Bowden Urban Village is a $1 billion redevelopment on a former site of the Clipsal Corporation in the suburb of Bowden, adjacent to Adelaide Park Lands and Outer Harbor railway line. The South Australian Government anticipates that the site, which covers about 10 hectares, will be used to develop around 2400 homes incorporating about 1500 residential apartments plus retail outlets and commercial offices around a town centre. The opportunity for an urban development on the site grew out of the government’s plans for transit-oriented developments in the Adelaide metropolitan area.

Fyfe’s role and responsibility

• Setup horizontal and vertical control for the site
• Complete detailed surveys of the site (plus adjoining parklands) to capture information, including surrounding road and service infrastructure as required for engineering design for civil and building works
• Complete an outer boundary survey of the site to ensure accurate boundaries for design and construction
• Undertake land divisions, marketing, easement and pegging plans
• Undertake pegging of boundaries and set-out of infrastructure.

Dr Ruth Keogh of Fyfe was engaged, as a Site Contamination Auditor accredited under Division 4 of Part 10 of the Environment Protection Act 1993 (EP Act), to audit a portion of the former Balhannah Railyards that was proposed for future low density residential use.

The audit covered an area of approximately 1 ha and had previously been used predominantly for the storage and burial of waste materials.

The audit process involved reviewing sampling and remediation plans as well as investigation and remediation/validation reports completed by the environmental consultant. In addition, the auditor provided advice regarding the assessment, remediation and management of the site and undertook field activities (i.e. site inspections and verification sampling).

Given the presence of contaminated soils as well as surface and buried wastes (including railway ballast and asbestos) on the site, a remediation strategy was devised that involved sieving the majority of the surface fill materials to remove wastes, thereby minimising the amount of material that required off-site disposal/re-use.

The auditor produced a Site Contamination Audit Report which concluded that the site was suitable for residential use, with no requirement for further site remediation or management.

Critical components The project required the development of a cost-effective remedial strategy that would ensure the site was suitable for the proposed use, without the need to emplace any on-going conditions on the future use of the land.

St Clair is a new real estate development in the suburbs of Woodville and Cheltenham, only 8 km west of the Adelaide city centre.

The Actil Avenue portion of the St Clair Estate is a 250-allotment residential development.

Fyfe’s role and responsibility

• Obtained development approval from the City of Charles Sturt.
• Completed the initial civil engineering assessment including survey and allotment creation.
• Completed design of road, stormwater and sewer, and contract administration.

Australia’s leading geothermal energy explorer Geodynamics is developing a centralised fluid storage dam for their five wells at Habanero.

The design and construction cost feasibility reviewed the impact and potential at Habanero 4 for a 50, 65, 83, 104 or 130 ML dam. Habanero 2’s design and construction cost feasibility reviewed the impact and upgrade potential of the existing dams for a 40, 56, 80 or 100 ML dam.

Habanero 2 was selected as the ideal location after consultation with the landholder and regulator, and because using the existing footprint of the Habanero 2 dam allowed for a substantial environmental risk reduction.

Fyfe’s role and responsibility

• Detailed civil design, civil engineering, contract documentation, technical specifications survey and regulator liaison for the approved dam concept at Habanero 2.
• Design and construction cost feasibility assessment at Habanero 2 and 4 for a new dam.
• Design and construction cost feasibility assessment at Habanero 4 for a dam.

In 2017 Sarah Constructions approached Fyfe to accurately survey the existing fence rails for the upgrade of the Adelaide Oval new LED Ribbon strip signage.

This survey included establishing survey control outside the grassed areas, locating the perimeter fence rails, centres of opening gate hinges, locating concrete footings, and incoming electrical conduits at the base of the current fencing. Plans and three dimensional coordinates were provided to the designers for the pre-fabrication of the new fence mounted strip panelling.

Fyfe’s dimensional control surveyors performed the survey works between sports events, working to a tight time frame for pre-fabrication and installation for key sporting events.

Vision on Morphett is a $75 million apartment development delivering 185 Community Strata titled dwellings in a new 18 storey building.

The Vision apartments range from studios to three bedrooms while offering spacious and inviting living areas including a proposed three levels of car parking. The top three levels are reserved exclusively for penthouse living and offer some of Adelaide’s most breathtaking views. Retail premises are located at the ground floor of the building.

This site is located in the heart of the city adjacent to the Adelaide markets, transport and the bus terminal, shopping precincts and a wide range of restaurants.

Fyfe’s role and responsibility

• Project surveyor for boundary creation
• Preparation of marketing plans for contract purposes
• Preparation of staged development applications (for land division) planning assessment
• Survey of over 180 new strata dwellings (retail and residential) following construction
• Preparation of plans suitable for lodgement in the Lands Titles Office

This Osmoflo water amendment plant processes water produced from coal seam gas wells and makes it suitable for irrigation purposes. The water is sent as a steady flow through filtering, buffer tanks, pH neutralisation and chemical addition.

Fyfe’s role and responsibility

• Civil concept and consultation.
• Electrical detailed design and documentation.
• Civil scope of works and contract documentation.
• Engineering survey.
• Hydrological assessment.

Changes to gas infrastructure required an odorant station to be installed at Ban Ban Springs meter station. The temporary odorant station first installed was not large enough to carry across frequent road closures in the area during the wet season. A larger odorant storage capacity was needed.

Design of a 12,000 litre capacity storage system for odorant utilising existing dosing systems (to be relocated), and design and supply of the pressure vessel (operated under a natural gas blanket) were the key project requirements.

The odorant storage facility includes two stainless steel pressure vessels, bunded area including a shelter, all safety equipment including safety showers for remote locations, fencing, access ways, and relocation of the odorant measuring and dosing equipment from the temporary facility.

Fyfe’s role and responsibility

• Project scoping and identification of site requirements.
• Use of data from a previous Fyfe 3D scan of this area, which was adequate for preliminary workings.
• Design and supply of two stainless steel pressure vessels.
• Design of the storage vessels, bunding, unloading area, shelter, safety showers, instrumentation and integration of the natural gas blanket system into existing pipework.
• HAZOP of the odorant storage system and blanket natural gas system.
• Safety management study to AS 2885.
• Preparation of specifications and technical documentation to tender work packages.
• Technical evaluation of tender submissions.
• Extensive support to APA in sourcing local contracting firms to help manage overall construction costs.
• Construction supervision for the work packages.
• Commissioning of the installation.

The Golden Mile commercial development on the Stuart Highway at Berrimah has 59 allotments on 27 hectares.

Fyfe’s role and responsibility

• Detailed design and documentation for construction.
• Design and documentation of the site’s internal roads, taking into account turning paths for commercial vehicles and requirements for drainage.
• Design of a future signalised intersection for the site on to Highway One, in accordance with specified requirements to establish a new junction on a federal highway.
• Negotiations with authorities.
• Estimation of construction costs to develop the site, including potential headworks, stormwater, road, sewer, water, electrical and other construction costs associated with developing the site; the cost estimate assisted the client in preparing a project feasibility.
• Preparation of contract documents in accordance with AS 2124 and technical specifications to assist the developer in letting the civil contracts.
• Assessment and provision of feedback on the tenders as engineers and designers for the project.
• Design of the sewer in accordance with the relevant standards and guidelines of the NT Power and Water Corporation, including determining pipe size via hydraulic capacity at peak wet weather flow and self-cleansing velocity at the most probable peak dry weather flow; and allotment connection requirements.
• Preparation of a water and fire reticulation system report, including a WATSYS hydraulic model for potable water and fire reticulation detailing the expected velocities and head losses in the pipes, and the residual head at the nodes, which demonstrated the development’s proposed system would meet Power and Water Corporation requirements and specifications.
• Hydraulic design for stormwater, including modelling of the site’s stormwater system using ‘Drains’ software, approved by Darwin City Council.

Fyfe provided survey services to facilitate the construction of a 174 km oil pipeline from the western area of the Cooper Basin to the Moomba processing facility, for the oil to be then on-shipped to Port Bonython.

Fyfe worked in conjunction with the construction crew and performed the following tasks on a daily basis:

• Construction alignment survey.
• Survey for facilities at Bauer, Growler, Lycium and at Moomba.
• Capture all as-constructed data.

Fyfe’s Role and Responsibility

• Mark out the extents of the “right of way”.
• Mark out of the access roads, truck turn-arounds and lay-down yards.
• Locating and marking of all underground services.
• Construction survey for all new facilities.
• As-constructed survey of the pipeline.
• Report daily on any depth of cover issues.
• Provide final as constructed alignment plans.

Fyfe was engaged to undertake engineering survey and detailed design and documentation for 115 km of haul roads, which included upgrade of six existing and creation of two new roads to service Heathgate Resources Beverley Uranium mine site. The existing roads were constructed of poor quality, local material and had become depressed compared to the surrounding area through regular maintenance, resulting in poor drainage and rutting following minor rainfall events.

These upgrades were to reduce mine downtime through providing all-weather heavy vehicle access to Beverley and satellite plants. Heathgate resources experienced some 39 days of road closures through a 12 month period, which resulted in significant downtime costs and delayed production.

Fyfe’s role and responsibility

• Liaise with stakeholders to confirm road alignments and design parameters to be adopted.
• Project manage aerial imaging engineering survey along the alignment of each road and intersecting roads, including watercourses and services.
• Project manage geotechnical investigation to determine sub-grade soil conditions and pavement design.
• Stormwater design to assess the capacity of each intersecting water course and culvert design required for the 5 year ARI event.
• Undertake detailed design including hydrological assessment and geometric design utilising 12D civil design software.
• Identification and specification of required traffic signage in accordance with AS 1742.
• Undertake detailed design and documentation in accordance with Austroads and Council standards.
• Produce technical specifications and Drawings for Construction.
• Provision of an opinion of probable cost estimate for construction.

The Australian Pacific LNG (APLNG) Project is a coal seam gas to liquefied natural gas (LNG) project owned by the joint venture partnership between Origin, ConocoPhillips and Sinopec.

APLNG is developing well-site infrastructure for its upstream operations. The contract will see WDS prepare sites and access for 345 well lease pads in South East Queensland – more than 760 km of gas and water pipelines, power distribution, and electrical and mechanical equipment.

The Surveying Services contract scope for the project includes: control surveys; right of way (ROW) pegging; set-out and as-built surveys of pipelines and associated utilities; quality assurance (QA) and production of client specific geographic information system (GIS) deliverables.

Fyfe’s role and responsibility

Fyfe’s five survey crews, vehicles and survey equipment are fully integrated with WDS’s systems, processes and procedures. Fyfe’s continuous coverage uses back to back crews on 15/13 rosters, including an on-site surveying supervisor.

A Fyfe full-time on-site GIS technician ensures that as-built data is provided to APLNG surveying and ESRI format GIS specifications.

Control survey activities

• From the outset of the project, Fyfe densified existing survey control to ensure sufficient coverage over the entire project.
• Fyfe proposed the use of a trailer mounted GPS base station to reduce the time required for base set up.
• A typical survey or day’s work requires set-up and dismounting on a tripod of a base station receiver.
• A separate base is required to be set up daily for each of the five crews.
• In the remote work locations, time is spent driving to where bases are to be set up at the start and end of the day and bases may also need to be moved during the day.
• Setting up bases adds approximately 1.5 hours per crew per day.
• Fyfe has to-date supplied two trailer mounted GPS base stations to improve efficiency of operations.

Right of way pegging survey activities

• Before setting-out ROWs on the ground, a Fyfe verification/ validation exercise ensured that design electronic data matched the contractual hard copy plans.
• Alignments were created and offset accordingly as part of this QA process.
• Data models are uploaded for setting-out, ROWs are set-out, points are recorded and QA checked at the end of the working day.

Setting-out and as-built survey activities

• Fyfe provides setting-out and as-built surveys to Origin technical specifications for standard survey and standard GIS.
• Trimble GPS controllers are used with feature code libraries and pull-down menus developed by Fyfe to match Origin GIS format requirements.
• Site supervisors and GIS technicians compile work pack models and undertake QA checks before issue to APLNG.

Due to corrosion, BHP Billiton required replacement of an existing molten sulphur tank and associated equipment. The replacement tank required to be functionally identical with design improvement to increase integrity, safety and meet current standards. To allow installation during a tight shutdown period the replacement tank was designed to be fabricated offsite and lifted into position as a single unit with associated structural members and small bore pipework.

Fyfe personnel attended the site to review the current tank and adjoining facilities. Extensive use of a 3D laser scan was used to align tie-in points with existing pipework. A 3D model was generated to facilitate an operating review with BHP Billiton onsite. Based on the final model construction drawings for the tank, pipework and structure were generated.

Fyfe’s role and responsibility

• Tank Design to API 650.
• Instrumentation upgrades including of tank level and temperature.
• Design of platform lighting and power distribution.
• Pipework, including jacketed piping, design and detailing.
• Structural design of tank and roof structure.
• Tank lift study using FEA.

Deliverables

Calculations

• API 650 compliance verification.
• Structural loads.
• Steam and condensate capacity.
• Tank Lift finite element analysis (FEA).

Documents

• P&IDs of upgraded tank and services.
• Data sheets for mechanical and instrumentation.
• Piping plans.
• Isometrics.
• Construction scopes of work.
• Piping and tie in lists.
• Electrical cabling and loop drawings.
• 3D model.
• Safety in design report.

Historical mine leaks and spills of caustic materials and hydrocarbons at various locations across the Rio Tinto Alcan site at Gove have resulted in contamination of soil and groundwater, which has been identified as an environmental risk for the site.

The site-wide 6-monthly groundwater monitoring event covers four main investigation areas:

• mine site/landfill – four groundwater monitoring wells.
• residual disposal area – 123 wells.
• refinery – 84 wells.
• light fuel tank farm – 29 wells.

Fyfe’s role and responsibility

• Collect groundwater samples by low-flow methodologies and submit for analysis.
• Prepare a comprehensive report for the client to submit to the regulator.
• Collect additional groundwater samples by hydrasleeves from 34 nominated wells so the sampling methodologies (low flow vs hydrasleeve) could be assessed by comparing analytical results.

Santos Limited engaged Jacobs E&C Australia Pty Ltd as its EPCM contractor for the front-end engineering design (FEED) stage of the Cooper Infrastructure Expansion Program, Upstream Projects Stage 1, which is modifying and expanding existing satellite stations at:

• Big Lake
• Daralingie
• Gidgealpa
• Moomba North.

Project details

• Sales gas line from Moomba to Big Lake satellite for fuel gas to compressors.
• Project specifications: DN 150, 20 km long.
• FEED and detailed design for pipeline, lateral off-take and end of line above ground pipework.

Fyfe’s pipeline design services for the Big Lake fuel gas pipeline included:

• 20 km buried DN150 steel fuel gas line from Moomba Plant to Big Lake with a lateral connected into Moomba South Central Facility.
• 20 km buried optic fibre cable terminated at the Moomba Plant, Big Lake and Moomba South Central Facility, ending at a junction box in a buried concrete pit at a convenient location adjacent to the trunkline pig traps.

Project challenges

• Route selection through the area south of Moomba required careful attention to the intensity of infrastructure development and large number of existing pipelines.
• The project team coordinated with two other projects and four other major pipelines terminating at the same location in Big Lake satellite.

Fyfe’s role and responsibility

• Pipe material selection study to review suitability of spoolable composite pipe.
• Route selection and survey.
• Environmental clearance.
• Safety management study and alignment sheets.
• Pipeline engineering including design basis, crossing design and stress analysis.
• Construction specification and scope of work.
• Constructability review.
• Cathodic protection and earthing design.
• Design of optic fibre cable located in the same trench as the pipeline.
• Engineering support for the construction tender process.

To reduce capital and operations costs, Santos drilled two extra wells within a 30 m radius of the existing natural gas well head, which had an all electric skid design of:

• Solar panels and batteries.
• ROC 407 RTU with radio communication to central SCADA system.
• Measurement of gas flow, temperature (mass flow) and pressure.
• Remote well control of flow and shutdown.
• Corrosion inhibitor injection system.

Fyfe’s role and responsibility

Fyfe adapted the standard equipment to allow control and monitoring of three wells with the existing equipment such as RTU, solar panel, batteries and frame.

The ROC 407 was replaced by an ROC 809 RTU because of its extended I/O count. The RTU software in the ROC units was upwardly compatible allowing relatively easy software modification. The existing well head standard program was modified by GPA Engineering for the two extra wells.

This design should continue to be used drilling programs as this method of cost reduction becomes accepted in the client’s business.

Santos needed to build a new discharge evaporation pond near the Big Lake Satellite to deal with excess water from increased gas production in the Cooper Basin and help alleviate any problems with internal corrosion from the build up of water in the pipelines.

Fyfe’s role and responsibility

Evaporation pond construction survey including:

• Detailed survey of the proposed area.
• Contour plan.
• Design of new pond layout including interceptor pond.
• Marking of pond extremities including top of bund level.
• As-built survey.
• Cross-sectional data of the as-built pond to verify design into construction.

Modifications at the Shell Birkenhead Bitumen Plant allowed direct remote control of gantries.

Fyfe scope of work:

• Supply and install a new switchboard for the variable voltage, variable frequency drives for pumps P001 and P003.
• Connect pumps and drives electrically, and supply and install sundry materials.
• Supply new drawings for the switchboard and modify all existing drawings.
• Analyse electrical equipment in hazardous areas and conduct detailed inspections.
• Modify Kingfisher remote terminal unit and Citect SCADA program.
• Complete site commissioning and testing.

Santos’ existing production facility at Tirrawarra receives electrical power from a number of gas fuelled generating sets. Operational personnel identified a lack of sufficient available generation capacity for a project requiring extra power to be drawn from the existing generators.

Fyfe’s role and responsibility

• Determined the plant maximum demand with extrapolation up to an ambient temperature of 50°C with assessment of available generating capacity.
• Identified there was insufficient capacity to run the new equipment without compromising the existing plant in a N+1 redundancy method.
• Extended the study to online monitoring, to capture live data and avoid large capital expenditure.
• Identified that there was no one location to measure the plant demand; programmed a standalone iFIX SCADA to collect data from a number of ABB breakers in the panel; found sufficient power available at most times provided certain conditions to be met.
• Identified the iFIX SCADA monitoring system together with an operational procedure as the low cost solution
• Installed a gateway to allow the plant FIX32 SCADA system to collect data from the ABB breakers with alarms to alert operators when system integrity was compromised.

The Blacktip Gas Field is 245 km southwest of Darwin. Blacktip is the first project to have been developed to supply gas for the domestic market. Gas produced from the field is supplied to the Northern Territory-based utility provider Power Water Corporation (PWC) under a 25-year agreement. The field provides gas to generate electricity for various Northern Territory locations.

Offshore-produced gas undergoes initial processing at the Blacktip platform to remove condensation and water. It is then processed at the onshore Wadeye processing facility before being supplied to PWC.

This is a very remote locality, in which Fyfe has conducted various surveying works. Preliminary works for the Wadeye processing facility conducted by Fyfe included detail for design, compiling lease plans, and investigations to plan for water supply and communications. To design the pipeline landing from the offshore platform, Fyfe conducted a combination of conventional onshore survey supplemented with hydrographic survey.

This was a Greenfield site, and being such a survey, was first on site to define boundaries, establish survey control for construction, and to ensure any sites of cultural significance were clearly marked to avoid disturbance.

Fyfe’s role and responsibility 

Fyfe provided survey consultancy for earthworks for the plant, access road and shore-landing facility including the wharf, south west of the community of Wadeye. Fyfe ensured client satisfaction through its understanding of highly accurate control networks in the plant site survey area.

One of the challenges the survey addressed for this project was setting out a fire system that was fitted after plant construction. The pre-fabricated pipeworks had to be fitted to millimetre accuracy around existing plant assembly.

Fyfe’s role in this project included assisting the client in dealings with the custodial landholder, the Daly River Aboriginal Land Trust.

Bluestone Hurling Drive development is a 130 hectare housing development at Mount Barker in the Adelaide Hills. The 6 stage, 835 allotment development will include 16 hectares of open space and 4 km of walking and cycle trails, and revitalise the site’s waterway.

Fyfe’s role and responsibility

Town planning, urban design, surveying, civil engineering including:

• Full engineering design and construction of all relevant infrastructure for the subdivision.
• Design of road, stormwater and sewer, and contract administration for Stages 1 and 2.

Bluestone Hurling Drive development is a 130 hectare housing development at Mount Barker in the Adelaide Hills. The six stage, 835 allotment development will include 16 hectares of open space and 4 km of walking and cycle trails, and revitalise the site’s waterway.

The development needed to comply with strict conditions imposed by the City of Mount Barker, the EPA and the NRMB. These conditions ensured that:

• All properties are protected for the 100 year ARI event.
• The central water course is rehabilitated with engineered erosion control measures.
• The development has no impact on the existing downstream established development.
• The runoff from the development is controlled quantitatively and qualitatively.

The project also included the detailed design of a large box culvert of three cells (2400×1200) BC.

Fyfe’s role and responsibility

• Preparing a stormwater management report for planning approval.
• Detail design of the roads, wastewater and stormwater infrastructures for Stage 1 to 5.

As part of SA Water’s Energy Use Optimisation Project for its Bolivar Wastewater Treatment Plant (WWTP), an increase in onsite power generation, with the potential to export power at peak periods, is being considered. The project would convert the existing 3.8 MW gas turbine engine to run on natural gas, rather than digester gas, when economically viable to do so. Digester gas will be fed to the new reciprocating engines.

Proposed Bolivar lateral and meter station

South East Australia Gas Pty Ltd (SEA Gas) was commissioned by SA Water to scope and supply options for a front end engineering design (FEED) study for the supply of natural gas to the Bolivar WWTP power house and develop a capital cost estimate. The natural gas will be supplied from the existing SEA Gas pipeline through a short lateral to a pressure reduction and metering station.

Fyfe’s role and responsibility

Perform the initial FEED for the lateral and pressure reducing meter station including:

• Pipeline connection to SEA Gas pipeline at an existing underground DN 100 offtake connection with manual isolation valve
• Pipeline lateral from offtake valve to the meter station
• Meter station, comprising:

• Inlet actuated shut down valve
• Horizontal filter separator
• Electric heater with associated control panel
• Coriolis mass flow meters with meter verification software
• Provision of future gas chromatograph installation
• Dual pressure regulator runs to control pressure as required
• Pressure relief valves and control valves for overpressure protection
• Instrumentation for control and monitoring, including instrument gas skid
• Manual process vents for system depressurisation
• Electrical supply including 400 V AC and 24 V DC distribution boards and control hut
• Combined flow computer and remote terminal unit and SCADA communications.

Develop a capital cost estimate for SEA Gas to use to negotiate a gas supply agreement with SA Water.

This land development on a 1.42 hectare site south of Adelaide contains 30 detached single-storey dwellings on 30 Torrens Titled allotments.

Fyfe’s role and responsibility

Town planning, urban design, surveying, civil engineering services including:

• Preparation of the land division layout, master plans, lodgement and monitoring of planning applications
• Full engineering design and construction of all relevant infrastructure associated with the subdivision
• In partnership with the architects and builders, project management of construction of the dwellings
• Development of productive and cooperative working relationships with planning authorities, government agencies and stakeholders.

The Northern Busway is an infrastructure project designed to connect Brisbane airport and communities in Brisbane’s northern suburbs to Brisbane City, major shopping centres and workplaces. It will become a vital link in the expanding busway network and reduce travel times for people travelling to and from the northern suburbs of Brisbane.

Fyfe won the tender to survey and prepare the volumetric survey plans for three of the lease areas of the Brisbane Northern Busway Tunnel Project.

Fyfe’s role and responsibility

• Design the extents of the three-dimensional model to comply with the tender requirements for the resumption of 123 residential lots and road reserve.
• Assess the extents of the tunnel, to a depth of 50 m below ground level, where excised from these lots and road, creating a new title for the residential lot and title for the tunnel.
• Prepare survey plans suitable for registration and the issue of new titles for each lot.

The extension of the major development area of Buckland Park to include an additional 312 hectares of land adjoining the southern and eastern boundary, improved the proponent’s ability to manage stormwater flows in the southeast section. The overall site area increase of 30% will create opportunities for including additional commercial and employment uses and a frontage for the township to Port Wakefield Road, the major regional transport link.

Fyfe’s role and responsibility

Town planning, urban design, surveying/GIS, civil engineering of:

• Land for approximately 15,300 dwellings, including some 3,885 medium density dwellings and a range of affordable housing options.
• A town centre, four neighbourhood centres and three smaller local centres incorporating a range of commercial and community facilities.

FKG Group engaged Fyfe to undertake the survey works required for the Bundi Road widening project for QGC. The section of road is located west of Wandoan approximately 130 km north west of Chinchilla.

Fyfe’s role and responsibility

• Control survey.
• Clearance and disturbance corridor surveys.
• All engineering setout surveys for the entire length of the new alignment.
• Setup and running of machine-guided GPS equipment.
• As-built survey.

The Bylong Coal Project proposes to mine up to 6.5 million tonnes of mine coal per annum for supply to the thermal coal export market. The mine will include two open-cut mining areas and an underground mining area.  Kepco Bylong Australia Pty Ltd (“KEPCO”) engaged WorleyParsons Services Pty Ltd (“WorleyParsons”) to provide Project Management Services for the Bylong Coal Project.  Fyfe were engaged by WorleyParsons to provide site survey for each of the following areas:

Fyfe’s role and responsibility

In undertaking this project, Fyfe delivered AutoCAD files with all data saved in appropriately labelled layers (e.g. kerb, invert, Endeavour Energy, Telstra etc.), including:

• 3D data (points, strings and contours)
• Contours at 0.25 m intervals
• Utilities sizes and specifications (e.g. pipe NB/concrete)
• DTM triangles
• Contours
• Cadastral boundaries with Lot/DP information
• Satellite imagery where appropriate
• PDF files showing the detail survey at an appropriate scale including annotations, legends, contours and spot levels.

Other

• Fyfe’s original contract with WorleyParsons has been extended several times to undertake further survey work packages.

A multi-unit development was highly sought after in the Carina Heights area. The Town RiskSmart development application, under Brisbane City Plan 2000, to gain approval to use this site for eight units, was fast tracked by Council. Approval, including the time taken for public notification, took less than 2 months.

Fyfe’s role and responsibility

• Completed high-quality town planning work through collaboration with architects, civil and noise engineers.
• Used 3D perspective drawings to show how the building’s design engages the streetscape in a non intrusive manner while providing casual surveillance to the street.
• Worked with Brisbane City Council, the Department of Transport and Main Roads, architect, engineers and the client, to create a successful development.

As part of the World Bank’s Pacific Aviation Investment Program, a number of remote airstrips throughout East Asia and the Pacific received funding in order to improve their operational safety and air transport infrastructure. Cassidy International Airport on the island Kiritimati (also known as Christmas Island) in Kiribati was included as part of this program.

Fyfe were engaged to undertake detailed survey activities including locating pavement levels, line marking and airstrip lighting at Cassidy International Airport. Due to scheduled once a week flights to and from the island, these works had to be completed in less than one week, so Fyfe derived a methodology utilising 3D laser scanning technology to ensure the maximum amount of data could be collected in the short time frame provided, whilst still maintaining the level of precision required for airstrip pavement surveys.

The resultant pointcloud enable a highly detailed 3D surface mesh to be created, at approximately 50 mm spacing between triangle nodes. In addition to this, the runway line markings and light locations could be digitised from the scan data and provided in AutoCAD DWG format.

Fyfe’s role and responsibility

• Undertake logistics planning for survey activities on a remote Pacific Island, ex Adelaide, Australia (including the provisions of over 100 kg of survey equipment as excess luggage).
• Undertake 3D Laser Scan survey for 2000 m long x 30 m wide airstrip, runway end safety areas, taxiways and apron.
• Undertake control survey including precise two way levelling run.
• Undertake Quality Control survey to ensure integrity of scan data once reduced to a single pointcloud data set.
• Edit and clean scan pointcloud data.
• Create a 3D surface mesh of the paved areas from the pointcloud data and export to Land XML triangle faces and edges.
• Digitise runway line markings from the pointcloud data and provide as 3D AutoCAD DWG linework.
• Digitise airstrip lighting and provide as 2D AutoCAD DWG blocks.

Fyfe was contracted to provide project management, engineering and planning services in a scoping study for the Cedar Grove Camp. We delivered strategic advice to support the development of a 500-bed accommodation camp with a value of $250 million.

The scoping study included a detailed review of the region’s mining, gas and infrastructure projects to demonstrate that a demand of additional accommodation was required in the area.

Fyfe’s role and responsibility

• Project management
• Scoping and demand analysis for the region
• Negotiations with council.

To facilitate a new alignment design and intersection relocation, DCINT required a detailed survey along Channel Island Road and Wickham Point Road intersection extending to the 100 m-wide road reserve boundary.

Fyfe’s role and responsibility

• Survey cross-sections at 25 m intervals along the identified road corridor
• Lodge a traffic management plan
• Oversee traffic management on site
• Conduct job safety analysis and proceed with survey in compliance with the analysis
• Process quality audit data
• Supply deliverables to client.

QGC engaged Fyfe to undertake inspection and non-destructive testing of the concrete footings at the various QGC gas assets in Chinchilla.

Fyfe’s role and responsibility

• Visually inspect the concrete footings
• Measure cover to reinforcement with a cover meter
• Undertake carbonation testing of a sample of footings
• Undertake chloride contamination testing of a sample of footings
• Prepare report on the findings.

Santos continues to expand the Fairview, Roma and Scotia Coal Seam Gas Fields, and is using a standard wellhead gas gathering skid, developed by Fyfe, for all wellheads and standard flowline components.

Fyfe’s role and responsibility

Fyfe design for gas and water gathering systems includes:

• Two-phase separator sizing and design
• FEED studies
• Detailed mechanical design
• HAZOP facilitation
• Detailed E&IC design (power and control systems and telemetry)
• Issuing of IFC packages and other documentation required for construction.

Fyfe engineering and survey services for wellhead connections and gathering systems and flowlines (gas and water) include:

• Location and survey for over 300 wells
• Survey and route selection for over 500 km of flowlines
• Modelling to determine pipe diameters and reduce gathering system pressure drops
• Test packs for hydraulic and pneumatic testing.

Santos required standard well head equipment for its CSG field in Queensland. The project began with conceptual design, and ran through the HAZOP process and detail design, and produced a construction package for use by the client.

The rollout of this standard was approx 30 units in the first year, 50 in the second and more in subsequent years.

The well head control package uses a ROC 809 RTU with various pressure, flow and level transmitters and is powered by solar panels and batteries. An optional module has a gas-fuelled generator, variable speed drive and progressive cavity pump to dewater the well in the early phases of it production life.

The instrumentation monitors production rate of both gas and water and well pressure. The safety system includes shutdown of the well on various faults including a SIL level 1 loop. All data collected on site is available remotely via the SCADA system. Most transmitters are HART devices running in multi-drop mode, which saves on power consumption and capital costs.

Fyfe’s role and responsibility

• Specification of the RTU program
• Functional testing of the two well heads at site
• Construction support.

Fyfe carried out surveying activities over a three month period for Fulton Hogan’s construction crews as a part of Coober Pedy’s regional airport upgrade project.  This upgrade included the widening of the main runway, improvement of the taxiways and re-marking of all pavements to meet current airport standards.

• Re-establish airport site datum and survey control.
• Locate existing bitumen, calculation of new runway and taxiways.
• Calculation and set-out of the new runway extents.
• Placement of offset marks with calculated elevations.
• As constructed survey of the finished surface.
• Set-out of line marking to strict aviation standards.
• Work with construction crews and air traffic management on an operating runway.

A new 170 km DN 100 oil pipeline from Cook in the Queensland Cooper Basin to the Merrimelia satellite in South Australia required route selection and alignment survey, modifications to existing facilities at Cook and Merrimelia processing plants and assessment of a new flexible pipeline material.

Fyfe’s use of aerial survey and photogrammetry technologies for the alignment survey reduced the project schedule by three months and the cost by approximately $150,000.

Fyfe’s role and responsibility

Survey

• Preliminary route selection and line of sight survey
• Development of alignment sheets
• Coordination of Cultural Heritage clearance survey.

Engineering

• Development of the design basis and process control philosophy
• Process and mechanical design of facilities, and modifications to existing plant facilitation and close out
• Safety Management Study to AS 2885.1
• Assessment of a flexible pipeline material as an alternative to the normal fibreglass material
• Preparation of scope of work for construction cost estimate
• Preparation of all licence applications and liaison with government regulatory personnel in both Queensland and South Australia
• FEED report.

Fyfe’s just-in-time approach to construction alignment and as-built alignment surveys for a 171 km composite pipeline constructed using spider plough, enabled the constructor to meet a demanding construction deadline.

The methodology eliminated the downtime between construction survey and data delivery to the constructor. Fyfe selected and sourced appropriate GPS guidance equipment for the construction equipment, and then produced and managed the required data for construction.

Fyfe worked in front of the construction crew and on a daily basis:

• Undertook a construction alignment survey
• Converted the data to a compatible file format for the GPS guidance equipment
• Uploaded the guidance file to the construction equipment each morning
• Captured and saved the GPS tracklog for as-constructed data.

The constructor did not have to wait for construction issue alignment sheets and the survey crew, who maintained a full-time presence on-site, made the required alignment adjustments in the field at the time of construction.

Fyfe’s role and responsibility

• Selected and sourced appropriate GPS equipment to be fitted to the constructor’s spider plough
• Completed construction alignment survey
• Produced and managed GPS data files for construction and as-constructed
• Produced as-constructed alignment sheets.

Fyfe’s role and responsibility

Detailed environmental impact assessment (EIA) for construction of a flowline between Cook and Merrimelia in outback SA and QLD. Fyfe assessed biodiversity of the alignment based on vegetation communities, flora and fauna observed during ground truthing. The EIA was then issued to Government authorities as part of licence approval requirements.

Project 

• Field survey techniques were used which enabled the delivery of Fyfe component of projects ahead of schedule.
• All deliverables were verified and issued in accordance with QA procedures with no client complaints or issues received.
• Project was delivered with the agreed budget.

Referees

• Peter Min
• Santos Lease Coordinator
• 8116 7753

Santos Ltd needed survey, spatial and engineering consulting to complete a pipeline application, route identification and design. A fix wing aerial survey gathered high resolution ortho-imagery and a digital terrain model captured and assessed the topography, land systems, existing infrastructure and vegetation to determine pipeline design.

The initial pipeline alignment planning and determination of the required area for imagery relied on GIS and GIS data sets. Available GIS data sets used were land system, drainage systems, flood data, infrastructure, civil infrastructure, topography, vegetation, environmentally sensitive areas, culturally sensitive areas, existing pipeline and pipeline furniture. Planning for the pipeline line of sight was quick, accurate and efficient, and aerial imagery was acquired within budget.

Fyfe’s role and responsibility

• Develop accurate pipeline line of sight with time and budget constraints.
• Acquire high resolution ortho-photography.
• Plan and design pipeline within project scope.
• Use full range of GIS data to assist with accurate and timely development of planning and approval documentation with minimal ground survey.

Fyfe was engaged to complete visual inspections of above ground oil flowlines throughout the Cooper Basin to assist Santos in their integrity management requirements.  Santos and Fyfe developed a reporting method in excel that could be completed directly in the field and then uploaded into the Santos Pipeline Integrity Management System.

Fyfe’s role and responsibility

Fyfe completed visual inspections of 195 above ground pipelines using agreed guidelines for recording of the following:

• Identifying and recording any evidence of corrosion. Where corrosion was found, a thickness measurement and pit depth measurement was taken.
• Any reference to corrosion on the pipeline required a thickness measurement and accompanying photo.
• As it was impossible to check every centimetre of pipeline touching the soil, the bottom of the pipeline was checked whenever the soil characteristic changed, for example, sandy dune country versus clay pan. Where there was evidence of corrosion, photos were taken and the type of corrosion was recorded.
• Where pipe supports existed, a photo of the pipe supports was taken to demonstrate the particular success/failure/effectiveness of the pipe support system for the particular soil type in question.
• Evidence of pipeline signs was recorded, especially when the pipeline was buried.
• An overall summary of the pipeline was made in the comments section of the spreadsheet – i.e. pipeline in good condition, all above ground or, pipeline condition hard to determine, many buried sections under sand dunes, no visible corrosion evident or, pipeline has several corroded areas and is still on line.

As part of Santos’ Cooper Infrastructure Expansion Project (CIEP) Santos engaged Fyfe to develop the concept design for several hundred new wells with associated flowlines and gathering lines into selected satellites in the Cooper Basin. Concept design also included a new trunkline from Gidgealpa to Moomba and a return fuel gas line from Moomba to Gidgealpa.

Big Lake Flowline Network Concept Design (yellow and black dashed lines represent new pipelines)

The work considered the wells as part of Stage 1 or Stage 2 activities to be implemented over an 8-year period. The wells were grouped into 21 networks feeding into five satellites (Big Lake, Daralingie, Gidgealpa, Tirrawarra and Moomba North).

Fyfe’s role and responsibility

Concept design services 

• Project management, project controls, earned value weekly reporting
• Establishing a design basis for all wells and associated field networks
• Mapping and desktop route selection using GIS and topographical data
• Material selection and pressure limit selection
• Evaluation of network options
• Hydraulics calculations to establish pipe sizing
• Preliminary corrosion mitigation definition
• Investigation of likely tie-in for F/G and trunkline tie-ins in Moomba plant
• Pipelines concept engineering report
• Cost estimating
• Preparation of engineering and construction schedule
• Assessment of project execution integration opportunities.

Deliverables

• Preliminary design basis for all pipelines, setting maximum allowable operating pressure (MAOP) and temperature limitations and other relevant design parameters as appropriate, with reference to the ‘Overall facilities basis of design for concept development’ (Document no. 5335540-G1-BoD) for fuel gas line(s) and Gidgealpa trunkline.
• GIS-based mapping of proposed overall pipeline networks, and more detailed mapping within each major field.
• Detailed listing of all pipelines by type, diameter, length, service and field as necessary to define the overall scope and scheduling of construction works.
• Hydraulics report detailing all assumptions, inputs, calculations and outputs for each pipeline sized.
• Summary level concept engineering report presenting all key technical recommendations.
• Cost estimate methodology document.
• Class 3 (+30%, -20%) cost estimate and basis of cost estimate for supply and construction all pipelines works.
• Class 2 (+20%, -15%) cost estimate and basis of cost estimate for the front-end engineering design (FEED) phase engineering including further project planning, costing, procurement and tendering support.
• Schedule estimate methodology document.
• Proposed schedule of construction of all pipelines to ensure that Basin Development Plan ‘on-line’ dates for each well are accommodated, for delivery of production as scheduled.
• Level 2 schedule (30–250 activities) and basis of schedule from FEED through to 2018.
• Level 3 schedule (250–1000 activities) and basis of schedule for the FEED phase.

Software

Pipeline engineering

The fire and gas system protects and shuts down unmanned compression stations on a major pipe line if a dangerous condition is detected. The stations are remotely operated from a central control room.

The existing separate fire and gas systems had reached the end of their economic life at a site in the Flinders Ranges and were replaced by new system was based on a safety PLC (HIMA).

Capital costs were extremely important to the client and were contained to approximately $850,000, 20% less than a previous similar project. The 16 weeks to FAT procurement time in the 6-month project was reduced to 14 week on-site for one major item.

 Fyfe’s role and responsibility

• Adapt the design from a similar compressor station to CS#6
• Select and procure all equipment
• Produce hazardous area dossier
• Undertake construction management (EPCM) of the new system
• Program commissioning around planned outages with guaranteed restoration of the plant of 1 hour if required by production
• Manage the technical details and interface between all parties, including other suppliers, for integration of Citect SCADA, AB PLC, HIMA PLC and Valmet
• Subsequently awarded CS#4 project in 2009.

Santos relocated the CS1 compressor station from Fairview to Castle Hill in the Arcadia Valley.

The existing compressor station was disconnected from its footing system at Fairview and shipping to the new site at Castle Hill where it was to be installed on a new footing system.

Due to the distance of the new site from an economical concrete supply the new footing system was to minimise the use of concrete. Steel piles were chosen as the footing system.

Fyfe investigated a steel grillage footing system for the compressor footings but found that the steel grillage system had insufficient mass to restrain the dynamic loads. Reinforced concrete was adopted for the compressor footings.

To inform the dimensional set-out of the footing system Fyfe undertook a 3D laser scan of the existing facility with supplementary traditional surveying for the critical compressor holding down bolts where the scanner could not see the bolts due to the adjacent piping and machinery.

Fyfe’s role and responsibility

• 3D laser scan and survey of the existing facility.
• Design of site levels to suit the relative levels of the relocated plant and to consider the natural falls of the new site.
• Design of earthworks to direct overland water flow around the relocated plant.
• Facilitate a footing constructability workshop with Santos’ installation contractors.
• Design of new footing system consisting of steel piles.
• Investigation into alternative footing systems for the compressors.
• Design of the compressor footing.
• Design of sound wall constructed from shipping containers.

Fyfe partnered with Transfield Services in an effective engineering, procurement, construction and management (EPCM) solution for Daandine Metering Station on the Braemar 2 Pipeline project. They installed a temporary meter skid to allow initial flows before EPCM of the permanent metering station.

Fyfe’s role and responsibility

Detailed mechanical, electrical and instrumentation design, construction and commissioning assistance including:

• Development of the design basis
• Detailed design (including meter runs and filter vessel)
• HAZOP facilitation and close out
• Preparation of equipment data sheets
• Development of the RTU programming specifications
• Survey (construction set out)
• Preparation of construction documentation including mechanical and E&IC
• Construction management
• Preparation of the hazardous area dossier (including the hazardous area classification)
• As-built documentation.

When Momentum Engineering planned to expand APA’s 50 Solar Centaur compressor stations in the eastern states of Australia, they turned to Fyfe (Robert Elks & Associates) who had delivered for them on the Wyloo West and Neds Creek compressor station developments during 2008 and 2009.

The site was located on extremely reactive clay and the footings had to be designed to sustain soil volume changes with extreme seasonal moisture variation.

Fyfe’s role and responsibility

• Work with Momentum Engineering  to design a cost-effective standard project template for the station within a tight schedule
• Assess the geotechnical report, particularly of the extremely reactive clay
• Liaise with the geotechnical engineer to establish footing design parameters
• Design screw piles to support all footings and infrastructure
• Liaise with the piping and mechanical departments of Momentum Engineering to establish the design data
• Complete civil and structural detailed design
• Ensure quick installation of the piles to fit the tight construction schedule.

The Devil Creek Gas Plant is located on Mardie Station pastoral lease approximately 45 km south-west of Dampier, in Western Australia’s north-west. The plant’s onshore facilities consist of a two-train gas plant designed to process 200 million standard cubic feet per day. REA (a Fyfe Company) provided detailed engineering services for civil works at the accommodation village. The completed village, located in the vicinity of the plant, is accommodating plant operators, contractors and visitors. The engineering design was carried out with full awareness of the environmentally sensitive areas surrounding the village.

Fyfe’s role and responsibility

Engineering design was carried out for:

• Earthworks
• Site drainage
• Typical accommodation unit drainage
• Access roads
• Wash down pads
• Retaining walls
• Footings
• Signage
• Tanks and storage containers tie down
• Walkways.

Fyfe is a pre-qualified member of the DPTI Survey Panel (since 1995).

Sites surveyed in 2013–2014 include: Prospect Road Kilburn; Birkenhead Bridge Port Adelaide; Jervois Bridge Port Adelaide; St Vincent Street Port Adelaide; Golden Grove Road, Modbury North; Main North Road Willaston; Emerson Crossing, Clarence Gardens; and RM Williams Way, Clare.

Fyfe’s role and responsibility

• For construction surveys, use a design file supplied by DPTI civil engineering office.
• Re-establish survey control on site, verify data and mark construction strings with offsets for road pavement formation.
• Complete follow-up surveys after construction to determine vertical accuracies of surface and pavement thickness.
• Report as-built surveys to strict DPTI standards and formatting, with results formatted to the nearest millimetre.
• On accompanying reports, detail site specific conditions, equipment that has been used as part of the survey, control inaccuracies, independent check strings, survey codes, compliance reports, survey control and anomalies.

As part of the early works for this major project, Fyfe were contracted by DPTI in 2009 to organise and locate Underground services for portion of the Northern Connector project. Fyfe organised and co-ordinated the subcontractor for these works as a contract under the Surveying Panel of preferred suppliers to DPTI.

Initially, Underground services and selected depths were required to be located. Ground marking of underground services was undertaken by a DTEI contracted supplier for “Engineering Surveys – Location and Depthing of Underground Utility Services” and these locations surveyed by Fyfe and supplied MGA 94 Zone 54 coordinates with AHD levels to DPTI.

Inductions were completed for access to SA Water land and also for the Salt Pans site.

A second instruction for work involved calculating MGA coordinates for the Underground Services points to be set out for potholing. Fyfe Set out coordinates and then recorded an AHD level for the natural surface and label each point and crosschecked that the type of service shown on the spreadsheet matches on the ground- these were then potholed for depthing the service by the contractor.  Depths were added to the spreadsheet.

The third instruction involved location of about a dozen Boreholes that had been drilled. Deliverables included a spreadsheet showing the borehole number and coordinates and supply of a Genio file for the locations.

Fyfe’s role and responsibility

• Coordination of subcontractors for the location of underground services.
• As-Built  surveys to DPTI (Transport) strict standards for design.
• Location of Pot holing (with others) for service depthing
• Establishment of GPS survey control
• Preparation of survey data in AutoCAD and 12D file formats.

Beach Energy’s well leases in the Cooper and Eromanga Basins require ecological constraints assessments, which are also used for biocondition reporting for the Queensland Government.

Fyfe’s role and responsibility

• Onsite assessment of potential constraints such presence of threatened species, habitat areas and listed ecological communities.

This largely unused site was re-mediated and redeveloped by the Land Management Corporation into industrial allotments.

Fyfe’s role and responsibility

• Level and feature survey to Department of Planning, Transport and Infrastructure strict standards
• Site feature and level survey to the water’s edge
• Perimeter boundary survey of the site reviewing historic easements and rights of way
• Closure of an unused road and arranging new titling
• Subdivision of Crown lands into more than 200 metres of new road and 35 industrial allotments
• Set out surveys for design and construction, volume calculations and earthworks calculations.

Bunnings proposes to redevelop the 24 hectare Islington Railyards on Churchill Road, Islington, to create a major retail destination, incorporating a mix of bulky goods and hardware tenancies, alongside a major supermarket, shopping centre and a mix of other retail opportunities.

Fyfe has been engaged for multiple roles over the life of the project.

Fyfe’s role and responsibility

Land survey (completed)

• Outer boundary and certified land division survey
• Land division to excise public road
• Lease plan preparation for registration with the Lands Titles Office:

• ‘Ownership of land is by lease’
• Registered or title
• Covenant rights/easements.

Engineering survey (current)

• Pre-construction topographical/detail survey
• Set-out survey of new Bunnings
• Building and civil surveys
• As-built survey of water main and stormwater levels.

Elizabeth Park is a 36 allotment brownfield sub-division located in Elizabeth Park. Fyfe has been involved with the project from pre-feasibility stage, including detailed design delivery, through to contract administration, practical and final completion certification.

A key outcome of our involvement with the development was the support we provided when the principal contractor went into liquidation. Fyfe assisted the government through this process, allowing for a smooth transition and appointment of a new principal contractor to complete the works.

Fyfe’s role and responsibility

• Infrastructure and staging assessment
• Opinion of probable cost
• Authority negotiations and advocating to council for optimised stormwater solutions
• Liaison with Development Assessment Commission, council, SA Power Networks, SA Water, Telstra, NBN Co and APA
• Project team formulation including tendering, evaluation and appointment of consultants
• Management and coordination of project team to ensure detailed design delivery
• Obtaining approvals with the authorities
• Detailed design of all civil works
• Tendering, assessment and recommendation for the construction of the works
• Contract administration.

Elizabeth Village is a 64 allotment retirement community on Andrews Road, Penfield. Fyfe’s role on this greenfield community titled development included survey, engineering and tender documentation.

Fyfe’s role and responsibility

• Project Management
• Engineering Survey
• Project Engineering and Service Authority Liaison
• Obtaining approvals from all relevant Authorities
• Geotechnical investigation and pavement design
• Civil and Stormwater detailed design
• Tender Documentation.

Fyfe has been engaged to conduct Environmental Assessments for flowline corridors and well locations. The scope of these assessments includes:

• Flora
• Fauna
• Land use
• Water resources
• Air and noise
• Wetlands
• Cultural heritage.

Fyfe’s role and responsibility

• Assessment of environmental impacts of proposed development.
• Determine and recommend management controls.
• Completion in accordance with Santos Health, Safety and Environment systems, including approval and acceptance.

Fyfe’s client was experiencing various integrity issues with large process vessels in the Mt Isa acid plant.  A number of inspections and surveys were planned and executed around plant shutdowns and scheduled maintenance activities.  Objectives included determination of failure modes, conditions assessments, survey input for detailed design of repairs/modifications and risk assessments for vessel entries.  Fyfe provided a range of specialist engineering survey, drafting, engineering and project management services.  Challenges included remote work site logistics, hazardous work environments and short time frames.

Project Details Part I – Exterior Vessel Inspections and NDT

The acid plant is attached to a smelter and cleans furnace off gas and produces sulphuric acid; two vessels were to be inspected and assessed the Final Absorption Tower (FAT) and the Drying Tower (DT), this case study will focus on the works carried out on the FAT.  The FAT is a large process column (10 m diameter x 24 m high) of carbon and stainless steel construction divided into two chambers with the lower chamber lined with refractory bricks and the upper chamber filled with 300T of ceramic packing.

The vessel shell was in poor condition with extensive patch work and previous repairs, visual inspections showed evidence of shell deformation and bulging.  A critical area of concern was the internal refractory lining integrity as this forms the main structural support of the vessel with the shell’s primary function being to containing the process fluids, however the refractory could not be directly assessed while the plant was operational.  A knock on consequence of any unscheduled shutdown of the acid plant would be a shutdown of the associated smelter.

An extensive external inspection program was undertaken while the vessel was in service.  Ultrasonic thickness testing was done over the entire shell with a maximum grid spacing of 150 mm, this required extensive scaffolding and was initially presented in a spreadsheet.  Thermographic imaging of the shell was done yielding hundreds of images initially presented in a written report.  Extensive 3D laser scanning of the vessel shell was done to determine nozzle locations, strake weld positions, repair patch locations and to analyse the shell deformation from a design baseline.

Discussions with the client engineers resulted in a plan to re-process all inspection data and create deliverables that would present the data on a common reference grid enabling correlation of artefacts from the different inspection methods.  A vessel shell development was drafted with a corresponding reference grid being established, all data was then transposed onto the same grid system.  Samples of the final mapped deliverables are presented in below.

Other deliverables produced included 3D point cloud data in various formats, and as-built 3D models of the Vessels.  All deliverables were presented on the local plant coordinate system with recovery survey marks left on site to enable coordination of any subsequent measurements and to allow any precision construction set-out.

The project and deliverables were well received by the client and enabled their integrity engineers to easily correlate the different inspection results, improving the interpretation and comparison between the different data types.  The project outcome aided the client in their failure analysis and planning for maintenance and further focused inspection.  As a footnote some research yielded the term “Multimodal NDT Data Fusion” for describing the process of data manipulation and deliverable format.

Project Details Part II – Internal Vessel and Refractory Inspections

Approximately 18 months after the initial inspections and surveys Fyfe were contacted by the client to submit a proposal to conduct a 3D laser scan of the FAT’s internal chamber.  Criteria for the proposal were to be extremely challenging and the time frame was extremely short with field work needing to commence just two weeks after the initial contact.  The principal objective was to assess the condition of the refractory brick lining, providing input information to a vessel entry risk assessment and planning for any necessary repairs.

Planning and logistics were critical to success and client also needed to review the results on site on the same day as the survey.  A scanner support mount and bracket need to be designed and fabricated, the instrument had to be shipped to site and a survey team trained in its use.  The scanner would be installed into the manway by the client fire and rescue team wearing full PPE and breathing apparatus, operation would be done remotely by Fyfe surveyors via an Ethernet wired connection.

Careful planning and preparations lead to a successful field campaign with data visualised during capture and quickly prepared and presented during a vessel risk assessment meeting on the afternoon of the survey.  The entire refractory brick lining of the lower chamber could be inspected, visualised and measured during the onsite meeting.  Due to active laser measurement, no ambient light was required to gather the measurements, also the instrument proved to be quite resilient to the conditions so extremely high resolution data was able to be captured.  Upon inspection it was instantly evident there had been partial collapse of the refractory brick work, the accurate scan data enabled a detailed “virtual” inspection including checking and measurement of brick alignments.

Ultimately the scan data enabled the client to make decisions on safe vessel entry and necessary corrective actions for implementation during the shutdown.  The data was also further analysed post shutdown against external data captured previously which provided further detail on shell deformations, refractory thickness and future areas to focus detailed inspections and potential repair works.

This land division development will deliver 2,000 dwellings over a 121 hectare site. The site was predominantly farming but contained a significant stormwater drain. Survey information was required by planners, City of Playford’s engineers, Department of Planning, Transport and Infrastructure (Transport) and other authorities for planning purposes.

Fyfe’s role and responsibility

• Complete a level and feature survey to DPTI (Transport) strict standards
• Locate the stormwater drain to the water’s edge
• Locate site trees with feature attributes (for arborist report)
• Complete road corridor survey including crossing services and drains
• Survey site boundaries for future allotment calculation
• Provide AutoCAD and data file for design purposes.

The Fairview gas production area in the Bowen Basin, of approximately 5000 square kilometres, contains some 130 wells. Santos required data capture of infrastructure and topographic information such as pipeline centreline and pipeline features as well as the natural environment so that it could build and maintain an accurate GIS dataset of location and attribute information. The surveyed data is to be incorporated into Santos GIS datasets on an ongoing basis.

Fyfe’s role and responsibility

Fyfe performed the large scale as-built survey project to:

• Accurately capturing as-built information for the Fairview area
• Migrating data into GIS using current Santos data standards
• Identifying and researching anomalies and correcting as necessary
• Migrating data quickly and effectively.

Santos required a vehicular road access track along a cliff face to a proposed lease on the crest of the mountain. The 2 km road design allowed for tiered embankments adjacent to the road to minimise hazardous risks.

Fyfe’s role and responsibility

• Coordinated survey services and prepared civil road designs
• Designed the road in 3D modelling software that analysed potential road paths for optimised road grades, cut/fill volumes, and vehicular turning movements
• Investigated a ‘low risk’ tiered benched embankment system and suitable road grades for heavy vehicles.

The investigation was carried out in order to determine the hazard categorisation of the existing fluid containment dams, provide recommendations for improvements and final certification.

Fyfe’s role and responsibility

• Assessment of the geotechnical integrity of the dam
• Hydrological assessment of the site and dams
• Environmental Hazard Category assessment for the dam
• Liner integrity assessment
• Soil investigation and testing of the site to determine impact to the environment of possible fugitive contaminants
• Recommendations for remedial works.

The Santos GLNG Project is a US$18.5 billion pioneering venture to convert coal seam natural gas (CSG) to liquefied natural gas (LNG) for export to global markets.

Fyfe has been surveying the upstream infrastructure for gas and water flowlines, powerlines, roads and well sites. Fyfe established the survey control network for the entire project that facilitates further survey activities by future contractors.

Fyfe’s preliminary survey of the infrastructure facilities allowed Fluor to progress engineering design and construction work required for expansion of the GLNG project.

Fyfe’s role and responsibility

• Set out and survey flowline corridors
• Set out and survey road corridors
• Set out and survey powerline corridors
• Set out all geotechnical test pits and boreholes
• Establish site survey control network
• Produce buried foreign service plans.

Ashton Valley Fresh, a fruit juice and beverage manufacturing company, needed a new wastewater treatment plant for its apple juice processing facility. They asked Fyfe Automation for an integrated automation solution. Fyfe Automation implemented high-end existing technology, making this process the first of its kind in the southern hemisphere. The system uses an advanced process control sequence that combines continuous and batch control methodologies, and has many process optimisations, equipment longevity and personnel safety features.

Fyfe’s role and responsibility

• Designed, project managed and commissioned the automation and instrumentation systems, which included a main plant programmable logic controller (PLC), several integrated primary screening and dewatering machines, automated bio-reactor control, filtration systems, pumping and level control, water quality monitoring, pH and dissolved oxygen control, flow and level monitoring/control and specialist chemical dosing systems.
• Worked closely with the process designers to determine the optimum sequential process control, functional specification and then developed a detailed control system functional specification.
• Developed the main plant PLC program, which interfaces with two other PLCs over EthernetIP (peer to peer messaging) and can be monitored and controlled remotely from Head Office.
• Developed the human interface of 28 screens, which display visual representations of the overall plant layout and subsystems on separate screens.
• Introduced process optimisation, equipment longevity and personnel safety features, through hardware, programming logic and alarming in the control system design.

Development approval, under Esk Shire Planning Scheme, was granted to reconfigure the subject site into 107 residential lots, one lot for stormwater purposes and a new road, in four stages.

Fyfe’s role and responsibility

• Identified the physical layout of the site, and prepared and submitted a successful development application and planning report.
• Resolved, through collaborative effort, issues affecting the site, such as stormwater drainage, highway upgrades, good quality agricultural land, and pedestrian connectivity.
• Exhibited quality project management throughout the development, through liaisons with Council, Department of Transport and Main Roads, traffic engineers, noise engineers, civil engineers and most importantly the client.

Santos had a significant number of compressors that were underutilised with a number of machines consistently running in suction pressure control. The fixed suction pressure control point specified was far from optimal under normal operation.  By implementing the floating compressor control system, the suction pressure control point (and ROC trip point) is able to ‘self-optimise’ based on actual process conditions to:

• Provide maximum possible compressor utilisation
• Reduce the need for future compressor setup reviews
• Return engine to running at its rated speed (improved reliability)
• Improve reserves recovery
• Reduce compressor trips through improved liquids management and control.

With suction pressure control and trip points being calculated based on actual operating conditions, the set point becomes much lower during normal operation and will automatically increase when there is a process upset downstream causing higher discharge pressure. Direct measurement and control of the compressor cylinder discharge temperatures allows for live compensation for the ambient temperature changes instead of allowing for extreme heat at all times.

Fyfe’s role and responsibility

Santos engaged Fyfe to provide engineering support to deliver the following:

• Overview and historical data collection to set up design basis for each of compressor facilities
• Optimisation of flow meters, suction pressure (level) control valves, recycle valves, and restriction orifices for blowcase and purge
• Optimisation of gas wellhead operating pressures
• Resolving liquid handling issues in the facilities
• Support on the approval of Critical Drawing Change Request (CDCR) for implementation.

Significant periodic rainfall events were exposing sections of the Moomba–Adelaide pipeline. Fyfe was engaged to investigate the washouts and find a solution.

The investigations included flood mapping, site visits, survey and detailed design. They showed that the velocity of stormwater runoff at certain sections across the pipeline was higher than allowable limits.

The Fyfe rehabilitation solution combined stabilisation and water dispersion devices. An environmental benefit is that the work has minimised the silt being deposited downstream.

Fyfe’s role and responsibility

• Project management
• Survey
• Civil engineering
• Flood mapping.

Epic Energy, owner and operator of the Moomba to Adelaide Pipeline (MAP), required installation of a meter station to supply around 1 TJ/hr of natural gas to Timbercorp’s new hothouse off Frost Road near Virginia. The design of this station was different to other stations on the MAP due to the large reduction in gas pressure from around 7000 kPa to 350 kPa and consequent temperature drop. The job was completed in 4 months.

Fyfe’s role and responsibility

• Completed an EPCM type contract with responsibility for all work associated with the station including connection to the MAP, supply of all equipment, detailed design work and installation and commissioning.
• Installed a gas heater to compensate for temperature drop.
• Overcame long lead time delays for items such as gas regulators, meter and gas heater by placing orders at project initiation.

The Frost Road meter station was initially designed and installed in 2007 by Fyfe with the intention of a capacity upgrade at a later date. Gas demand necessitated an upgrade to the station to ensure it is capable of double the existing design capacity from 2,349 GJ/d to 4,698 GJ/d.

In order to increase the capacity of gas delivery from the Frost Road meter station and improve the reliability of the facility the following design changes were implemented:

• Replacement of the water bath heater with a unit capable of the new capacity.
• Allowance for meter proving capability (by meter upgrade), pressure regulation runs in a duty and backup configuration.
• The associated changes to cabling, piping, supports, footings and expansion of the site boundary.

Epic Energy’s key customer consideration is the target project execution window of 5 days.

Fyfe’s role and responsibility

• Fyfe provided engineering services for detailed design involving process, mechanical, structural and electrical disciplines which included the following deliverables:

• Documents – Design Basis, equipment and valve datasheets, equipment lists, construction scope of work, P&ID, PFD
• Calculations – Line sizing, equipment sizing (PSV, PCV, heater), stress analysis for pressure piping code compliance, hazardous area calculations
• Workshops including facilitation and associated documentation – HAZOP, SMS, Safety in Design
• Drafting – P&ID, PFD, piping layout and isometrics, foundation layout and details, structural steel, Hazardous area, termination diagrams, panel layout, instrument cable and earthing layout, cable block diagrams, cable schedule and junction box termination drawings.
• To complement the engineering services Fyfe provided survey services for the determination of existing site boundary and as-build location of piping, equipment and supports to ensure minimal on-site work through the use of prefabricated spooling.

Subcontract Structural Engineering Work completed for Priority Engineering Services,

from 2007 to 2012

• Olympic Dam, Whenan Shaft Chock Beams, 2007
• Olympic Dam, Auxiliary Boiler Shed, 2008
• Olympic Dam, Refinery Building, 2008
• Olympic Dam, Concentrate Unloading Slab, 2008
• Olympic Dam, Concentrated Pond 18m Light Pole, 2009
• Olympic Dam, Piperack support post, 2009
• Olympic Dam, Concentrate Pond Monorail, 2009
• Olympic Dam, Smelter 2 Table Feed Platform, 2009
• Olympic Dam, Auxiliary Boiler Platform, 2009
• Olympic Dam, Concentrate Receiving Facility Scales Platform, 2009
• Olympic Dam, Auxiliary Boiler D.A. Stand, Platforms & Stairway, 2009
• Olympic Dam, CAF Plant Truck Window Spray System, 2009
• Olympic Dam, Whenan Shaft Conveyor Platform, 2009
• Olympic Dam Expansion, Warehouse – Mezzanine Floor, 2009
• Olympic Dam, 1000T Surge Bin 4211BN1001 Refurbishment, 2009
• Olympic Dam, MESP Electrodes Cleaning frame, 2010
• Olympic Dam, Smelter 2, Sulphur Melting Tank, 2010
• Olympic Dam Expansion, Bag House Lifting Lugs, 2010
• Olympic Dam, Furnance 2 Scrap Bin, 2011
• Olympic Dam Bulk Bag Hoist Assembly – Design Review Verification, 2011
• Olympic Dam, Sheave Lifting Frame, 2012

Trevor John & Associates Pty Ltd (Now Fyfe Structural Division, SA), Subcontract Structural Engineering Work completed for Mynehart Engineering Services, 2007 to 2011

• Olympic Dam Expansion, Bypass Stack ST1007, 2010
• Olympic Dam Expansion, Smelter 2 Dust Pump Bench Footing, 2010
• Olympic Dam Expansion, Smelter 2 Dissolving Area Pipe Support Frame, 2010
• Olympic Dam Expansion, Smelter 1 – S02 Duct Support Structure Repairs, 2010
• Olympic Dam Expansion, Cyanide Bag breaker Roof Structure, 2010
• Olympic Dam Expansion, Mould Wash Platform, 2011
• Olympic Dam Expansion, Tailing Leach Tank Platforms, 2011
• Olympic Dam Expansion, Fin Fan Heat Exchanger Access Platform, 2011

Fyfe has been contracted by Santos to provide ongoing GIS data supply and maintenance. This data is supplied bi monthly and is subsequently incorporated into the Santos GIS data sets. The data is expected to comply and pass the assessment of a national standard with regards to entity and feature type, accuracy, location, naming conventions and standards, object feature codes and specific feature attribute information.

The GIS allows for and is currently used across most Fyfe projects in various spatial / visual analysis capacities. It allows for current, easily identifiable spatial and textual information to be disseminated and used across the organisation. The information may be presented in highly accurate digital and hard copy format (maps) as well as user interactive work spaces in multiple enterprise GIS. Furthermore, the GIS capability allows for Fyfe to perform analysis tasks on the data for planning purposes.

Fyfe’s role and responsibility

• Accurate data capture and migration into GIS data sets.
• Data Standard development and provide date within the specified data capture and attribution standards.
• GIS anomaly investigation through use of survey data, aerial imagery and communication with surveyors in order to perform existing error correction.
• Rigorous QA of location and attribute data.
• Spatial location assessment.
• Data capture includes  pipeline, pipeline features, topography, vegetation, infrastructure, hazards and crossings.

A power upgrade project became necessary for the Gidgealpa gas site in the Cooper Basin because power outages were adversely affecting gas production.

The equipment age of 30 years meant that failures were common and spare parts unavailable. The system’s manual operation also required extra generation equipment to be kept on-line at all times to cater for anticipated load. Three generators ran lightly loaded causing excessive maintenance costs and under performance when loaded.

The newly installed system fully automates the generators to start, synchronise and stop as required. It also fully shares active and reactive power. Remote diagnostics and management are possible, giving backup to local operators in the event of faults. The system is also connected to the iFIX SCADA system.

Load management was also applied to three motors that ran on demand to ensure the plant could run on two generators. These motors were interlocked with the spinning reserve of the generator system and this was implemented in the existing on-site Allen-Bradley programmable logic controllers.

Fyfe’s role and responsibility

• Feasibility study
• Front end engineering design (FEED)
• Plant load study/maximum demand
• Shutdown procedure
• Commissioning
• Procedure and operational manual update
• Management of change documents.

Fyfe was engaged by Santos to undertake concept development, detailed design and construction documentation for the water supply scheme to support field drilling operations.

The water supply system included:

• New pond off-take and pump section lines
• New diesel driven skid mounted pump and associated pipe work
• 17 km rising main pipeline (reinforced thermo plastic pipe)
• Rising main outlet connection to above ground storage tanks
• Line of sight survey and alignment drawings.

Fyfe’s role and responsibility

• Preliminary and concept design development
• Front end engineering design documentation(FEED)
• Detailed design including development of datasheets, hydraulic calculations, PSV sizing , pump selection, road crossing design
• Development of engineering work packs and construction drawings.

Project outcomes

• The project was fast-tracked from preliminary design to construction documentation to meet tight operational time frames. Long lead items were identified early to ensure delivery would not delay construction activities.
• The water supply scheme was commissioned successfully and operator feedback was that the system met all project requirements.
• Following completion of well drilling activities, the pipeline system was reversed to capture wastewater and return waste water for treatment.

The developer Makris required a comprehensive site survey of its property, Gilles Plains Shopping Centre, for the purposes of planning and future design. The survey located features within and external to the site, and several feature surveys were carried out in stages.

Fyfe’s role and responsibility

• Complete level and feature survey to Department of Planning, Transport and Infrastructure (Transport) strict standards
• Locate site trees with feature attributes (for arborist report)
• Complete road corridor survey including crossing services and drains
• Complete property and lease surveys for registration on titles
• Survey and calculate site boundaries for future allotment calculation
• Complete land tenure surveys for planning
• Set out gridlines for construction
• Provide AutoCAD and data file for design purposes.

The Gladstone LNG is a project to convert coal seam gas (CSG) to liquefied natural gas (LNG). The CSG is piped from the CSG field at Fairview 435 km to Gladstone.

The existing digital cadastral data base (DCDB) was not a reliable system in rural and remote areas. It did not match the surveyed compiled boundary locations of boundaries and boundary fences, and required adjustment along the pipeline route to agree with the surveyed location of road boundaries, boundary fence lines, parallel property and easement boundaries, and boundary corners in close proximity to the pipeline.

The corrected DCDB allowed the final position of the pipeline to be assessed against correct information for boundary location and offsets, easements, and stock route and road reserve locations. It assisted in the design of pipeline bores/drills, profile, type and cover through major rail and road crossings, and with project GIS for detailed design, GIS management and alignment sheet preparation.

Fyfe’s roles and responsibilities

• Full search of survey plans and existing control survey marks; confirmed ground survey and marking of desk top route selection
• Used quality procedures for land access and contact details to keep landowners informed
• Profiled the 40 m wide pipeline corridor
• Prepared boundary layers for Zone 55 and for Zone 56, allowing for the difference in zones
• Adjusted DCDB to the property boundaries compiled in the cadastral surveys
• Produced a final adjusted DCDB capable of informing accurate proposed easement plans to cover the proposed pipeline
• Presented the final DCDB adjustment in MapInfo with subject land parcel attributes from the existing DCDB polygons still intact along with landowner attributes added by Santos.

Santos required a ‘fit for purpose’ design of a tank bunding area, water containment systems and roads for a new petroleum well lease site in New South Wales. The site had significant environmental constraints imposed by the environmental licensing. The design was tailored to meet the constraints and not impact on operational requirements of the lease. This project made the first use of self bunding water storage tanks.

Fyfe’s role and responsibility

• Detailed civil design and documentation of construction drawings
• Scope of work for civil works
• Mechanical engineering works for the lease
• Electrical engineering works for the lease.

Australian Tailings Group Ltd intends to extract magnetite from the creek bed, beneficiate it and return rejects to the creek bed. The historic goldfield site, near Yunta in the Flinders Ranges Region of South Australia, has been mined since the early 1800s.

An ecological assessment was required to gain a better understanding of the baseline ecology of the site. The heavy level of disturbance had negatively impacted on vegetation and flora but had generated good quality fauna habitat. Further detailed trapping and survey efforts are scheduled for this site later in 2014.

Fyfe’s role and responsibility

Undertake field surveys and reporting.

Fyfe (Robert Elks & Associates) civil engineering design services to Enerflex Process were part of an engineering, procurement, construction and pre-commissioning contract for the Gorgon domestic gas custody transfer meter station.

The project site, near Compressor Station 1, is about 150 km south of Karratha in WA. When completed, the facility will enable Gorgon joint venture partners to supply gas to the Dampier to Bunbury natural gas pipeline.

Fyfe’s role and responsibility

• Assess the geotechnical report
• Liaise with the geotechnical engineer to establish footings design parameters
• Assess borrow pits in the area to source the required fill material
• Complete a risk assessment on available fill material to achieve the criteria
• Complete a risk assessment on long-term settlement of the pad
• Liaise with piping and mechanical departments of Enerflex to establish design data
• Complete civil and structural detailed design.

Due to load growth within the Adelaide gas distribution network, APA undertook a project link two north south transmission pipeline mains with an east west transmission pipeline.

Fyfe was engaged to undertake the detailed design phase of the project including:

• Detailed Design
• Alignment review
• Full construction documentation
• SMS
• Cathodic Protection.

The pipeline has since been constructed.

Fyfe’s presence in Darwin started with the purchase of a small Darwin survey company, John Matthews & Associates in 2008. Fyfe has grown that small practice of five to a point where it now employs over 30 people in Darwin and Alice Springs.

Many of Fyfe’s Northern Territory based survey team have worked on projects on Groote Eylandt, these include:

Fyfe’s presence in Darwin started with the purchase of a small Darwin survey company, John Matthews & Associates in 2008. Fyfe has grown that small practice of five to a point where it now employs over 30 people in Darwin and Alice Springs.

Many of Fyfe’s Northern Territory based survey team have worked on projects on Groote Eylandt, these include:

Origin Energy flowlines project in the Denison Trough included the engineering design of the wellhead equipment and connection of three wells via a total of 1500 m of flowlines to three different existing flowlines. Fyfe partnered with WDS in an EPCM solution for the project.

Fyfe’s role and responsibility

• Route selection survey
• Detailed design
• Design coordination
• BOM
• Cost estimate
• Facilitation of procurement via Origin Energy system
• Project management
• Construction supervision
• As-built drawings and dossier
• Commissioning of the flowlines.

Ecosol gross pollutant traps are installed throughout Australia for the management of water quality.

Fyfe has provided structural engineering design services to Ecosol for these traps on an ongoing basis for many years.

Fyfe’s role and responsibility

• Design and document Ecosol gross pollutant traps for installations throughout Australia.

The City of Onkaparinga has implemented a number of catchment wide initiatives aimed at addressing issues associated with existing drainage systems within the Hackham Industrial area catchment. The initiatives aim to address formal requirements enforced by the Council and, more specifically, address site specific drainage issues affecting local roadways and residents. The site covers a total area of approximately 41.6 ha and the land use is generally industrial land. The site has an upstream catchment of approximately 103.3 ha which drains towards the site in a number of different locations. The aim of the project was to investigate the capacity of the existing stormwater drainage, identify any infrastructure upgrades/ extensions required to meet Council service standards and design and documentation of any drainage system upgrade or extensions.

Fyfe’s role and responsibility

• Detailed survey (2013 and 2015)
• Catchment definition and hydrological study
• Investigation of existing drainage system
• Stormwater drainage design and modelling
• Sub-catchment plans, concept drainage design layout plan including the existing and proposed pipes, pits, overland flow paths and relevant stormwater management devices and drainage longitudinal sections for all the roads
• Stormwater calculations for major storm events including backwater analysis of the surface drainage flow, including the volume of flow, depth of water, maximum velocity and extent of inundation
• A concept cost estimate for drainage scheme.

The HBWS gas fields are located in the offshore Otway Basin in Victoria but due to their proximity to shore, and to avoid sensitive marine environments, they are being drilled using extended reach drilling techniques from onshore location and tied back to the existing Otway Gas Plant.

Fyfe was engaged by McConnell Dowell to undertake an inspection of the HBWS Road (refer figure below).  In addition to the road survey, photographic documentation of specific access points along the HBWS pipe alignment was also undertaken.

Fyfe’s role and responsibility

• Visual examination of roads indicated as part of the HBWS road usage.
• Photographic documentation of indicated access points along the HBWS pipe alignment.
• Assess the existing conditions of the roads and identify the types and locations of major defects.
• Provide a written report of the findings from the road dilapidation survey.

For the 52 ha Hamley Bridge development of 450 residential allotments, land to be rezoned residential could not put people or property at flood risk. Gemtree required a flood mapping and infrastructure report to support the residential land rezoning.

Fyfe’s role and responsibility

• Prepared an infrastructure report reviewing existing and required future infrastructure to service an additional 450 allotments
• Specified in the report how water, electricity and wastewater infrastructure would be built and funded for the staged development over the next 10–15 years
• Included in the report indicative costs to develop the proposed required infrastructure, including headworks and augmentation fees.
• Prepared hydraulic and hydrology modelling of both Light and Gilbert rivers catchments to demonstrate the impact of the 100 year ARI flow on the proposed residential development zones
• Flood mapping included:
• Definition of the overall catchment of each river up to their junction at Hamley Bridge township
• Analysis of catchment characteristics
• Hydrological calculation for 1 in 100 year ARI flow rates generated by each catchment using the ‘rational method’
• Extraction of cross sections along both rivers using the GIS contours of the site
• Analysis of the characteristics of each river (cross sections, slopes and Manning roughness coefficient)
• Flood mapping simulation using Hydrologic Engineering Centre, River Analysis System
• Recommendations of earthwork fill changes to protect land from flooding.

1 in 100 Year ARI Flood Mapping Plan

The Amadeus Basin to Darwin gas transmission pipeline and its associated sites required a hazardous area study, and as-built data and a clear picture of current plant equipment condition.

Fyfe’s role and responsibility

• Produced a hazardous area classification report for each site
• Produced a hazardous area dossier for each site
• Produced hazardous area plans and elevations for each site
• Conducted installation inspections of equipment
• Compiled 3-dimensional scans and photographs of each site in electronic files
• Produced as-built drawings of sites using 3-dimensional scan outputs
• Identified non-conforming items, specifically the area of non-conformance.

Due to the construction of the Mitchell Freeway Extension a portion of the existing Hester Avenue pipeline owned and operated by ATCO Gas Australia required realignment.

Fyfe was engaged to undertake the detailed design phase of the project. This involved assessing the plans for the Mitchell Freeway Extension and requirements from the Passenger Rail Authority and Western Power. Fyfe facilitated and documented the pipeline Safety Management Study including assessment of threats presented by the road construction.

 Fyfe’s role and responsibility

• Detailed Design and AS 2885 compliance
• Alignment Plans
• Safety Management Study
• Construction HAZID.

Deliverables

The project created a separate land parcel and title for a disused factory and converted the factory into a storage warehouse, producing a cost-effective reuse option for a large under-utilised facility. Service alterations were required along with a new heavy vehicle entrance and parking and turning hard stand area.

Fyfe’s role and responsibility

• Designed a sewer pump station to isolate the sewer system from the original parcel, called tenders for the construction and administered construction and commissioning.
• Designed a hard stand parking and turning area in the new site to accommodate heavy vehicles including B-double trucks, and the entrance off Cross Keys Road to a B-double standard.
• Managed feasibility and development approvals process.

A new intersection was required (Type CHL & BAL) for access to the new development on Inman Valley Road, on the edge of the township of Victor Harbor. The junction was designed in accordance with DPTI Road Design Services & Standards and the Austroads Guide to Road Design (Parts 3, 4 & 4a).

New street lighting was also provided and designed in accordance with AS/NZS 1158: Lighting for Roads and Public Spaces, road category V3.

The key issues and requirements to be addressed in the design were:

• Existing boundary constraints prevented road widening in vicinity of junction, preventing right turn in to Development from Inman Valley Road.
• Existing excessive road crossfall on the bend along Inman Valley Road (12%), preventing right turn out of Development due to the adverse crossfall and the potential for vehicles overturning. Approval was given to change the design to achieve 8% crossfall which involved additional road shoulder works.
• Pavement design was based on geotechnical testing of sub-grade materials.
• Road lighting was required on the new intersection due to the bend and increased conflicts relating to traffic movements.
• The drainage cross-pipe headwall fell within the required clear zone for the road due to close proximity of the existing boundary. Approval for a new headwall protection system was required which varied from the standard DPTI products.

Fyfe’s role and responsibility

• Detailed design and documentation to DPTI and Austroads requirements of the new intersection including hydrological assessment for upgrade to the existing RCP crossing beneath Inman Valley Road.
• Stormwater management.
• Facilitation of a road safety audit for independent verification of the design.
• Tender call and Contract administration.
• Issue of ‘For Construction’ drawings and documentation to DPTI and Council for Approval.
• Construction of part of the new road intersection.

The Ichthys project is located in the Browse Basin, off the north-west coast of Western Australia, approximately 820 km south-west of Darwin. It will have an initial capacity to produce 8.4 million tonnes of liquefied natural gas (LNG) and 1.6 million tonnes of liquefied petroleum gas (LPG) per annum, and approximately 100,000 barrels of condensate per day at peak. The project is now in the construction phase, following a final investment decision in January 2012.  The plant has both offshore and onshore facilities.

The Macmahon John Holland JV was engaged as the sub-contractor for Ichthys Project’s Site Development Civil Works (CVL2/CVL6). The Scope of Work for this package encompasses the civil work for the onshore LNG facilities following completion of the site development work at Bladin Point, Darwin, including:

• Provision of Site preparation work and earthworks.
• Provision of pavements, hardstands and roads.
• Provision of rock armour shore protection.
• Engineering, design, construction and monitoring of suitable ground improvement work.
• Provision of stormwater drainage system, including concrete perimeter regulating reservoir, open lined drains, reinforced concrete pipe drainage outfalls and associated drainage structures.
• Provision of all temporary Site drainage in order that erosion and sedimentation are limited.
• Provision of all temporary facilities required for the Works (including Site offices, power, water and wastewater disposal).
• Provision of security fencing and gates.
• Construction of the Site Access Road (approximately 2.7 km long) linking existing Wickham Point Road with the proposed Ichthys Onshore LNG Plant Site at Bladin Point, including Wickham Point Road intersection.
• Provision of approximately 200m of permanent water main.
• Pile load testing.

Fyfe’s role and responsibility

Fyfe is providing field survey and data management activities associated with:

The Tipton Water Treatment Facility required a pumping system and 10 flowlines connecting a series of its dams. Tipton Joint Venture called on Fyfe to complete the survey and engineering.

Fyfe’s role and responsibility

• Reviewed existing pumping system and pipelines
• Prepared FEED to determine suitable pumps and sizing of pipes for new pipeline system, and generated P&IDs
• Prepared detailed process and mechanical design of facilities including location of high point vents
• Completed a risk assessment
• Completed HAZOP
• Conducted a safety management study to AS 2885.1
• Developed alignment sheets for all flowpipes
• Produced construction drawings
• Produced valve, pump and instrumentation datasheets.

In order to reduce down time while loading iron ore onto their barges due to hang up of material, CSL Transhipment engaged Dotmar Engineering Plastic Products to install Ultra High Molecular Weight Polyethylene (UHMWPE) sheet liners to each of the 25 hoppers on two barges (50 hoppers in total). These sheets had already been installed as a trial on two hoppers successfully utilising field fit installation method however it was determined that the field fit process of installing liners in the remaining hoppers caused too great a delay and loss of production.

A solution to reduce the installation time required was to accurately measure each of the hoppers and prefabricate the UHMWPE sheets offsite, removing the need to cut-to-fit each sheet onsite during installation. Fyfe were engaged to undertake 3D laser scan survey in order to obtain the internal dimensions for each of the 50 hoppers. The scanning instrument was setup on the elevated barge walkways to ensure safe, remote data capture for each of the hoppers without the need for confined space entry.

Fyfe converted these 3D pointclouds into dimensional drawings which could then be used by Dotmar in the design and prefabrication of the UHMWPE sheets.

Fyfe’s role and responsibility

• Undertake 3D Laser Scan survey for each of the 50 hoppers on two barges.
• 3D Modelling of the hopper internals from the pointcloud data and export AutoCAD DWG.
• Prepare 2D development drawings of internal surfaces showing as-built dimensions.

A 270 km oil pipeline connects Santos’ Jackson facility to its Moomba facility. It replaced an existing pipeline to facilitate oil from Jackson to Moomba and trussing a number of smaller oil satellites.

Fyfe’s role and responsibility

• Undertake route selection survey to determine most constructional route
• Produce detail alignment plans for construction
• Undertake all survey activities to help facilitate construction of the pipeline, including:

• Right of way pegging
• Laydown/access and turnaround
• Mark out depth of cover
• Survey all facilities for construction.

PNG Civil Aviation is redeveloping the Port Moresby International Airport (Jacksons) precinct and asked Pacific Energy to relocate operations and construct a new aviation jet fuel depot. Pacific Energy purchased and now operates the ex-Shell Jacksons International Airport Aviation Depot.

This project is constructing a brand new Jet A-1 fuel storage and handling depot which is connected to the underground fuel hydrant system servicing the Jacksons Airport Domestic and International Terminals.

Fyfe’s role and responsibility

• Prepared concept layout for the new jet fuel depot in consultation with the client.
• Completed detailed engineering design for site civil, mechanical, piping and electrical, instrumentation work for the jet fuel storage and handling facilities, and related site drainage, pavements and building pads.
• Undertook mechanical design in Plant 3D, fully automated piping isometrics and generated bill of materials for project tender and eventual construction.
• Prepared and coordinated the tendering of project works and provided project management support for the overall tender process up to tender award.
• Handed project over to client for implementation/construction while retained for ad hoc technical advice during this phase of the project.

Fyfe was engaged on behalf of Fluor to provide engineering input for an 80-bed camp site. Fyfe’s construction drawings were complemented by a hydrological and sedimentation engineering report to satisfy DERM environmental guidelines, which received no comments from DERM and Fluor.

Fyfe’s role and responsibility

• Project management
• Civil engineering
• Hydrological and sedimentation reporting
• Survey
• As-built drawings.

The study area comprises the northern portion of the suburbs of Kilburn and Blair Athol. The objective of the study was to provide a robust and flexible renewal strategy for the renewal of the study area, particularly the future redevelopment of government assets.

Multiple development scenarios were considered having regard to the key factors influencing the study area, in particular the impacts of industry on the development potential of the area.

In addition to a spatial structure plan for the overall study area, the team was required to deliver concept planning and a project business case for the existing SAHT housing and vacant land within the study area.

The structure plan extended beyond the study area boundaries to address issues such as stormwater management, traffic management, pedestrian movement and linkages etc.

Team

• Fyfe Pty Ltd: Project Lead, Town Planning, Infrastructure Analysis
• Stimson Consulting: Urban Design and Implementation Strategy
• Design IQ: Urban Design
• Oxigen: Public Realm/Place Making
• Natalie Fuller & Associates: Community Consultation and Social Planning
• Colliers International: Property Advice, Market Analysis and Business Case
• Infraplan: Transport Engineering.

Beyond Today’s 89-allotment retirement village is located on the Ocean Road at Port Elliot.

Fyfe’s role and responsibility

• Roadways design and documentation including the site’s internal roads with appropriate turning paths and drainage requirements; and a junction in accordance with AustRoads guidelines.
• Provision of estimated construction costs to develop the site and help with the project feasibility study, reviewing potential headworks, stormwater, road, sewer, water electrical and other construction costs.
• Preparation of contract documents in accordance with AS 2124 and technical specifications, to assist the developer in letting the civil contracts.
• Assessment and provision of feedback on the tenders as engineers and designers for the project.
• Review and advice on progress claims for contract administration and construction management throughout the project.
• Preparation of water reticulation plans and sewer plans for submission to regulator (as a level 1 accredited sewer designer with SA Water).
• Preparation of a water modelling system report for Country Fire Service and SA Water to demonstrate the adequacy of the specified water and fire main systems.
• Preparation of a stormwater management report for Council approval, including water sensitive urban design techniques for capturing clean stormwater runoff for reuse as irrigation on the site; hydraulic ‘Drains’ modelling of the site stormwater system; and water quality ‘MUSIC’ modelling.
• Detailed design for all stormwater infrastructure after Council approval.

Fyfe was engaged to undertake the design of a roadway within an existing road easement corridor. The design was constrained due to the corridor having existing allotments fronting it and also containing existing services.

The design also included a drainage design for the roadway, including a significant outlet design.

Fyfe’s role and responsibility

• Project Management
• Concept Design
• Detailed Road Design
• Stormwater Design
• Stormwater Engineering.

The Department of Infrastructure required the detailed design of approximately two kilometres of road upgrade (chainage 331.360 km to 333.360 km), incorporating part of the existing unsealed Lajamanu Road as sub-base. The objectives are:

• To improve overall road safety and ride quality
• Improve flood immunity and road drainage
• Minimise and/or eliminate restrictions during the wet season
• Support current and future demand from mining, cattle and tourism industries.

The design services incorporate the following elements:

• Two traffic lanes, each with a width of 3 metres
• A 7 metre wide road seal
• 1.5 metre wide shoulders
• Total of a 9 metre formation.

Fyfe’s role and responsibility

Complete design and documentation incorporating the above and following:

• Flood Immunity and Drainage design
• Preliminary Geometric Design taking into account the following:
• Aust roads Guide to Road Design guidelines
• Relevant Australian Standard (e.g. AS1742)
• Hydraulic constraints (flood immunity)
• Significant vegetation and protected site constraints / considerations
• Existing boundary constraints and existing service locations and constraints
• Detailed design incorporating feedback from preliminary design
• Final Design report including Geometric Details, Cross Section and Earthworks Volumes.

The Halikos Group were engaged by Defence Housing Australia for the construction of 97 new houses at Larrakeyah Base.  The development increased the number of houses on-base at Larrakeyah and reduced pressure on the Darwin housing market.   All of the homes were built to a minimum six star Energy Efficiency Rating and designed specifically for the tropical environment. They feature cross-flow ventilation, open-plan design, decks, pergolas and elevation.

Fyfe’s role and responsibility:

• All aspects of day to day survey
• Building and engineering survey.

The load in, load out (LILO) facility at Moomba operates round the clock. The oil normally comes in jacketed tankers and is in liquid form at around 40°C. At a lower ambient temperatures, the residue oil in the pipeline and pumps solidifies.

LILO operations were interrupted on colder days and nights, and Santos requested electrical heat tracing installation on pumps and piping to maintain the temperature above pour points. However, the power supply in this area was considered to be at its safe limit and not capable of supplying enough power for electrical heat tracing. The heat tracing cable and its accessories were also to be installed in a hazardous area.

Fyfe’s role and responsibility

• Designed and managed the project.
• Designed a circuit interlocking with pumping operations to manage the power supply bottleneck.
• Designed the work pack and commissioning plan for installation and commissioning of heat tracing circuits.
• Installed the 3-phase distribution board with interlocking circuits in a safe area.
• Segregated the heat tracing in 10 different circuits based on installation convenience and susceptibility of failure due to dismantling of piping for maintenance.
• Performed all necessary design drafting, calculations for cables and maximum demand to comply with the client’s management of change procedures.
• Managed all documentation necessary for compliance such as Hazardous Area Inspection Sheets and Hazardous Area Register for the proposed installation.

Surveys required to facilitate exchange of land (Road Resumptions) between Brisbane City Council and Transurban Queensland to allow for road widening and new ramps at the Beaudesert Road interchange.

Undertake a cadastral boundary survey of the complete site and the Local Roads and present in a single document (rectified cadastral boundary model). The site comprises approximately four kilometres of the Logan Motorway from west of the Beaudesert Road interchange to the Wembley Road interchange, and approximately 10 kilometres of the Gateway Extension Motorway from the Logan Motorway to Logan Road.

Provide a Register of Permanent Marks and Secondary Control within the project site.

Fyfe’s role and responsibility

• Fyfe were engaged to complete cadastral surveys suitable for creation of road resumption plans, suitable for registration with the Department of Natural Resources and Mines.
• Fyfe were required to compile a full seamless boundary model of the Logan Motorway through the project limits.
• Fyfe were required to examine and survey sufficient existing survey control marks to enable a satisfactory coverage of control for the construction phase of the Logan Enhancement project (LEP). Fyfe were required to compile a register of these survey marks.
• Fyfe are in the process of completing significant surveys of existing infrastructure, including bridges, along the LEP site to enable comprehensive design of the widening works.
• Fyfe are in the process of completing surveys to mark clearing limits.

The Longford to Long Island Point pipeline replacement project will construct and commission 186 kilometres of DN350 crude oil transmission buried pipeline with mainline valves. The project along the existing easement will replace a crude oil pipeline between Longford and Long Island Point in Victoria, Australia.

Fyfe’s role and responsibility

Fyfe has undertaken:

• Project management
• Control survey
• Bathymetric survey of waterway and river crossings
• Locating of buried crossing services and parallel liquids pipeline
• Laser scanning of existing pipeline facilities to deliver 3D point cloud models for detailed design
• Cadastral survey to re-establish the existing easement boundary
• Alignment pegging of the proposed pipeline
• GIS data management and quality assurance
• Geo-database delivery.

Aerometrex as a sub-consultant to Fyfe has completed:

• Flight planning
• Aerial photography capture and photogrammetric processing
• Geo-referenced ortho-photo production
• Detailed digital elevation model.

Innovative solution

Fyfe’s approach to this survey was to employ aerial survey and photogrammetry in partnership with Aerometrex Pty Ltd. Fyfe assembled a highly skilled and capable ground and aerial survey team experienced in similar pipeline survey projects. Team members have the broad industry experience to incorporate survey techniques and ideas that help deliver a modern and innovative survey solution that is cost effective and timely.

Verification of the integrity of over 50 low hazard dams in the Fairview and Arcadia Valley in Queensland began with categorisation under new Department for Environment and Resource Management licence conditions and then assessed hydrological performance, embankment stability, liner acceptability and locational suitability for risk factors.

A key component of assessment was Fyfe’s geographic information systems (GIS), which allowed for an accurate suitability, stability, acceptability and locational analysis of the low hazard dams within the 2D/3D desktop environment.

The GIS interface allowed civil engineers to use high resolutions images with an overlay of dam locations, geographical contours, flood levels and nominated government environmental constraints and buffer zones.

Fyfe’s role and responsibility

Workspace development, maintenance and presentation of raster and vector GIS data sets for use throughout project including:

• High resolution Arial and satellite geo-referenced imagery set to various viewing scales across project area
• Environmentally sensitive areas as well as primary, secondary buffer zones with associated attribute information
• 5 metre contour data
• GIS datasets for dams, wells, pipelines and infrastructure providing location, shape and attribute information
• Data migration between enterprise GIS (MapInfo and ESRI) and CAD
• Dataset coordinate transformation
• 3D contour line converted from shape to shape.

The engineering integrity of more than 50 low hazard dams in Fairview and Arcadia Valley, Queensland needed to be verified. The dams were categorised as ‘low hazard’ under new Department for Environment and Resource Management (DERM) licence conditions and then assessed for hydrological performance, embankment stability, liner acceptability and location suitability for environmental and human safety risks.

The work has helped Santos develop new protocols for constructing low hazard dams to enable them to be readily verified for use.

Fyfe’s role and responsibility

• Categorised dams under new DERM licence conditions
• Assessed dams for relevant conditions
• Prescribed practical and expedient upgrades before certification if existing dams did not meet DERM requirements.

Penrite Oil Company was originally based in Beenleigh and proposed moving its operation to a new site at Magnesium Drive. The new site required a material change of use to noxious and hazardous industry for the purpose of storage, blending, packaging and distributing lubricants for the automotive industry. The proposed industrial use had two environmentally relevant activities (ERAs): petroleum storage; and chemical manufacturing, processing or mixing.

Fyfe’s role and responsibility

• Fyfe (formerly MJ Hedges) advised the client to ensure that all aspects of the project were covered from the outset to avoid an overly lengthy process and collaborated with them to gather most of the information on its operation before it submitted a formal development application. The information included environmental management plans, site based management plan, MSDS, spill/cleanup procedures and stormwater management plans.
• Fyfe also assisted in the design of stormwater treatment from the site from the early stages. A bunded area and sump were put in place to catch potential spillages. Runoff water was treated in a triple interceptor and waste oil was captured in holding tanks. The hydrological values of the site and sensitive receiving areas would thus be maintained.
• Engineering consultants engaged at an early stage ensured the majority of information necessary to demonstrate that the ERAs were compliant with the requirements of both Logan City Council (LCC) and the Environmental Protection Agency (EPA) were included in the report. Most significant was the development of a stormwater quality management plan and a site based management plan.
• Fyfe successfully negotiated with LCC to resolve issues associated with the development and coordinated the secondary consultants who contributed to the project. Our excellent planning knowledge of LCC and EPA regulations and understanding of state legislation and LCC by-laws relating to hazardous industry facilitated the process.

This project comprises the Detailed Engineering Survey and Land Division Application to create an allotment for Council suitable for a further development in the “Regional Centre” zone. The site features survey identified levels, contours, paths and services to assist Council with its design.  The planning application has been lodged and is undergoing planning assessment (December 2014).

Fyfe is continuing to liaise with other agencies on behalf of council. These include DAC, SA Water, SA Power Networks and LTO. Further survey will be required for the land development including the Cadastral certified survey and pegging of boundaries.

Fyfe’s role and responsibility

• Level and feature survey for planning and design engineers
• Traffic management, Underground service marking and survey
• Preparation of base plan for review, and then lodgement of a Land division DA
• Liaison with authorities and management of the application.

Mid Murray Council engaged Fyfe to upgrade a series of creeks/watercourses and the drainage system for part of the council area. The entire site was divided into five different sites A, B, C, D and E.

A highly eroded creek in site A was restored by providing new inlet headwall with erosion protections, drop structures using gabions and reno mattresses. The existing undersized drainage system in site B has been removed and replaced by new drainage system. Sites C and D consist of water courses which were severely eroded due to flow from Crawford Crescent catchment, were rehabilitated. All the erosion measures on the creek surface were completed to the Council satisfaction. A flood detention basin was designed at Site E to protect the adjoining property and Mannum-Purnong road from flooding by the runoff from Site B, C and D.

This project was completed on time, budget and to the satisfaction of Mid Murray Council. The significant benefits to the community of the project include: flood protection of properties, less water on the roads during frequent rains and hence less traffic hazard along the roads. The newly constructed detention basin acts not only as a flood protection structure, it also prevents silts from being discharged into the Murray River.

Fyfe’s role and responsibility

• Identification and analysis of the existing watercourse and drainage system
• Catchment study
• Hydrological study
• Design and documentation for reshaping and stabilising the existing creek/watercourse
• Design and documentation of stormwater drainage system
• Design of new detention basin
• Cost estimate.

Marden Connect is a comprehensive and sustainable medium density brown field redevelopment located at an inner-metropolitan area, five minutes away from the Adelaide CBD.

The site is a former SA Housing Trust public housing site located adjacent the River Torrens linear park. By working in partnership with State Government’s Affordable Homes Program, it achieved more than double current affordable housing targets of 15 percent. It provides 158 dwellings comprising a mix of two/three storey detached dwellings, two/three story group dwellings in the appearance of town houses and three level apartments in the form of residential flat buildings.

Fyfe provided “one-stop-shop” services through the full life cycle of this development, including planning, survey, engineering, project managing other consultants including landscaping architect, electrical designer and NBN designer, coordinating with all the stakeholders including City of Norwood, Payneham and St Peters, SA Water, SA Power Networks, APA Gas and NBN.

Fyfe’s role and responsibility

• Urban Design
• Planning
• Survey
• Project Management
• Project Engineering and Service Authorities Coordination
• Water Sensitive Urban Design
• Civil Design and Documentation
• Tender Call and Contract Award
• Contract Administration.

The successful development application, made under Logan City Council Planning Scheme, was to reconfigure one lot into 32 residential lots, one park and a new road.

Fyfe’s role and responsibility

• Verified the physical layout of the site with quality surveying work, and prepared and submitted a successful development application and planning report.
• Coordinated planning with civil engineers, hydraulic engineers, architects and acoustic engineers to create the planning report for gaining approval.
• Negotiated with Department of Natural Resources and Water and Department of Environment and Resource Management to gain approval to the proposed development, which included the clearing of State significant vegetation.
• Maintained contact with Council throughout the development, responding to an information request and working together to agree on reasonable conditions.
• Gained a favourable outcome for the client through commitment, communication and flexibility.

The bulk of Pickanjinnie 14 lease equipment will be relocated to new Mayfield 3 Lease for the Mayfield pilot project. Individual skids from Pickanjinnie 14 (CSG wellhead separator skid V119 and CSG gas meter skid F039) are to be installed at Mayfield 3 along with a diesel generator set, diesel tank skid, variable speed drive and progressive cavity pump. During appraisal, gas produced by the well will be flared and the formation water produced will be captured in a 1.8 ML concept tank at Mayfield 3 lease.

Fyfe’s role and responsibility

• Lease P&ID design
• Hazardous area classification
• Cause and effect matrix
• Mechanical statement of work
• Electrical statement of work
• Equipment datasheets
• Industry Foundation Classes (IFC) packages and other documentation required for construction.

Five new wells (Mayfield 3–7) will be drilled for the Mayfield pilot project. Each requires flow-lines and gathering systems for water and gas. An underground system will gather water from Mayfield 3–7 well leases and transfer it to an 1.8 ML (concept) tanks on Mayfield 4 lease site. A gravity line will connect the Mayfield 4 tank to a tank of similar size on Mayfield 3, which collects the overflow. An underground gas gathering system will transport coal seam gas from Mayfield 3–7 well leases to a future gas connection.

Fyfe’s role and responsibility

Fyfe design for gas and water gathering systems:

• Design basis
• Gas and water gathering system sizing and design
• Hazardous area classification
• Hydraulic calculations
• Maximum allowable operating pressure and maximum allowable pressure (MAOP & MOP) calculations
• Industry Foundation Classes (IFC) packages and other documentation required for construction.

Fyfe engineering and survey services for gas and water gathering systems:

• Alignment survey and route selection
• Excavation plan
• Test packs for hydraulic and pneumatic testing.

As part of the development of Mayfield pilot project, the bulk of equipment of Pickanjinnie 15 Lease will be relocated to new Mayfield 4 Lease. Individual skids from Pickanjinnie 15, which are CSG Wellhead Separator Skid V120 and CSG Gas Meter Skid F040 are to be installed at Mayfield 4 along with diesel generator set, diesel tank skid, variable speed drive (VSD) and a progressive cavity pump (PCP). During appraisal, gas produced by the well will be flared and produced formation water (PFW) will be captured in a 1.8ML Concept Tank at Mayfield 4 Lease.

Fyfe’s role and responsibility

Fyfe design for Mayfield 4 lease facilities includes:

• Lease P&ID Design
• Hazardous Area Classification
• Cause and Effect Matrix
• Mechanical statement of work
• Electrical statement of work
• Equipment Datasheets
• IFC packages and other documentation required for construction.

Development of Mereenie Field in the Northern Territory required the drilling of 13 new wells, installation of a production flowline and gas lift line for each well, a 6 km extension of the West Mereenie production flowline, a 10 km East Mereenie reinjection flowline and 2 km connection line from the East Mereenie Field to the Central Treatment Plant.

Fyfe’s role and responsibility

Fyfe completed the survey requirements for the field development, construction set out and as-built survey of the flowlines, and survey, excavation plans and set out for the development’s accommodation camp. Fyfe supplied a project engineer to Santos to assist in coordination, construction and commissioning of the camp.

• Pegging of 13 well locations and completion of well sketches
• Route selection and alignment survey for 42 km of flowlines/pipelines
• Compilation of threat analysis as per AS 2885 for all flowlines
• Preparation of alignment drawings
• Updating of Santos GIS
• Preparation of excavation plans for construction
• Construction set-out
• Assistance in setting up and organising machine mounted GPS units to collect as-built data
• Survey and excavation plans for camp installation
• Set out for camp construction
• Project engineer for construction and commissioning support.

In December 2015 Sitzler Pty Ltd was awarded the Managing Contractor Role to complete the sealing of the Inner Mereenie Loop on Larapinta Drive.  The project will see 43 kilometres of Larrapinta Drive between Hermannsburg and Glen Helen sealed for $25 million investment by the Northern Territory government.

Fyfe has been awarded a contract by Sitzler to provide surveying services on the road upgrade projects.

The complete sealing of the Inner Mereenie Loop will provide travellers two wheel drive access to destinations that include the home of Albert Namatjira, Palm Valley, Gosse Bluff (ancient asteroid impact crater) and the West MacDonnell Ranges.  The Mereenie Inner Loop forms part of the 1,335 km Red Centre Way tourist drive, which links many of Central Australia’s iconic tourist attractions including Uluru and Kings Canyon.

The road construction contract has been awarded in three packages to Exact Mining Services, Black Cat Civil and Ostojic Group.

• Survey pickups for the purposes of determining quantities for materials stock piles
• Survey and set-out to assist with the resolution of design discrepancies and/or the development of design alternatives
• Machine control systems support to sub-contractors
• Control survey to establish infill control for UTS machine control
• Tolerance checks on completed pavement layers
• Interim or final as-constructed survey pickups
• Checking levels of subgrade at 25 m intervals
• Checking levels of basecourse at 25 m intervals
• Checking levels at centre line, edge of seal, edge of shoulder, invert of table drain, top of drain batter at 25 m intervals
• Check levels of intersections are in accordance with IFC Drawings
• Check culvert and floodway levels, alignments and grades
• Preparation of as–built documentation.

In 2012 Santos Ltd was undertaking concept development for the production of substantial gas reserves from Mereenie in the Amadeus Basin in the Northern Territory.  The delivery of large volumes of gas from Mereenie to a market requires the construction of a pipeline to an export facility at Darwin or to the existing gas pipeline network at Moomba.

Mereenie is located within oil and gas production tenements (OL 4 and OL 5) operated by Santos Limited.  It is located approximately 240 kilometres west of Alice Springs in the Western MacDonnell Ranges, Northern Territory.

Fyfe was commissioned by Santos to provide professional consulting services to identify and provide assessment on potential gas pipeline corridor options from Mereenie to Moomba and Mereenie to Darwin.

Fyfe’s role and responsibility

Fyfe’s services are comprised of three main work components:

• Sourced geospatial data and compilation of a project GIS
• Undertook a preliminary desktop study to identify and provide independent assessment potential of pipeline routes from Mereenie to Darwin and Mereenie to Moomba
• Pipeline constructability analysis and assessment workshop facilitation
• Produced a study report and alignment maps documenting the results of the desktop study.

A FEED study examined the feasibility of constructing a natural gas pipeline from Mereenie to Yulara (approximately 200 km), including an off-take at Kings Canyon, with three custody transfer stations and associated facilities.

Fyfe’s role and responsibility

• Preliminary route selection
• Development of the design basis
• Process design of facilities including metering, pressure reduction and heater requirements
• HAZOP facilitation and close-out identification of detailed design considerations
• Setting the process control philosophy
• Determining environment and cultural/heritage considerations
• Preparation of geotechnical investigation scope of work
• Preparation of scope of work for construction cost estimate
• FEED report.

Gas for domestic and commercial customers in Mildura is sourced from the Moomba to Adelaide Pipeline via the Epic Energy Angaston metering station located adjacent Envestra’s existing Angaston Compressor Station. The gas currently undergoes compression via an existing 150kW compressor and is delivered to Mildura via the DN 100 Riverland Pipeline and DN 100 Berri-Mildura Pipeline. To increase delivery capacity to Mildura from 2.82 TJ/day to 4.38 TJ/day required the installation of a new 600 kW horizontal two-stage reciprocating electric driven compressor and associated auxiliary equipment and facilities (including a VSD, cooler unit, transformer, control room, acoustic enclosure and maintenance workshop). The existing compressor was retained on site for use as a backup compressor and a diesel fuelled back-up generator installed run the backup compressor.

The project also included installation of two new water bath heaters at downstream facilities.

Fyfe’s role and responsibility

The production of detailed designs for pipelines and facilities has been at the heart of Fyfe’s engineering business for many years.  Fyfe used advanced design tools and specialist staff to produce detailed design deliverables including:

• Design Basis, updated through critical stages the project
• Critical process drawings including PFDs, P&IDs and Cause and effect matrices)
• 3D piping models, and associated layout drawings and isometrics
• Civil design and survey drawings
• Hazardous area classification and drawings
• Electrical, loop and wiring diagrams
• Caesar II piping stress analysis and accompanying stress analysis reports
• Design report for Downstream Pipeline Environmentally Assisted Cracking
• Functional description
• Equipment specifications for duty compressor, water bath heaters, acoustic enclosure, fire suppression, switch room
• Datasheets for equipment such as generator, VSD, instruments, valves (actuated and manual), waste oil sumps and oil storage tanks
• Construction and supply specifications for valves, piping, painting, piping fabrication, piping testing and structural steel
• Construction scopes of work (Civil, Mechanical Piping and Structural, Instrumentation and Electrical)
• Management reports and documents including registers for documents, hold points and technical queries
• Procurement assistance and associated documents such as bills of material, valve lists, equipment lists
• Construction assistance with TQ and RFI responses, design deviation acceptance and site reviews.

Fyfe worked to produce a safe design by employing safety in design techniques such as:

• HAZOP studies
• Safety management studies (SMS)
• Safety in Design Risk Assessment.

Miles airport upgrade was required to facilitate the rapid expansion of fly in, fly out employees in the region.

Fyfe’s role and responsibility

Fyfe’s town planners obtained development approval for a material change of use to an airport for the upgrade, and a reconfiguration of the lot to realign the boundary of the airport. They prepared a comprehensive development application and managed the assessment process with council to gain satisfactory conditions of approval.

The Ingle Farm Shopping Centre has direct access to Montague Road, a dual carriageway arterial road carrying substantial traffic volumes of 21,000 vehicles per day. There have been 12 right angle casualty crashes over the five year period up to 2012, involving vehicles turning right when exiting the shopping centre and colliding with vehicles travelling west along Montague Road.

DPTI developed a concept design to improve visibility for vehicles turning right when leaving the shopping centre and to separate vehicles travelling west along Montague Road from those wishing to turn left into the shopping centre.  Fyfe was engaged to prepare the detailed design of the shopping centre access so that the necessary works can be undertaken to improve safety for motorists and pedestrians.

Fyfe’s role and responsibility

• Realignment of the southern kerb and water table of Montague Road to allow for the provision of a 3.2m wide painted separation median between the left turn slip lane into the shopping centre and the adjacent westbound lane on Montague Road.
• The kerb realignment of both the southern slip-lane kerb as well as central median kerbs, including the relocation of one light pole and double side entry pit.
• The existing pedestrian ramp on the north side of Montague Road is to be relocated to the east of the left slip lane so that the new pedestrian crossing is perpendicular to the existing southern pedestrian ramp.
• An assessment of street lighting in the area will be undertaken to determine whether the level of lighting illuminance (lux) complies with Road Lighting level V3 across the entire intersection.

Fyfe were engaged by Santos to undertake the project management and design works required for the tender and construction purposes of the Moomba Crocker Street and FC70 camp car park upgrade. A “Cat A” excavation plan was also to be undertaken to accompany the work pack.

The design needed to incorporate a review of drainage from the area including design and construction set-out information for realignment of the existing watercourse running through the site, design of a swale system along Crocker Street to divert runoff from the site to the road crossing culvert and general car park drainage.

Engineering drawings and an engineering work pack needed to be developed to enable construction works to be priced by Civil Contractors.

Detailed survey over the allocated was completed to assist in the design of the car park and realignment of the existing watercourse. Set-out of the works for construction was undertaken by Fyfe surveyors based on the civil design drawings developed.

Fyfe’s role and responsibility

• Project Management
• Civil Engineering including car park design
• Stormwater drainage design
• Mechanical Engineering  Drawing search / Cat A Excavation Plan
• Survey: Topographic survey and preparation of data for Survey Plans
• Survey Plans:  Excavation plan dig drawing
• Site Superintendence  attendance onsite during the construction works for inspection and contract management.

Santos wished to expand its main camp at Moomba (FC47). A previous review of the available services had shown that the existing sewer system did not have the available capacity to support this expansion. A new rising main sewer system was required to transfer the waste from the new camp expansion to the existing waste water treatment plant (WWTP).

Fyfe were contracted to complete the design of the sewer rising main and the tie in to the existing WWTP. Fyfe were also engaged to provided the line of sight and alignment pegging surveys (which were to be conducted simultaneously), and the preparation of the required excavation permit plans and construction work pack.

• Determination of design inputs
• Sizing of rising main
• Survey and pegging of alignment of new rising main
• Environmental assessment of the proposed route
• Design of the WWTP tie-in
• Production of construction SoW documents (Drawings/Work Pack)
• Production of Excavation Plan.

The expansion of shale gas development in the Cooper Basin requires upgrades and augmentation to existing water transfer schemes.

This project designed and constructed two new water lines, 8.5 km and 7.2 km in length, and a branch connection from an existing water supply system to support new well stimulation operations.

Upgrades also included design and selection of an in-line booster pump, needed to achieve the required operational low rate specified by Santos fracture stimulation engineers.

Fyfe’s role and responsibility

• Concept phase engineering services
• Survey and alignment selection
• Detailed design phase engineering
• Construction documentation.

Santos has installed a 750 kVA 11 kV / 433 V pad mount transformer (1000-T-068) and ring main unit (1000-S-021) to provide dedicated power supply to both Halliburton and Baker Hughes compounds at the Moomba main contractor’s yard.  The contractor yards were originally fed from its existing area transformer (1000-T-035) but as part of the Santos thermography program, this was found to be overloaded and causing the low voltage fuses inside the transformer blowing over the summer months.

Santos engaged the Fyfe engineering team and surveyors to work with the Santos electrical team in Moomba to undertake the concept design work for the most feasible solution.

• Concept design work
• Detailed design work and critical drawing change request
• Site surveying and excavation plan
• Engineering Site Support and Commissioning.

Fyfe was engaged to design a 17.5 km DN100 raw water pipeline. The system consists of a water supply pump station with two diesel-driven multi-staged centrifugal pumps on duty-standby arrangement. The pipeline delivers raw water to three separate tank facilities with approximately 16 ML of storage each. Water is delivered by a spool-able reinforced thermoplastic pipeline capable of up to 30 Bar operating pressure.

Following completion of water supply, the pipeline flow is reversed by two single-stage 100 kW centrifugal pumps used to return wastewater to plant for treatment.

Fyfe’s role and responsibility

Fyfe’s scope of services included initial concept design followed by detailed design of pump intake chamber, pipeline route survey and selection, risk assessments, pump sizing and selection, tender documentation for supply of equipment, engineering and fabrication drawings, as well as developing construction work packs, operational and commissioning procedures.

Sales gas line from Moomba to Gidgeapla satellite to supply fuel gas to compressors.

Project specifications: DN 200, 26.5 km long with two mid-line risers with provisions for future connections.

Fyfe’s role and responsibility

• Front End Engineering Design (FEED)
• Route selection, survey and alignment plans
• Environmental clearance
• Safety management study and alignment sheets
• Pipeline engineering including design basis, crossing design and stress analysis
• Wall Thickness, Fracture Control Plan and Fatigue Study
• Construction specification and scope of work
• Safety Management Study (SMS) Report
• Hydrostatic Test Specification and Hydrostatic Test Calculation
• Pipeline Construction Specification and Construction Scope of Work
• Cathodic protection and earthing design
• Hazardous Area Classification Report and drawings
• Detailed design drawings including piping isometrics, layouts and footing plans
• Typical drawings for crossings such as roads, washes, sand dunes and underground services
• Bill of Materials for the pipeline, mid-line and end of line facilities
• Engineering support for the construction tender process.

Design Brief: 

• Transformer T-35 tripping frequently during hot weather.
• Both Halliburton and Baker Hughes contractors demanded more power due to electrical upgrades in their yards.

Fyfe was engaged by Santos Moomba Area Owner to investigate the frequent tripping of transformer T-35 in the Moomba Main Contractor’s Yard. It was determined that the fuses in transformer T-35 trip when the ambient temperature reached 40°C (during summer months).

In September 2013, the blue phase fuse has blown 3 times in 6 weeks and it was found that the plastic shroud around the combined fuse switch terminals within transformer T-35 was burnt. Santos Reliability Strategist (Mark Noack) captured the incident using a thermal graphic camera which showed a temperature rise on the blue phase of the transformer T-35.

A field inspection by a Fyfe Electrical Engineer and Santos IE Technician, determined that both Halliburton and Baker Hughes contractor yards used large amounts of power (compared with other contractor yards) based on the existing electrical loads (number of offices, workshops and air conditioning loads) installed on site.

Halliburton and Baker Hughes play major roles in production of Santos oil and gas wellheads. Both requested more power for upgrades in their yards to prepare for the future Moomba expansion project.

Fyfe’s role and responsibility

Preliminary engineering work:

• Visited Baker Hughes and Halliburton sites in Moomba and liaised with Operations Supervisor to discuss their existing and future power demands
• Assessed and determined maximum demand/capacity of the existing transformer T-35
• Assisted Santos in justifying the cost of installing a transformer versus a temporary diesel generator
• Reviewed existing high voltage and low voltage electrical installation in Moomba main contractor’s yard
• Produced preliminary engineering drawings for installation of a transformer
• Liaised with transformer manufacturer and electrical contractors
• Produced electrical (high voltage and low voltage) and civil scope of work to request quote from electrical contractors.

Detailed engineering work:

• Submitted critical drawing change request for new installation
• Produced electrical calculations for the new transformer installation
• Produced detailed engineering drawings and engineering work packs (electrical and civil) for construction
• Met with Santos and contractors for planning of installation work flow on site to reduce operational down time; produced project Gantt chart and work breakdown structure as agreed by Santos and contractors
• Selected transformer, and high voltage and low voltage cables and fuse sizes to be used for installation.

Construction and commissioning phase:

• Provided onsite engineering support to contractor and assisted in problem solving during installation of the transformer
• Produced a commissioning plan for the new transformer, ring main units and supply pillars
• Ensured installation in accordance with detailed engineering work pack and in compliance with Australian Standards
• Ensured all Santos required documentation was complied and completed before starting work
• Managed and organised cranage and transportation on site
• Ensured all required materials and tools were in placed as required
• Supervised electrical and civil contractors and liaised with Santos area owner, IE Supervisor, Halliburton and Baker Hughes
• Reported progress to Santos Project Manager on a daily basis
• Assisted and witnessed in the commissioning of the new transformer, ring main unit, supply pillars and downstream distribution boards
• Produced as-built drawings for back drafting and registration in the Santos Technical Information System.

Compressor Station #1 near Moomba, one of a number of compressor sites along the Moomba–Adelaide natural gas pipeline, required a hazardous area equipment register. Non-standard equipment installation issues were also identified against AS/NZS 60079 and AS/NZS 2381 to accommodate a targeted future upgrade program.

Fyfe’s role and responsibility

• Collect, review and analyse all related documents and drawings such as P&ID, hazardous area drawings, cable schedules, connection diagrams and cable block diagrams to generate an equipment index checklist.
• On-site at Compressor Station #1, conduct a visual inspection, develop an equipment photo archive and identify equipment installation-related issues.
• Prepare a summary report with emphasis on equipment installation-related issues.
• Generate a hazardous area equipment register.

Enerflex Process appointed Fyfe (Robert Elks & Associates) for detailed civil and structural engineering for Node 3 compression facility near Moranbah in the Bowen Basin, Queensland.

The Moranbah Gas Project is one of the largest operating coal seam gas projects in Australia.

Fyfe’s role and responsibility

• Assess the geotechnical report
• Liaise with the geotechnical engineer to establish footings design parameters
• Mitigate the impact of the expansive soils of the area
• Liaise with piping and mechanical departments of Enerflex to establish design data
• Complete civil and structural detailed design, including fabrication detailing of structural steelwork.

The Moranbah Gas Project (MGP), located in the Bowen Basin region, is already one of the largest operating coal seam gas (CSG) projects in Australia. It currently supplies gas to the Moranbah and Townsville power stations, mineral refining facilities in north Queensland, and ammonium nitrate plants run by Incitec Pivot Limited and Dyno Nobel.

Background:

A significant number of CSG wells in the PL196 tenement of the MGP have been unable to dewater since commissioning in 2008. The wells are typically able to turn on but experience unreasonably high back pressures and shut down, thus stopping gas flow.

Field trials and remedial corrective action sessions, conducted from May 2011 to April 2012, indicated a very high probability of partial vapour lock in numerous locations throughout the water gathering system due to incorrect high point vent locations.

Fyfe’s role and responsibility

The project is reviewing all previous design work and drawing, contractors’ construction drawings and current problems of the entire as-built PL196 gathering pipeline system.

A Stage 1 project report will detail recommendations for remedial measures and form the basis of detailed design work (Stage 2) to rectify the current non-operation of the gathering system.

Specific activities:

• Carry out field survey of entire existing pipeline alignments to verify as-built details (including lengths, size, burial depth, elevation and any other relevant survey information) of the pipelines in the entire gathering system
• Develop preliminary and final long sections for as-built pipelines
• Review all previous design work and drawings used in construction of the pipelines to troubleshoot and determine possible reasons for non-operation
• Review all previous operational and commissioning reports and studies carried out since construction of the water gathering system pipelines to determine possible reasons for non-operation
• Facilitate a retrospective (5-year) safety management study of the pipelines in the gathering system and issue of a matrix
• Validate the existing P1W pipe specification and include vacuum pressure limitations for selected temperatures
• Complete redrafting of existing P&IDs including all field valves and proposed high point vent locations
• Design and draft new high point vent drawings to detail mechanical design and guidelines for the construction and placement of these HPVs for the water gathering system pipelines
• Produce Stage 1 project report detailing all findings and recommendations for rectification
• Produce design basis for use in detailed design (Stage 2) to implement remedial actions
• Produce budget cost estimation for construction of the scope of work as detailed in the Stage 1 project report.

Fyfe’s role and responsibility

• Land and Engineering Survey, including pegging of allotments
• Service authority registration and negotiations
• Liaise with Council, SA Power Networks, SA Water, Telstra, NBN Co and APA
• Project team formulation including tendering, evaluation and appointment of consultants
• Management and coordination of the project team to ensure detailed design delivery
• Investigation options to optimise stormwater solutions including offsite detention options
• Coordination of SEAGas safety management workshop
• Obtaining approvals from all authorities
• Detailed design of all civil works including Detention Basins
• Engineering inspections
• Construction survey
• Land division management.

The Murray Bridge Racing Club is relocating to new facilities on a 800 ha site, which required rezoning and engineering. The site contains a new race track and proposes a Community Title Equine Village of 56 lots specifically designed for thoroughbred racehorse trainers. State of the art training facilities are planned including opportunities for industry training centres and an equine veterinarian hospital. The Master plan proposes some 3,500 housing allotments, town centre, and schools with associated service infrastructure.

Fyfe’s role and responsibility

• Obtain rezoning of land for special uses and provide feasibility information for the development
• Surveying
• Civil engineering
• Project management.

Following an assessment of the capacity and condition of the ponds and associated pipework at the Narcoonowie Oil Facility, it was revealed that the interceptor and evaporation ponds had insufficient freeboard and silting up of the transfer pipes had occurred. The pond walls had been degraded due to continual erosion since construction and required rehabilitation to ensure operational serviceability.

Furthermore, due to the extensive works involved with remediation of the ponds, Santos requested design be undertaken for replacement of facility pipework and rundown lines at the same time. The overall civil and mechanical project scope included:

• Ponds
• Pond wall repair and re-establishment to meet current engineering standards
• Removal and replacement of transfer/balance pipes
• Removal of existing and installation of new pond discharge pipe
• Interceptor pit liner removal and replacement with new
• Fence repairs and modifications
• Relocation of existing skimmer tank, pumps and related hoses
• Tank area
• Separator and production tanks piping replacement
• Production tanks drain line piping replacement
• Clearing of tank farm bunded area and bund repair
• New bunded truck load out facility.

Fyfe’s role and responsibility

Due to the complexities associated with replacement of equipment, repair of infrastructure and undertaking of extensive civil earthworks, Fyfe developed a construction staging plan to ensure that works could be undertaken in discreet packages to meet tight operational time frames. Fyfe’s role included:

• Development of overall site plan and construction staging plans
• Safety in design workshop
• Detailed survey for civil and mechanical piping works
• Plant 3D detailed modelling of tank farm area
• Mechanical GAs, ISOs, P&IDs, BOMs and datasheets
• Mechanical demolition and construction workpacks
• Pipework fabrication workpacks for pre-fabrication of pipe spools
• Pond civil construction drawings and 3D modelling
• Civil construction workpacks.

In the 2008 State budget, the South Australian Government announced a $2 billion investment over ten years aimed at transforming Adelaide’s rail network into a vibrant, state-of-the-art and sustainable system, providing faster, cleaner, more frequent and efficient services for commuters.

Part of this funding was directed at the Electrification of the Seaford (formerly Noarlunga) line.  The Seaford line was the first of the Adelaide Passenger Metropolitan Rail Network to be fully electrified.

Fyfe were engaged by DPTI to provide engineering survey services for the electrification of the rail network from Noarlunga to Seaford.

Fyfe’s role and responsibility

• Boundary Model Calculation
• Engineering Survey for design and construction
• Location of underground services
• Digital terrain modelling.

The Northern Territory Government is working to facilitate the development of a gas pipeline connection from the Territory to meet energy demands on the eastern seaboard and to contribute to national energy security.  The pipeline extends from the Palm Valley Inlet Hub in the Northern Territory to its terminus at the Moomba Outlet Hub in South Australia.

Through a competitive tender process, four organisations were invited to progress to a final request for proposals stage, one of those organisations was DDG Operations.  Fyfe formed part of the DDG Operations Team.

Fyfe’s role and responsibility

Fyfe provided preliminary design, environmental, planning and surveying services to DDG to enable them prepare a commercially competitive bid to the Northern Territory Government to design, construct, operate and own the NEGI pipeline.  Fyfe’s services included:

• Definition and recommendation of route options through a GIS model
• Identification and assessment of overall Regulation/Licensing requirements (based on the known Regulatory environment)
• Preparation of documentation for lodgement of application for the necessary approval permits and license for Northern Territory, South Australia and the Commonwealth
• Cost and schedule estimate for heritage, environment and land access activities for the project
• Provided input to, and participated in Project Risk Identification
• Provided engineering support to supplement DDG team as required
• Pipeline alignment design
• Location specific threat identification and analysis for pipeline design
• Constructability analysis
• Provision of project online web GIS platform and content
• Preparation of GIS maps and figures for stakeholder engagement and regulatory approvals process
• Preparation of pipeline alignment sheets
• Aerial survey and corridor feature mapping including Digital Terrain Model.

Part of Adelaide’s 78 km North-South Corridor, the Northern Connector Project is a new $985 million project that includes 15.5 km of new motorway (three lanes each way) connecting the Northern Expressway and Port Wakefield Road to the Port River Expressway and South Road Superway.

Fyfe was awarded the DPTI contract to survey the Northern Connector Underground Services which was undertaken during November and December 2015.  Fyfe delivered this project to DPTI on time and within budget on 14 December 2015.

Fyfe was subsequently awarded the full Engineering Survey contract which commenced on completion of the underground services survey in December 2015 and was delivered at the end of February 2016.  Fyfe provided DPTI a seamless transition from one project to the next with many of its surveyors and drafters working through the Christmas/New Year break to ensure the tight timeline was met.

Fyfe’s role and responsibility

• Coordination of subcontractors for traffic management
• Engineering survey of full corridor including existing bridge decks and underside of bridges to DPTI (Transport) strict standards for design
• Including survey of wetlands and existing connection roads. The connection roads included large sections of the Port River Expressway and Port Wakefield Road
• Establishment of GPS and third order levelling survey control
• Preparation of the survey and other model as per DPTI specifications.
• There were no safety incidents for this project which involved many hours working on major roads and expressways plus through wetland areas
• Six day per week operation through Christmas and New Year period
• Tight timeline with staged delivery for data
• Full project survey report.

Adelaide’s 78 km North-South Corridor, the Northern Connector Project, is a new $985 million project that includes 15.5 km of new motorway (three lanes each way) connecting the Northern Expressway and Port Wakefield Road to the Port River Expressway and South Road Superway.

Fyfe was awarded the DPTI contract to survey for the Northern Connector Underground Services.  The Utility Services Scope of Work is shown in blue in the DPTI diagram (below).  Fyfe carried out this work using RTS and RTK GPS equipment with the assistance of four service locators and traffic management subcontractors.

Fyfe’s role and responsibility

• Coordination of subcontractors for the location of underground services and traffic management.
• As-Built survey of services to DPTI (Transport) strict standards for design.
• Establishment of GPS survey control.
• Preparation of Underground Service Models divided into capture classes as per DPTI specifications.

The Northern Expressway project involved a new 23 kilometre road linking the Gawler Bypass with Port Wakefield Road and an upgrade of the existing Port Wakefield Road.

Fyfe were contracted to complete a large portion of the engineering surveys prior to the design of the road and the junctions at each end. This involved surveying a large section of Port Wakefield Road, the Gawler Bypass, the Gawler Soaring Club and open farmland in between.

Fyfe also surveyed the location of ground testing boreholes, set-out of services, earthwork levels and volumes.

Fyfe’s involvement commenced in late 2006 with survey along Port Wakefield Road and continued until March 2010 for various types of survey services including as-constructed survey. Fyfe used two field crews on site for a large part of the survey.

Fyfe’s role and responsibility

• Engineering Surveys
• Location of ground testing boreholes
• Set-out of services for construction
• Survey of existing earthwork levels and calculation of volumes
• Survey setup on AHD and MGA 94 co-ordinate system
• Coordination of survey activities with rail safe workers.

In 2016 Fyfe completed an alignment survey for the Northern Primary Main Stage 1 Pipeline for Jemena which required survey for 4 km of proposed pipeline corridor through metropolitan Sydney.

Fyfe’s role and responsibility

• Alignment survey to provide inputs for detailed design
• Alignment selection
• Underground services location for buried service crossings
• Engineering line list
• Pipeline alignment sheets
• Aerial survey imagery acquisition
• DBYD enquiry and complication of buried services records
• Compilation of project GIS and Geo-Database
• Digital survey data delivery in GIS format.

Northgate, in Adelaide’s northern suburbs, is a land development by Northgate Joint Venture (of AV Jennings, Canberra Investment Corporation and Land Management Corporation). Precinct 2 holds approximately 1200 lots; Precinct 1 included up to 700 residential allotments. The precincts include medium density housing under Community Title legislation. Urban layout includes water sensitive urban design for control of stormwater from upstream catchments as well as stormwater generated within the development.

Fyfe’s role and responsibility

• Obtained development approval and monitored all required statutory aspects of the development through to final plan deposit and issue on new certificates of title
• Completed a detailed survey of the site to capture all site information, including all surrounding road and service infrastructure as required for master planning and engineering design
• Undertook urban layout including water sensitive urban design
• Took lead for panels and metering.

Fyfe’s role and responsibility

• Surveying services including the site survey(s), boundary design and pegging, set out and as-built surveys, set out of the constructed lakes and Lands Titles Office plan lodgements.

The objective of the feasibility study is to identify a preferred alignment for the proposed pipeline having consideration for geospatial, construction, environmental, regulatory and social issues. Another objective of this study was to provide project construction costing to a + 25% confidence level, this incorporated preliminary pipeline engineering and design. Including the integration of design / option parameters with facility upgrade feasibility study.

Fyfe’s role and responsibility

• Development of project GIS, web based.
• Preliminary Pipeline Engineering and design including wharf / port off loading arms.
• Environmental review of alignments with consideration for contaminated water and soil.
• Determination of appropriate regulatory framework for approval / licensing application.
• Social impact assessment and advice on management of interested / third parties.
• Facilitated route selection work shop.
• Project Safety Management Study.
• Project procurement and construction costing + 25%.

The project was to undertake and coordinate development of a 500-bed camp site.

Fyfe’s role and responsibility

Santos required a design for a 4 CSG well pad at Pickanjinnie in its Queensland CSG fields. Fyfe began with the existing well head design and questioned all its aspects such as:

• Total life cost
• Fit for purpose
• Stakeholder buy-in.

Left  Gas water separator and CSG well head.

Right top  Render side.

Right bottom  Render skid.

Fyfe’s role and responsibility

Fyfe was responsible for the total design including process, mechanical and electrical disciplines. Fyfe’s E&I team provided engineering for:

• Hardware design for RTU and VSD panels
• Instrument specification for metering
• Communication design
• HMI and RTU programming, which allows flexibility for complex operation scenarios.

Santos’ Piping Integrity Management Program needed to use new technology to enable ongoing monitoring of the integrity of Cooper Basin assets. This program was put in place to identify ‘at risk’ pipework, develop as-built isometric drawings for the identified pipework, map non-destructive testing (NDT) points accurately and assign the test data to those points.

Fyfe’s role and responsibility

• Use three dimensional laser scan technology to enable ongoing monitoring
• Scan existing Moomba gas plant and satellites
• Complete as-built P&IDs
• Produce inspection isometrics from scanned data to assist with NDT and data recording.

Arrow had this gathering system installed in 2008 and have not had full production since due to various design and pressure issues. Fyfe were engaged to survey the existing line and determine locations for HPVs and LPDs as well as redesign sections of the pipeline to alleviate these issues.

Fyfe’s role and responsibility

Fyfe design for this water gathering system included:

• Pipeline flow analysis calculations
• Redesign and realignment of sections of pipeline
• Design of LPD and associated tank
• Identification of requirement for HPVs and location of same
• Issuing of IFC packages and other documentation required for construction.

Playford Grove Estate, a 44-allotment subdivision in Munno Para West, has seen the benefit of Fyfe involvement from pre-feasibility. Fyfe completed detailed design delivery through to contract administration, practical and final completion certification.

Fyfe successfully advocated for an optimised stormwater strategy for the development and region, which allowed for increased allotment yield and sales revenue of 10%.

Fyfe’s role and responsibility

• Infrastructure and staging assessment
• Opinion of probable cost
• Project reporting
• Authority negotiations and advocating to council for optimised stormwater solutions
• Liaison with Development Assessment Commission, council, SA Power Networks, SA Water, Telstra, NBN Co and APA
• Project team formulation including tendering, evaluation and appointment of consultants
• Management and coordination of project team to ensure detailed design delivery
• Obtaining approvals with authorities
• Detailed design of all civil works
• Tendering, assessment and recommendation for construction of the works
• Contract administration
• Liaison and obtaining approvals from SEAGAS
• Survey for offsite stockpiles
• Environmental testing and certification for offsite fill.

In the 2008 State budget, the South Australian Government announced a $2 billion investment over ten years aimed at transforming Adelaide’s rail network into a vibrant, state-of-the-art and sustainable system, providing faster, cleaner, more frequent and efficient services for commuters.  Part of this funding was directed at the Electrification of the Seaford (formerly Noarlunga) line.  The Seaford line was the first of the Adelaide Passenger Metropolitan Rail Network to be fully electrified.

The project provides a 5.7 kilometre extension of the dual track rail line from Noarlunga Centre Railway Station to the Seaford District Centre.

Fyfe were engaged by DPTI to provide engineering survey services for the electrification of the rail network from Noarlunga to Seaford.

Fyfe’s role and responsibility

• Boundary Model Calculation
• Engineering Survey for design and construction
• Location of underground services
• Digital terrain modelling.

Fyfe has extensive experience in the survey and design of water disposal and storage systems. Our scope of work has ranged from simple set out of ponds to the site selection and design of staged water disposal systems.

Pond Construction Survey Project List

POND CONSTRUCTION CASE STUDY

BIG LAKE SATELLITE EVAPORATION POND 

Client Santos Ltd

Location Big Lake, South Australia

Brief description

Santos needed to build a new discharge evaporation pond near the Big Lake Satellite to deal with excess water from increased gas production in the Cooper Basin and help alleviate any problems with internal corrosion from the build up of water in the pipelines

Fyfe’s role and responsibility

Evaporation pond construction survey including:

• Detailed survey of the proposed area
• Contour plan
• Design of new pond layout including interceptor pond
• Marking of pond extremities including top of bund level
• As-built survey
• Cross-sectional data of the as-built pond to verify design into construction.

Fyfe’s experienced team is working with Santos to complete a number of pressure safety valve (PSV) campaigns in the Cooper Basin and South West Queensland.

During these campaigns, Fyfe developed processes to efficiently gather, sort, search and select the data required for each PSV and progressively applied lessons learned to continually improve efficiency and the accuracy with which datasheets are completed. A key development was the creation of a macro that automatically makes datasheets from a Microsoft Access database. This macro also performs sizing check calculations for each PSV using the process information manually entered into the information database.

Fyfe’s role and responsibility

• Completing a desktop study of PSVs to produce datasheets (where previously no datasheet existed or was outdated)
• Completing sizing checks on existing PSVs in service to ensure they are fit for purpose
• Revising P&IDs to include the as-built PSV information.

The North South Corridor Torrens Road to Torrens River is a critical piece of infrastructure for the creation of an improved north-south transport link in Adelaide.

The route of the new road goes through a residential area with a significant portion of long term elderly residents. These residents have concern that their houses may be damaged by construction activity and have concern that the process for determining if the damage was caused by construction activity. Similarly, the commercial and industrial premises in the vicinity of the works share the same concerns.

Fyfe has been engaged to complete building inspections for over 300 premises and buildings to undertake the condition assessment and critically advise on any structural issues arising from the construction works.

Fyfe’s role and responsibility

• Inspect and photograph over 300 premises for condition assessment
• Advise any structural issues arising from construction works
• Complete detailed reports on all inspected properties.

Other

Undertaking the condition assessment of properties is a sensitive issue and may cause concerns for residents whose premises are either being inspected or not being inspected for various reasons.  Fyfe developed a project plan and list of response to most likely asked questions in conjunction with DPTI to ensure residents and owners are equally informed.

The Park Terrace, Fitzroy Terrace and Torrens Road capacity upgrade is being undertaken to improve capacity and ease traffic congestion during construction of the North-South Corridor Torrens Road to River Torrens project.

The capacity upgrade goes through a residential area with a significant portion of long term elderly residents. These residents have concern that their houses may be damaged by construction activity and have concern that the process for determining if the damage was caused by construction activity. Similarly, the commercial premises in the vicinity of the works share the same concerns.

Fyfe has been engaged to complete building inspections for over 70 premises and buildings to undertake the condition assessment and critically advise on any structural issues arising from the construction works.

Fyfe’s role and responsibility

• Inspect and photograph over 70 premises for condition assessment
• Advise any structural issues arising from construction works
• Complete detailed reports on all inspected properties.

Other

Undertaking the condition assessment of properties is a sensitive issue and may cause concerns for residents whose premises are either being inspected or not being inspected for various reasons.  Fyfe developed a project plan and list of response to most likely asked questions in conjunction with Bardavcol to ensure residents and owners are equally informed.

Fyfe was engaged by Senex Energy to provide survey services to capture data on known or potential constraints to construction of a pipeline along the preferred route alignment based on desktop studies, constraints mapping and on-ground investigation.

Fyfe’s surveyors located construction constraints at the same time as the ecological and environmental constraints were mapped.  Survey was completed using Trimble R10 GPS (Global Positioning System) utilising RTX differential correction signal. This technology allowed continual movement along the pipeline eliminating the need for a base station.  Environmental data was collected in the field using a Trimble unit.  This enabled teams to upload the geodatabase of potential constraints into the unit for real time verification. The Juno allows for the use of dGPS ensuring a minimum accuracy of +/- 5m. Data was transferred daily to Fyfe’s office for validation of data quality.

Fyfe’s role and responsibility

Fyfe Key constraints that were identified included:

• Land use (including mining and petroleum)
• Topography
• Infrastructure
• Environmental and/or ecological constraints.

QGC is developing coal seam gas (CSG) in the Surat and Bowen Basin of southern and central Queensland for domestic and export markets through its Queensland Curtis LNG (QCLNG) Project.

The Scope of work covered the survey of 2000 CSG wells and 3500 km of access and pipeline gathering corridors.

The Engineering Survey Services contract scope for the QCLNG Upstream Project included control surveys, trunkline surveys, detail/cadastral/setout/cultural heritage and fencing surveys, pegging party surveys, rectification of digital cadastral database (DCDB) boundaries, petroleum well location survey, dual surveys for earthworks calculations, QA and GIS mapping.

Fyfe’s role and responsibility

Fyfe mobilised 12 survey crews, 10 site office personnel, 15 vehicles and survey equipment within four months. Maximum crew numbers on site peaked at 16 crews, with 23 vehicles, 16 sets of GPS equipment and several Robotic total stations.

DCDB rectification and control survey activities

• Densify survey control to nominal 3 km spacing over an area of approximately 500 km².
• Produced a base drawing for each block in the following formats:

• PDF Plan
• ArcGIS
• AutoCAD 2007 drawing created from C3D file (ACAD2007)
• Photographs taken during survey (IMAGES).

• Conducted a full search of survey plans and existing control survey mark to ensure the efficiency and effectiveness of any field work.
• Obtained contact details of owners and used Fyfe quality procedures for land access to communicate with landowners to ensure there were no issues for gaining access to survey marks and obtaining knowledge of security and environmental issues.
• Adjusted the DCDB to property boundaries compiled in the cadastral surveys; adjusted property boundaries where there was uncertainty in the location and geometry of the DCDB affecting the pipeline and well location.
• Presented the final DCDB adjustment in ArcGIS and CAD formats with subject land parcel attributes from the existing DCDB polygons still intact.

Pegging party survey activities

• Complete pre-field preparation including exhaustive land access approval checks, exporting GIS background information, uploading survey control, preparing land access maps.
• Escort client field party including ecologist, cultural heritage officer, construction supervisor and land holder through subject property to identify potential CSG well locations, access and pipeline corridors and surveying all relevant features.
• Downloading and processing survey data using attributed feature codes suitable for import into client GIS and preparation of plans used in landowner negotiations.
• Transmittal of approved data to client document control department following strict QA processes and procedures.

Petroleum well location survey activities

• Conducted a full search of survey plans and existing control survey mark to ensure the efficiency and effectiveness of any field work.
• Complete prefield preparation including exhaustive land access approval checks, exporting GIS background information, uploading survey control, preparing Land access maps, adhering to the client permit to work system.
• Using registered surveyors, complete the final location survey of all Petroleum wells drilled by the client to a standard acceptable to the Department of Natural resources and Mines (DNRM) including wells from Moonie to Middlemount.
• Reduce all data and prepare a Mining Plan (MP) suitable for registration in the DNRM.
• Upload final MP and photos to client Maintenance Connect system for future records.

Dual surveys for volume calculations and QA of contractor earthworks totals

• Upload survey control, prepare Land access maps, and adhere to the client permit to work system.
• In consultation with civil contractors, complete a dual survey of unsuitable and earthworks materials on ponds, camps, compressor station and laydown yard sites.
• Compile independent volume calculations of each material.
• Summarise and compile in end of month packages for delivery to client to assist in QA of monthly contractor claims.
• Complete final as-built surveys of each large pond and prepare as-built plans to submit to the EPA for final records.

Safety Awards

Fyfe surveyors worked under the direction of MPC completing survey field work for the construction of the QCLNG gathering network, including the collection of all as built data for submission to QGC.

Fyfe’s role and responsibility

Fyfe surveyors liaised with Project Managers Engineers and the Survey Manager to ensure the following:

• Delivery of high quality work with high levels of accuracy
• Maintained accurate survey control
• Accurate setting out of excavations, roads, footings and services as required
• Maintaining accurate as built records
• Adherence to data management and record keeping procedures
• Compliance with all HSSE legislation, codes of practice, standards, policies and procedures
• Create a harmonious working atmosphere
• Awareness of all stakeholders involved, including landholders
• Clear communication with construction field staff.