilisation units, three LPG fractionation units as well as storage and loading facilities for LNG, LPG and condensate. The facility is located 1,260km north of Perth, Western Australia and covers about 200 hectares.

Challenge

Following the non destructive testing of five gantry cranes above the gas turbine compressors in train one at KGP, it was determined that several locations required cut out and replacement to allow the cranes to operate at full capacity. Due to the potential for product release from the surrounding process areas, pressurised habitats were required for the completion of red hot work.

The job location was 16 metres above the turbine deck, so all equipment had to be manually lifted to each individual crane location. The safe air location was in excess of 40 metres away from each habitat location, so significant ducting was required.

Karrath Gas Plant
Hot work welding habitat

Planning

The scheduled time frame to complete the work scope was very stringent, and it was therefore determined that work would be carried out 24 hours a day, with a team of two technicians working back to back 12 hour shifts.

Solution

Our technicians successfully designed, built, installed and maintained nine habitats over a three week period, to suit the existing scaffolding.

We customised magnetic panels to seal the habitat to each gantry crane, allowing for rapid construction of each individual unit. Multiple GSM’s were also used in line with the air supply to eliminate risk of gas ingress.

 

Gas Sensing Module
Safehouse habitat

Outcome and benefits

This was the first red hot work scope undertaken with a SAFEHOUSE habitat on this facility, so there was a great deal of focus on the system. The feedback from the client’s HSE personnel, operations and project teams was very positive – and they were particularly impressed with the way our technicians worked with and helped all other contractors on site.

The SAFEHOUSE habitats allowed for red hot work to be completed in a known hazardous area while plant still fully operational. All work was successfully completed within the scheduled time frame.