A new compressor station was constructed at Ned’s Creek, located approximately 200 km northeast of Meekatharra in Western Australia, as part of the Goldfields Gas Pipeline Expansion Project. The expansion project, also involving the construction of a compressor station at Wyloo West which was constructed by Enerflex, increased capacity of the Goldfields Pipeline by 20 per cent.

The Goldfields Pipeline is owned by Goldfields Gas Transmission (GGT), a joint venture company between APA Group (88 per cent), who operates and maintains the pipeline, and Babcock & Brown Power (12 per cent). APA’s Western Australian Projects Department was responsible for delivering the two compressor station projects to GGT.

Compressing at the Creek

The compressor station features a turbine driven centrifugal compressor, gas filtration and cooling systems, and associated hardware. The site is powered by gas engine alternators with a battery backup.

Enerflex was responsible for all civil, mechanical, electrical and instrumentation fabrication, construction and installation. The contract also included the procurement of minor equipment and materials.

Enerflex mobilised to the site in December 2008 to begin construction on an access road into the site, and to establish the construction camp. Construction of the facility commenced in late January, and the compressor station was fully commissioned in August 2009, three weeks ahead of schedule.

During the same time period, Enerflex also constructed an almost identical compressor station at Wyloo West, but with the schedules offset to facilitate a sequential construction approach. The Wyloo compressor station was constructed approximately three months ahead of Ned’s Creek, allowing the Ned’s Creek team to learn from the Wyloo project and optimise resources.

Enerflex Project Manager Mike Roberts said the Wyloo project allowed Enerflex to recommend changes to the Ned’s Creek design to reduce construction costs, time spent onsite and improve construction safety. APA and Enerflex approached the project collaboratively and attribute much of the success to this strategy.

Working in a remote location: staffing and safety

Mr Roberts said the remoteness of the site was one of the biggest challenges of the project. Enerflex had to construct approximately 15 km of roads suitable for construction vehicles in order to gain access to the site.

As typical for a location such as Ned’s Creek, the remoteness presented safety challenges. Enerflex collaboratively contributed to the APA’s construction safety case to incorporate site specific measures to manage the risks of isolation and detailed how the project interfaced with key stakeholders such as nearby mine sites, emergency services and the Royal Flying Doctors service.

“Enerflex and APA recognised early that travel to and from the site presented a major safety risk and consequently developed and closely managed a stringent travel management plan,” said Mr Roberts.

“Personnel safety onsite and effective site support for construction activities were our prime concerns.

“Our emergency response procedures and medical support onsite was also established to ensure that we had comprehensive support for our site personnel at all times,” he said.

Safety onsite was managed closely and effectively by Enerflex and APA safety personnel, resulting in an excellent safety record for the project and a clean and safe working and living environment despite the difficult conditions. Enerflex, and the project overall, reported zero lost time injuries throughout the entire project.

Mr Roberts said “Enerflex established and maintained a healthy and open relationship with APA Group over all aspects of the project.

“Enerflex was able to provide experience and advice on a range of issues that arose throughout the project. Our experience helped to reduce construction costs, minimise construction time and limit stress levels within the project team.”

The onsite construction camp accommodated up to 48 people. Numbers fluctuated throughout the different phases of the project as trades and specialist subcontractors came and went.

Enerflex also had experienced civil, mechanical and electrical fabrication teams in its Perth workshops fabricating everything on the project such as pre-cast concrete foundations, fuel and valves skids and electrical boards and instrumentation assemblies.

The APA system of work permits and job hazard analysis was strictly adhered to, and the APA site safety representatives worked with Enerflex management to actively encourage and work to achieve a strong safety culture onsite at all times.

Mr Roberts said that Enerflex supervisors and tradesmen are generally well experienced in building these types of facilities and working and living in remote locations, so their experience and expertise was also fundamental in achieving an excellent safety record for the project. Other parties involved

Mr Roberts said that Enerflex under the guidance of APA worked closely with landowners to ensure that their requirements were satisfied at each stage of the project.

Once the project was completed, the company demobilised from site and rehabilitated the site to the same condition as before Enerflex arrived.

Conclusion

Overall, the Ned’s Creek compressor station project was a team effort, focused on safely and efficiently delivering a high quality result to APA.

Enerflex is currently running a number of projects in Western Australia, Queensland and also in Oman in the Middle East. The company is constantly on the lookout for other opportunities to apply its expertise and work positively with clients to deliver high quality projects.