Client:        Origin Technip Alliance
Location:    Picton, New Zealand
Contract:    Construct Only
Currency:    May 2009

Project Summary

The establishment and operation of a temporary spoolbase to support the overall Kupe Gas Project. The Kupe field over its life will provide the New Zealand gas network with approximately 253 petajoules of natural gas, LPG, and 15 million barrels of light oil (condensate). The spoolbase contract was an important part of the Kupe Project and included:

• A fabrication facility and bridging of a 60m wide stormwater pond
• Welding a total of 28,000 m of pipes into 70 individual 420m long strings (pipe stalks)

The Challenge

This high profile project was always going to be challenging with limited space and tight timeframes in which to build an effective spoolbase operation. The MacDow team had 15 weeks in which to build a fully functioning, world-class temporary spoolbase. The steep terrain and existing buildings behind Waimahara Wharf limited the spoolbase size and restricted the maximum pipe stalk length to 420m.

The Solution

The 300mm diameter pipe was delivered to the spoolbase in 12 metre lengths. The pipes were then placed on a roller system and passed through the enclosed pipe preparation, automatic welding, testing and coating facility to create 120 metre pipe strings. A tie-in welding operation extended these to pipe stalks of 420 metres.

From here, the stalks were loaded onto the Apache reel barge. The tie-ins were then welded to make a total reel length of approximately 9,300 metres. The Apache subsequently transported the pipe to South Taranaki for laying on the seabed in depths of up to 35 metres. This was the first time a subsea gas pipeline was laid in New Zealand using this method.

Key to Success

Critical to our success was developing and qualifying the bespoke welding procedures to meet stringent quality and safety standards as well as retaining key technical staff throughout the project.

Project Stats

• 120m fabrication facility
• 68 pipe stalks
• 50 welds averaged per day
• 27,000m of underwater pipe
• 20,000 man hours