The Ichthys LNG Project is a major infrastructure project for the Northern Territory and Australia.
It is expected to produce 8.4 million tonnes of LNG and 1.6 million tonnes of LPG per annum, along with approximately 100,000 barrels of condensate per day at peak. Detailed engineering, procurement and construction (EPC) operations for the Project are ongoing and production is scheduled to commence by the end of 2016.
With an expected operational life of at least 40 years, the Ichthys LNG Project offers rare multi-generational opportunities to communities, economies, businesses, energy markets and its workforce.
Constructing the offshore pipeline
The construction of Ichthys LNG Project pipeline by Saipem started with a shore-pull operation in late June 2014. The company’s work is expected to be completed with final hydro testing in late 2015.
Saipem is laying all but 7 of the 889 kilometre, 42-inch gas export pipeline (GEP) from the Ichthys Field to Blaydin Point, Darwin Harbour.
SEMAC-1, Saipem’s semi-submersible pipelay barge is scheduled to deliver the 164 km shallow water pipelay component of the GEP installation.
This work included laying the first 18 km section of pipe through Darwin Harbour from Middle Arm earlier this year.
Working from east to west in Darwin Harbour, SEMAC-1 first fed pipe to the Project’s landfall site for a 3 km shore-pull.
This enabled SEMAC-1 to connect the offshore component of the pipeline to the onshore component, which will stretch about 7 km from the beach valve at Middle Arm to the Blaydin Point onshore processing facilities.
Saipem will also utilise its latest generation pipelayer, Castorone, which is characterised by flexibility, high productivity and ultra-deep water capabilities to lay the remaining 718 kilometres of pipeline to the Field through deeper water.
Project management
A number of challenges were faced by Saipem during the pipelay component of the Project, particularly in Darwin Harbour.
Operations within the harbour had to be carried out within several environmental and heritage areas as well as Aboriginal sacred sites that needed to be preserved.
Commitment to technological innovation and sustainability were among Saipem’s top priorities on the work in the harbour.
Throughout the project, health, safety and environment (HSE) has been a key factor. Both INPEX and Saipem have a high safety focus and several initiatives have been implemented to ensure the health and safety of people and the protection of the environment.
Besides Risk Management processes aiming to identify any HSE impacts and its essential control measures, Saipem has implemented initiatives to improve safety on the GEP project.
These include leadership in Health and Safety (LiHS), a Saipem internal behavioural-based safety program, aimed at improving the safety culture within Saipem and its projects and “˜Keep Your Hands Safe’ which is aimed at reducing the number of hand injuries (common in the offshore industry).
Project challenges
Saipem has over 1,200 people employed on its two vessels, as well as more than 100 people in Perth, Darwin and overseas sites.
Despite this, a number of challenges have been faced during the early part of the pipelay and construction of the pipeline.
The engineering of the shore pull required significant effort as several issues had to be taken in consideration: tide excursion of up to 8 m, 3 km length, uneven sea bottom, presence of hard and soft soils, strong tidal current and the use of rollers in the dry section.
The remote nature of the north western coastline of Australia will also prove a challenge for Saipem with the majority of the pipeline lying miles away from the Australian coast which, except for Darwin, is scarcely populated with no real infrastructure or facilities available for the project.
The Ichthys LNG Project is a joint venture between INPEX (Operator), major partner Total and the Australian subsidiaries of Tokyo Gas, Osaka Gas, Chubu Electric Power and Toho Gas.
For more information on the Ichthys Project visit www.inpex.com.au/projects/ichthys-project or visit Saipem at www.saipem.com/site/home .