The Dampier to Bunbury Natural Gas Pipeline (DBNGP) Stage 5B Expansion Project involves the construction of a total of 440 km of 26 inch diameter pipeline, by looping the existing DBNGP spread between Karratha (Loop 0) and Bunbury (Loop 10), Western Australia.

The project is to be carried out in eleven separate loops, with the initial two loops (Loops 9 and 10) to be constructed just to the north and south of Perth respectively. Loop 10, located in the Pinjarra region, was the first to commence, followed closely by Loop 9, which in part runs through the Swan Valley and includes both residential and vineyard areas. Loops 0 through 8 are in remote locations between Karratha and Gingin and their construction will involve teams working from remote base camps.

The project commenced in October 2008 with the mobilisation of personnel. Construction commenced in January 2009 and as of mid-February, lowering in had commenced on Loop 10, while Loop 9 has seen the commencement of camp mobilisation and pre-construction activities associated with locating the position of the existing DBP asset.

Clear and grade activities on the first two loops in the Perth area have commenced, with clear and grade on Loop 10 commencing ‘without a hitch’ according to WestNet Energy’s Health and Safety Executive. In addition, MacDow and its project partners recently received and unloaded the first large diameter pipe shipments for the expansion.

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MacDow has said that all job hazard analysis, pre-starts, plant risk assessments, personal protective equipment and permit to work requirements are being followed by the crew, with huge enthusiasm.

This enthusiasm has been further boosted by MacDow’s decision to invest in major specialist pipeline plant. The new plant will initially be utilised exclusively on the DBNGP Stage 5B Expansion.

The most significant of these acquisitions are ten Caterpillar 583T pipelayers. With a large 45 t capacity, they are the first of their kind to be used on any gas pipeline in Australia, superseding the older style 583s. The shipment from the US went smoothly and all ten were received in Perth in perfect condition, ready for pipe laying activities to commence on the DBNGP expansion.

MacDow has also purchased a new American Augers DD625 Horizontal Directional Drill spread. The drill rig arrived in Perth in December 2008, with commissioning due to be completed in February 2009. The rig will initially be used on Stage 5B, to complete a 480 m long bore under the Murray River, which is approximately 7 km south of Pinjarra. The 300 t pull-back capacity and the current assisted down hole tooling enable the team to ream out holes greater than 50 inches in diameter.

MacDow said that having an in-house HDD capability provides the company with greater surety and improved control in managing HDD crossings for clients’ pipeline projects.

MacDow has also upgraded its welding spread with nine Challenger Fill and Cap rigs and Tack rigs, which included the addition of rear facing cameras for improved safety.

Mainline construction of the DBNGP is due for completion by December 2009 and mechanical completion by March 2010. MacDow’s commitment to new specialist pipeline equipment will help to ensure that all these milestones are met, without incident or compromise.

In addition, MacDow said that with these investments the company has secured the necessary specialist, large capacity plant to successfully deliver the DBNGP project for its project partners and they will subsequently be available for future large diameter pipeline projects, like those associated with the proposed LNG projects in Queensland and Papua New Guinea.