Woodside Petroleum has implemented multiple contractors through construction management consortium Foster Wheeler

WorleyParson’s (FWW) for the development of the Pluto Gas Project, aiming to ensure safety for construction crews through an innovative approach to production.

Under the approval of FWW, fabrication contractor Ausclad Group put forward the use of automated welding systems to weld large diameter heavy-walled pipe situated throughout the LNG project site near Dampier.

Ausclad approached local Lonestar Automated Welding for the use and management of equipment. Dry hire of equipment and direct hire of specialised labour for site welds of the main trunkline and slugcatcher was the approach agreed upon by both parties to execute the work.

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The two components of works to be executed using Lonestar equipment included the onshore trunkline connected to the offshore leg of pipeline, consisting of 36 inch pipe with a wall thickness of

29 mm and 30 degree bevels; and, the slugcatcher, consisting of 42 inch pipe with a wall thickness of 32 mm and 30 degree bevels. Both were suitable dimensions for the automated welding process, as they required multiple pass welding.

Ausclad provided facilities and supervision during the welding process, which was overseen by FWW. Lonestar supplied automated welding systems and specialised labour to provide flux-cored fill and cap welding parameters, data collection, and welder training specific to procedure. Early welding trials had convinced all involved that quality and repeatability of welds would evolve to site welding. The procedure qualifications were successful and were soon followed by welder qualifications.

Site mobilisation of automated welding equipment was carried out, followed by production welding. Welding days consisted of seven hours arc time out of a ten hour working day. All welds were closely monitored by Ausclad supervision and management throughout the project, fostering an enjoyable working environment for the welding crews involved.

Lonestar’s Geoff Barker said “It was a pleasure being invited to work on this project by Ausclad. Our welding systems from the United States have gained a great deal of credibility thanks to Ausclad and have allowed us to move forward in the future with Ausclad and other companies thinking of using automated welding on their projects.”