AJ Lucas Operations was contracted by Jemena to construct a 113 km DN400 looping of the existing Queensland Gas Pipeline (QGP) between Oombabeer and Callide.

Early construction works began in mid-May 2009 and all construction and testing works were completed by early November 2009. Construction activities were organised to take advantage of the region’s dry season and limit any wet-weather construction delays.

The QGP looping works took place in a typically rural and agricultural region in central Queensland and required the use of a construction camp to accommodate the project workforce. The camp was constructed 1.5 km from Banana, on the Leichardt Highway, and had a maximum occupancy of 200 persons. The number of people working on the project peaked in September 2009.

Providing local opportunities

AJ Lucas encouraged local industry participation on the QGP looping project and utilised local suppliers and subcontractors wherever possible. The company used concrete and stabilised sand, construction camp food, water and gas, steel fabricated gates, fertiliser and grass seed and general day-to-day items from businesses in the township of Biloela.

AJ Lucas also used construction aggregates from Banana Shire quarries and various other essential materials and equipment from the townships of Moura, Gladstone, Theodore and Rockhampton.

Challenges presented

Working closely with Jemena, AJ Lucas had to overcome a number of unique situations including dealing with environmental constraints along the pipeline right-of-way and completing construction within a tight timeframe.

AJ Lucas encountered steep terrain and some very hard rock in both the Banana and Dawson Ranges. Working in both these ranges required extensive civil works by the clear and grade crews in order to provide a safe working platform for subsequent pipeline crews to move through the area. As a result of the rock encountered, trenching was slow through the ranges and a substantial quantity of rock hammering was required.

The QGP looping crosses two significant watercourses at the Dawson River and Denby Creek. Horizontal directional drilling (HDD) was the method chosen to cross these watercourses. Both HDD crossings were completed with no adverse environmental impact on the surrounding areas and with the integrity of both pipe strings unaffected by the pullback operation.

Due to environmental constraints, construction was required to progress in an east to west direction. Jemena had identified and provided a water source for hydrotesting at the Dawson River (KP80) but using this water source would have required the completed construction of 80 km of the looping pipeline before any hydrotesting could commence.

AJ Lucas overcame this problem by redeveloping and filling an existing farmer’s dam adjacent to the Burnett Highway (KP17). By using this dam, hydrotesting was able to proceed in a timely and efficient manner.

The looping pipeline was constructed within a 25 m easement. With the existing DN300 pipeline operating simultaneously within this easement, space was at a premium and stringent safety measures had to be enforced to protect the integrity of the existing pipeline and the safety of the workforce.

Environment and cultural heritage

Parthenium weed is a major agricultural problem in certain parts of Queensland and prior to the looping construction works commencing the weed was identified within the QGP easement. To avoid the spread of Parthenium as a result of construction activities, AJ Lucas installed five temporary wash-down facilities along the easement and utilised the existing permanent wash-down facility at Moura. All vehicles and equipment passing through a weed zone had to be extensively washed and cleaned and then certified ‘weed free’. All vehicles or items of equipment entering or leaving the project had to be certified clean and ‘weed free’ by a qualified individual.

Cultural heritage monitors were employed on the project by Jemena and worked in front of the clear and grade crews to identify and isolate any potential cultural heritage sites. Cultural heritage was addressed at weekly toolbox meetings and presentations were made to the project workforce to further educate them on the issue.

Lucas upcoming projects

AJ Lucas currently holds the Barrow Island shore approach contract using HDD for the Gorgon LNG Development upstream joint venture. The company is also in the field working with APA Group on the next program for the Moomba to Sydney Pipeline stress corrosion cracking works.

In Western Australia, AJ Lucas is a partner in the Southern SeaWater Alliance, which is developing the Western Australian Desalination Plant. In addition, Lucas is in the constant process of tendering many other projects across Australia.