A rope access technician during the Gladstone LNG shutdown project.

Gladstone LNG Shutdown

Santos engaged Vertech to provide a wide range of inspection services during the critical Train 1 shutdown in 2019. Vertech completed the inspection of over 70 vessels and exchangers, using a combination of conventional non-destructive testing (NDT) methods, in-service inspection (ISI), remote digital visual inspection RDVI and advanced NDT inspection techniques.

The Gladstone LNG (liquefied natural gas) project is a joint venture between Australia Pacific LNG, Santos, and PETRONAS. The project involves constructing and operating an LNG plant on Curtis Island, near Gladstone, Queensland, Australia. The plant receives natural gas from coal seams in the Surat and Bowen basins, which are then processed and cooled to their liquid state, allowing more accessible transportation and storage. The Gladstone LNG project was completed in 2015 and could produce up to 7.8 million tonnes of LNG annually.

Scope of Work

Vertech successfully completed the based scope of work and several additional inspections that were identified during the shutdown. Our teams of AICIP, NDT, rope access, advanced NDT, tube inspectors and RDVI inspectors completed inspections on time, on budget and with an exceptional safety record:

PRE-SHUTDOWN WORK

Review inspection work packs to determine inspection scope requirements in terms of labour and equipment; estimating all equipment and labour hours, providing detailed RDVI, CVI and NDT work packs that included scaffold and lagging requirements as well as organising all equipment and specialist inspection personnel to mobilisation to Site.

Two Vertech IRATA Rope Access Technicians scale the side of the Gladstone LNG plant.
  • 8 yearly internal and external inspection of hot oil trim cooler and pipeline gas preheater.
  • 5 yearly internal and external inspection of 4 lean solvent coolers.
  • 8 yearly internal and external inspection of HP and LP fuel gas ko drum absorber ethylene purger condenser section.
  • 8 yearly internal and external inspection of hot oil surge drum and fuel gas heater lean solvent cooler.
  • 8 yearly internal inspection of ethylene purger absorber section and surge drum.
  • 8 yearly internal and external inspection of propane purger adsorber section, refrigerant accumulator and purger condenser sections.
  • 8 yearly internal and external inspection of 2 l.s. propane-ethylene condenser feed chillers.
  • 8 yearly internal and external inspection of i.s. propane-methane, ethylene feed chiller.
  • 8 yearly internal and external inspection of h.s. propane - methane and ethylene chiller.
An RDVI Crawler begins it's inspection duties as it enters the opening of a pipe
  • 8 yearly internal inspection of 2 regeneration gas heaters.
  • 8 yearly internal and external inspection of de-gassing, solvent regenerator reflux and solvent flash drums.
  • 8 yearly internal and external inspection of solvent regenerator.
  • 4 yearly internal inspection of co2 absorber.
  • 8 yearly internal and external inspection of ethylene compressor discharge cooler.
  • 4 yearly internal inspection of 2 regenerator reboilers.
  • 8 yearly internal and external inspection of 2 low stage propane suction drums.
  • 8 yearly internal and external inspection of regeneration gas cooler.
  • 8 yearly internal and external inspection of h.s. propane - feed chiller.
A vertech IRATA Rope Access Technician in the process of scaling the side of the Gladstone LNG Facility - ocean and a barge visible in the background.
  • 4 yearly internal inspection of dryer feed ko drum.
  • 8 yearly internal and external inspection of 2 mercury removal beds.
  • 8 yearly internal and external inspection of 3 molecular sieve dehydrators.
  • 4 yearly internal/external inspection of hot oil start-up heater.
  • 2 yearly internal inspection of waste heat recovery units x2.
  • 8 yearly internal and external inspection of condensed water collection tank.
  • 8 yearly internal and external inspection of ethylene compressor discharge cooler, intercooler, ethylene compressor and disch. Coolers.

Outcomes

Due to the detailed planning, work packs, spread of best-in-class RDVI cameras, crawlers and people the full scope of work was completed along with several emergent pressure vessels, pressure piping systems and other non-destructive testing (NDT) inspections on process, plant, and structure.  The shutdown was delivered safely on time, on budget and with great feedback from the Santos operations team.

 

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Two Vertech IRATA Rope Access Technicians scale the side of the Gladstone LNG plant.
Gladstone LNG Shutdown Case Study
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