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Matt Barber and Michael Wells - Piling Contractors Pty Ltd - Practical Piled Foundations for Gas Compressor Stations

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Matt Barber and Michael Wells delivered the presentation at 2014 Gas Compressor Stations Conference. …

Matt Barber and Michael Wells delivered the presentation at 2014 Gas Compressor Stations Conference.

The Gas Compressor Stations Conference is the only conference specifically dedicated to the design, build and maintenance of gas compressor stations.

For more information about the event, please visit: http://www.informa.com.au/gascompressors14

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  • 1. Practical Foundations for Gas Compressor Stations Michael Wells and Matt Barber 20 April 2014
  • 2. 2 WHAT ARE PILES AND WHAT ARE THEY USED FOR
  • 3. 3 APLNG GLNGQCLNG
  • 4. 4 QCLNG FIELD COMPRESSOR AND CENTRAL COMPRESSOR STATIONS 1. Argyle FCS 2. Bellevue FCS 3. Ruby Jo CPP 4. Ruby Jo FCS 5. David FCS 6. Harry FCS 7. Broadwater FCS 8. Glendower FCS 9. Isabella FCS 10. Jordon CPP 11. Kenya East FCS 12. Jammit FCS 13. Poppy FCS 14. Matilda John FCS 15. Mc Nulty FCS 16. Woleebee Creek CPP 17. Woleebee Creek FCS 18. Polaris FCS 19. Cam FCS 20. Kathleen FCS 21. Ross FCS 22. QCLNG pipeline with MCJV (Entire length of pipeline from Dalby to Curtis Island)
  • 5. 5 QCLNG
  • 6. 6 APLNG COMPRESSOR STATIONS  Spring Gully  Condabri North  Condabri South  Condabri Central  Orana  & Curtis Island
  • 7. 7 APLNG
  • 8. 8 GLNG  Access points for the Narrows Crossing
  • 9. 9 GLNG – Narrows Crossing Mainland and Curtis Island
  • 10. 10 TYPES OF DRILLING RIGS Rubber Tired Rigs  Cost effective to mobilise  Used for exploratory holes  Limited depth – 9m  Limited ability to drill rock Tracked Rigs  Small units limited torque 13t.m  Larger units up to 28t.m  Costly to mobilise  Effective for larger diameters 1.2m dia +  Drill depths greater than 9m
  • 11. 11 SLEEVED HOLES
  • 12. 12 CASED HOLES
  • 13. 13  SAFETY  on-line test prior to being accepted for induction.  The OneTest Online Safety assessment is a tool that looks at the values and beliefs of an individual surrounding safety at work. The assessment will make a comparison against a set benchmark, to determine whether someone is deemed fit to mobilise to site.  We have been using this system for nearly 18 months with no problems. If people fail to meet the safety benchmark, guys are not able to resit it for 12 months.  Inductions  48 hours’ notice required for induction bookings.  We need to submit:  Scanned colour copies of Licences / Qualification;  National White Card or QLD Blue Card;  Medical and D&A Test;  2 x references, (or letter of employment if they have been with us more then 2 years)  Individual Requirements checklist  Subcontractor Induction Request
  • 14. 14  SAFETY  Accomodation  7 days’ notice for new bookings and 48 hours’ notice for any name changes.  Trouble getting confirmations from the camp team in the past.  Locations the guys are booked into camp depends on their work site location.  The main issue - a very large turnover of staff so the standards applies to us seem to change constantly.  Getting onto site  Inductions for Personnel  4WD Training  All Plant Operators must be VOC’d and signed off by the client  Client Plant Inspection (re done every month or so depending on item of plant)  Weed & Seed Inspection for all Plant (incl vehicles).  All Boilermakers need to be certified in the clients welding procedures – This can take up to 2 weeks  Piling Crew to complete clients Work Pack before starting any work on site
  • 15. 15  Getting onto site  All Vehicles must have PC Logo on the side  PC responsible for all delineation of work  Paperwork required  PC Safety Plan  PC Quality Plan  PC Environmental Plan  SWMS  Plant Risk Assessments  ITPs/VCs  Daily Drilled Record Sheets  Daily Site Diary – to be signed and Submitted by 10am each morning  Prestarts
  • 16. 16  Vehicles & travel  Strict IVMS (In Vehicle Monitoring System), which all people working on the gas field sites have to abide by.  System monitors the drivers speed and location every hour of every day.  With the greater distances employees are now being asked to travel, PC have developed a journey management policy.  Minimum PPE Requirements:  Hard Hat  Safety Glasses  Gloves (to be worn at all times)  Steel cap boots  Long Sleeve High Vis Shirt/Pants  Safety requirements on site  All open bores must be surrounded by hard barricading.  If left overnight, then a mesh hole cover must be pinned over the hole.  If there is rain around the hole may need to be bunded/covered.
  • 17. 17  All works must be completed outside the barricading (checking offsets etc)  All reinforcement ends must be covered with a Reo Sok safety Cap
  • 18. 18  Safety Performance on Site  To Date (since August 2011) we have had 0 lost time at work Incidents (Approx 125,000 hrs)  This is something, we at PC are very proud of and has ultimately set a benchmark for the rest of our operations in the future!!  Received commendations from the client - pro-active, team approach to safety.  PC have developed a preference for working the 21 day on and 7 days off rotation system.  One PC foreman received a Safety Award from QGC for asking them to move out of PC work area as they were not signed in!  Continuing to implement methods/procedures to improve safety performance on site:  PC Safety advisors involved with the sites – regular visits & inspections (shared with client for benefit of the whole project)  Safety Observation Registers on site so crews know what needs to be closed out.
  • 19. 19 Materials  Typical reinforcement cages are very light, as the piles are usually only 6-9m in depth, meaning that they are easily handled on site by franna’s.  Cages are usually made in Brisbane.  Drilled holes sleeved with cardboard tubes, as per specification for the piling works  Cardboard tubes wrapped in 2 wraps of fortecon plastic, 200 micron in thickness.
  • 20. 20  Concrete supply - by the client on our CSG piling works.  Low slump requiring vibration over the top 3m.  Batching plant locations are so remote - often situations where the plant has ran out of ingredients to formulate the concrete required.  PC opinion that it is worthwhile setting up an on site batching plant in order to reduce all potential delays with the concrete supply.  Pile lengths were very conservative - shortened significantly by allowing for on site geotechnical certification.  Placement of reinforcement cage & cardboard tube  At the completion of drilling the formatube is placed into the hole to prevent movement during the pour. Top section of tube to be cut back after pour (without damaging pile)  All reinforcement cages that need to be welded, has to be carried out by a certified boilermaker who has been signed off on the clients procedures  All cogs need to be welded in at correct orientation (different orientation on corner piles)  All welds need to be inspected by clients weld inspector prior to placing the cage in the hole  Clients require a pre pour ITC to be completed for every pile. This requires 11 PC signatures
  • 21. 21 TESTING – PILE INTEGRITY
  • 22. 22 TESTING – PILE CAPACITY
  • 23. 23 TESTING – PILE CAPACITY
  • 24. 24 Testing  Pile testing has not been carried out thus far by Piling Contractors, as the design for the piles has been carried out by others to a higher factor of safety, negating the need for testing.  The biggest driver for these projects seems to be time, and getting them completed in an efficient timeframe with as little QA and safety issues as possible during the completion. Therefore the time spent on completing preliminary static load tests on sacrificial piles before main piling works is commenced, is not seen as a big ticket item at the moment.  Integrity testing of Piling Contractors piles is ongoing and to date has not revealed any anomalies within the piles constructed.  As a joint research exercise we completed with one of our clients, Piling Contractors completed a successful pull out test on a pile. The pile had concrete that was directly discharged without the use of a tremmie. The tests concluded that the concrete was of adequate standard and proved that within dry conditions the use of a tremmie was not required.  The results of this testing negated the need for Piling Contractors to carry on using tremmie’s on that project from that point.
  • 25. 25 Programme & Costs  FCS (350no piles)  450mm, 600mm & 750mm dia  Approx 15-23 shifts to complete.  May alter depending on the rig types that have been allocated to the site, as if there is a site with more rock than others this rate may slow down.  Typical cost for the completion of an FCS site would be approx $950k. This includes two piling rigs, craneage, labour, steel reinforcement and all other associated ancillary plant/equipment for the piling works.  CPP (900no piles)  450mm, 600mm, 750mm & 1200mm dia piles  Approx 50-63 shifts to complete.  May alter depending on the rig types used and whether there are any other influences on our production rates.  Typical cost for the completion of a Central Processing Plant would be around $2,900k. Again, this includes 2-3 piling rigs, craneage, labour, steel reinforcement and all other associated ancillary/equipment for the works.
  • 26. 26 Common Issues affecting Piling Productions  Concrete supply – This is a major issue on site. There are a limited number of batch plants in the area required to service all these projects  A way to reduce the risk of poor concrete supply to the piling works is to plan ahead with the concrete supplier with regular communication informing them of the estimated daily and weekly outputs required on site in order to meet targets.  ITP Sign off’s – On some sites, pouring a pile cannot proceed until all the ITP’s have been completed fully for each pile. There are 30 spots just for PC to sign off (per pile). Commonly, our client and the overall employer also need to sign off this document.  Weld inspections – If cages are not inspected by the weld inspector, they cannot be placed in the hole. This is a common problem particularly when there is a limited number of inspectors servicing a number of sites!  Piling platform levels – Some sites insist on different pad levels for different slabs. This makes it hard to move rigs and means we can only work in a set sequence/our movements are restricted. Also, it creates in some instances, small swimming pools, if there is a downpour in the area!
  • 27. Thank you for your attention foundations@pilingcontractors.com.au