Getting the job done: LNG plant outback in Western Australia

Gemma Bowers, process engineer, Foster Wheeler Energy Limited, MEng chemical engineering with diploma in industrial studies, Loughborough University (2004)

The project in brief

• PROJECT The Woodside LNG Phase V expansion is a joint venture led by Foster Wheeler to increase the capacity of an existing 11.7 million tonnes per annum (MTPA) liquid natural gas (LNG) complex.
• CLIENT Woodside Energy Ltd (Operator) on behalf of the North West Shelf Venture comprising six participants: Woodside Energy Ltd, BHP Billiton (North West Shelf) Pty Ltd, BP Developments Australia Pty Ltd, Chevron Australia Pty Ltd, Japan Australia LNG (MIMI) Pty Ltd, and Shell Development (Australia) Pty Ltd.
• REASON FOR PROJECT To expand the LNG complex at Karratha, Australia, by adding an extra LNG liquefaction train of 4.2 MPTA capacity.
• SCHEDULE Engineering, procurement and supply began fourth quarter 2004. Construction started third quarter 2005. Prefabrication started fourth quarter 2005. Commissioning kicked off second quarter 2006. Full start-up is expected fourth quarter 2008.
• COST Approximately Australian $2 billion.

Adding a fifth LNG train (Train 5) along with acid gas removal and fractionation units, a jetty extension, two power generators, boil-off gas and fuel gas compressors and various ancillaries to the existing LNG facilities at Karratha is no mean feat. Karratha is about 1,100 km north of Perth. It’s very isolated and resources are limited. The key challenge was to modularise the plant into sections that could be built off site, shipped in easily and then put together to form the working units. This involves a high level of planning and communication between all groups to follow the schedule exactly and for all the modules to fit together precisely as intended.

Working as a graduate engineer in a global team

It would be difficult to find a more global team. Engineering and design for ‘Train 5’ and for the ‘offsites and utilities’ took place in the Reading office in the UK, while engineering and design for the acid gas and fractionation units took place in our Sriracha office in Thailand. Certain computer-aided design (CAD) work was carried out at our Chennai operation in India; there are also teams in the module yard at Batam Indonesia and in Perth, and on site at Karratha, Australia. At the peak of the design and engineering phase, about 200 engineers and 100 support staff were involved in the Reading and Chennai taskforce.

I was assigned to this project as part of the Foster Wheeler graduate training scheme working within the projects group. As a project engineer, I dealt primarily with mechanical equipment, the lubrication schedule and special piping items, as well as co-ordinating the flow of information to site. The projects group is a great place to forge good working relationships with all of the other disciplines working on the job. I worked particularly closely with the equipment engineers and piping group and our team on site. Being able to communicate well was the most important skill I developed on the job. I quickly learned that the best way to resolve issues and maintain good relationships between the groups was by talking to people across the disciplines.

It was demanding from the word ‘go’, but I have worked with some of the best engineers in the industry and in a project team that bonded well – I’m still working off all the cakes and biscuits that were in regular supply on the project floor! I’m pleased to have experienced working on such a large and fascinating project so early in my career.

The next stage for the project and me

This expansion will bring both economic and social benefits to Western Australia and, as the market for LNG continues to grow, there is certainly potential for future expansion. However, delivering this massive project to the highest standards is the current target.

As for me, I have been based in the Reading taskforce during my current placement, so I’d like to follow the project ‘down under’ on my next placement and see the plant ‘in the flesh’.