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Gorgon Project

Construction of the Gorgon project, the largest single resource natural gas project in Australia’s history, is under wayThe Chevron-operated Gorgon project is one of the world's largest natural gas projects and the largest single resource development in Australia.

The Gorgon Project is developing the Gorgon and Jansz-Io gas fields, located between 130 and 200 kilometres off the northwest coast of Western Australia. The project is operated by an Australian subsidiary of Chevron and is a joint venture of the Australian subsidiaries of Chevron (47.3 percent), ExxonMobil (25 percent), Shell (25 percent), Osaka Gas (1.25 percent), Tokyo Gas (1 percent) and Chubu Electric Power (0.417 percent).

The downstream project includes:

  • A gas-processing facility on Barrow Island consisting of three nominal 5-million-tons-per-annum (Mtpa) liquefied natural gas (LNG) trains, carbon-dioxide injection facilities, and a domestic gas plant with capacity of 300 terajoulesper-day (TJ/d) to Western Australia.
  • Two 180,000m3 LNG storage tanks, four 38,000 m3 condensate tanks, five 118MW gas turbine power plants, over 8km of CO2 pipeline, 2.1km MOF causeway and 2.1km loading jetty, associated site infrastructure, utilities and preconstructionworks.

Barrow Island has been a Class A nature reserve since 1910 and is an internationally important conservation estate. It is the site of Australia's largest onshore operating oil field for the past 45 years.

Scope of Services
Hatch, as a member of Kellogg Joint Venture Gorgon (KJVG), was contracted by Chevron Australia to undertake both pre-FEED and FEED studies. Following completion of the FEED studies in 2009, KJVG was awarded the engineering, procurement and construction management (EPCM) contract for all LNG downstream facilities and logistics management services.

Hatch is directly involved in:

  • Project planning and execution
    • Project execution strategy
    • Project management
    • Construction management
    • Modularization and construction sequencing
    • Environmental compliance and monitoring
    • Interface management
    • Safety and quality management
  • Balance of plant infrastructure engineering
    • Plant layout and optimization
    • Marine and jetty
    • Utilities and water treatment
    • Early works and civil/structural
    • Pioneering facilities
    • Temporary and permanent buildings
  • Procurement, supply and logistics
    • Planning and execution
    • Fabrication yard quality assurance
    • Transportation and freight
    • Materials handling
    • Quarantine management
    • Supply base and warehousing
    • Waste management
    • Contract administration
  • Construction management and planning
    • development and implementation of the construction program
    • quality management plan and implementation
    • HSE management
    • contractor management
    • materials management
    • pre-commissioning planning and implementation

Project Highlights
Hatch project members have had the opportunity to experience the development of an execution and construction strategy that addresses the geographic and logistic aspects of the project. The remoteness of the island and stringent environmental commitments has enhanced the complexity of the execution methodology, with Hatch personnel assisting with the management of the environmental commitments resulting in a world-class example of how environmental conservation and industrial development can successfully co-exist in very unique and sensitive location.

Other key challenges and highlights of the project to-date include:

  • Hatch provided key personnel and input for the development of the modularization strategy for the project, and is currently providing quality management and site-based supervision of the modularization yard activities along with associated logistical and transportation planning. A world-class modular-construction strategy was developed to minimize impact on the island during the construction phase. The project utilizes several fabrication yards across South East Asia and Australia to support approximately 270,000 tons of LNG modules, the largest being over 6,300 tons.

  • Significant procurement, supply, quarantine and logistics challenges exist as a result of the construction occurring on the Barrow Island nature reserve. Hatch has made significant contributions to the management of these challenges.

  • Leading environmental and quarantine procedures are in place to protect the indigenous flora and fauna on Barrow Island. Hatch participated in the development of a comprehensive project quarantine management plan to manage all quarantine aspects and inspection requirements across the entire project supply chain.

  • The project requires a global team to deliver such a large and complex undertaking. During the study phases project planning, engineering and procurement was undertaken across five countries using resources based in Perth, London, Houston, Singapore, and Jakarta. As the project has progressed into execution, supply and fabrication is being undertaken on five continents including major modular construction yards in China, South Korea and Indonesia, with marshalling facilities in Thailand.

  • During 2013, KJVG reached its peak of about 2,650 personnel, which included about 800 people from Hatch.
Project Stats
Client:
Chevron Australia (Operator)

Location:
Barrow Island, Western Australia

Start:
December 2004

Completion:
2015

Cost:
US$54 billion

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