We partnered with NACAP to complete an advanced hydrotesting technique and complex pig navigation on the 12.2km Port Kembla Lateral Looping Project, connecting
Squadron Energy’s new Port Kembla Gas Terminal at Spring Hill to Jemena’s Eastern Gas Pipeline at Kembla Grange in the Wollongong City Council region.

The project involved the construction of 10 technically and logistically complex horizontal directional drills (HDDs) across the pipeline alignment. NACAP commenced construction in December 2022 with the help of trenchless subcontractor UEA Group, and subcontracted Pipe Tek to pre-test all HDDs as well as mainline hydrotesting works and a caliper pig run following the completion of construction activities.

Pipe Tek strength and leak tested the 450mm diameter, 12 km looping mainline at 22 MPa in accordance with AS2885.5 using its custom-built hydrotest trailer with in-built Protech pump. The team also completed a tie-in spool test on the 0.1 km Kembla Grange Meter Station to the EGP.

TESTING
Because there was limited storage space for test water available on the right of way, we tested the mainline in two sections – one 6,500 m section and one 5,500 m section – using a pipeline filling technique called ‘jumping’. This technique allowed us to use the same water to test both pipeline sections.

We used water from bladders installed in the middle of the two pipe sections. The bladder bags required careful handling to ensure that no damage and water loss occurred. After completing testing on the first section, the test water was pushed through to the second section with pigs via break tanks. We scheduled a 24-hour roster to make sure everything went smoothly.

PIG DATA
We completed cleaning and gauging with bi-directional pigs and used a cupped magnet pig to help remove ferrous material in the pipeline.

We also completed a caliper run using an Enduro Pipeline Service 18 inch Digital Data Logger (Ddl) to confirm their were no dents and the ovality of the pipe. The Ddl tool was chosen because it logs anomalies in clock positions and can collect up to five datasets in one pass, making it efficient and thorough, allowing other project work to continue.

We used desiccant dryers, compressors and foam pigs to dry the pipeline to -20 degrees Celsius for commissioning.

URBAN LOCATION
The project’s urban location presented a challenge when pigging the pipeline. The pipeline runs through a major town – Wollongong – and includes numerous HDDs, meaning there were a lot of bends and it was difficult to navigate the pigs through the network. This tested our team’s abilities and made the project a rewarding one to work on following positive feedback from NACAP.

“Nacap and Pipe Tek worked well together to successfully deliver the Port Kembla Pipeline Project hydrotesting program. Pipe Tek brought well established systems and processes to the project as well as enthusiasm to deliver their work safely. Nacap are grateful to Pipe Tek for their efforts on the project and look forward to future collaboration opportunities.” – James Povey, Operations Director, NACAP