Kellog Joint Venture Gorgon

Kellog Joint Venture Gorgon The Kellog Joint Venture Gorgon, an unincorporated joint venture between KBR, JGC, Hatch, and Clough, is the Gorgon's Project's downstream engineering, procurement, and construction management contractor. The scope of work includes three LNG trains, LNG storage, and load-out facilities, including a jetty, domestic gas plant, utilities, materials offloading facility, and a construction village.

In 2012, Fulton Hogan Industries transported its new highly portable Astec asphalt plant to Barrow Island, a remote island off the western coast of Australia. Fulton Hogan Industries is a very prominent business "down under," which specializes in building and maintaining transport and civil infrastructure in Australia, New Zealand, and the South Pacific so that communities can operate safely and efficiently.

The plant was custom-designed and built for Fulton Hogan's Asphalt Surfacing Operations to provide them with a highly portable asphalt plant which could be moved easily from state to state and offshore.

The first and biggest test for the plant's "ease of portability" came when Fulton Hogan won the supply of hot-mix asphalt for the Gorgon Project on Barrow Island. To undertake the project, Fulton Hogan would need to move its new highly portable asphalt plant through four of Australia's six states over 4,345 km (2,699 mi) by road across the breadth of Australia and then by sea to get to the remote Barrow Island. The plant was moved along the project route using ten trailers to transport the plant components. Each trailer customized to meet strict Australian standards for safety and registration. Thanks to innovative engineering by Astec, Inc. engineers, the trailers met the transport solution required to keep Fulton Hogan's Gorgon Project moving forward.

Barrow Island
Barrow Island Beach

Home to Australia's largest operating onshore oilfield, Barrow Island is a Class "A" Nature Reserve. This brings the highest level of protection under State legislation for the island's plant and animal life. Approvals for work on the island underwent an intense assessment before being granted. State and Federal Governments put measures in place to protect the area throughout the life of the project.

The Plant's Arrival

Fulton Hogan's portable asphalt plant was originally bound for Brisbane, Queensland (Eastern Coast of Australia), which is the Port of Arrival of the portable asphalt plant. It was stored at Astec Australia's head office facility for pre-commissioning work and registration with Queensland's Department of Transport, something difficult to achieve if the plant does not comply with ADR regulations and Australian standards. Thanks to the efforts of Astec's engineering team and liaising with Astec Australia, this was a successful task.

After the arrival of the plant into Brisbane, Fulton Hogan was then awarded the Barrow Island project in partnership with the Kellog Joint Venture Gorgon. The portability of the plant was showcased as it was transported from Brisbane, Queensland, through New South Wales, South Australia, and all the way through to Perth in Western Australia.

Transport Prep

In Perth, the asphalt plant was shrink-wrapped and quarantined in order to comply with Barrow Island's stringent environmental quarantine regulations, which applies to all buildings, materials, and equipment introduced to Barrow Island. The requirements include thorough cleaning and disinfection treatment of all items prior to transportation. After treatment, small items are placed in shipping containers and larger items, such as building modules and plant components, are shrink-wrapped to prevent contamination during transport. Shipping to Barrow Island is carried out by barges departing from both Perth and Dampier.

The Gorgon Project

The Gorgon Project is a $43 billion joint venture developing the Greater Gorgon Area gas fields. Touted as the largest resources project in Australian history, it will also be the single largest investment of its kind in the world. The Greater Gorgon Area gas fields contain about 40 trillion cubic feet of gas. This is the nation’s largest undeveloped gas resource. The Gorgon Project is owned by the Gorgon Joint Venture, which includes the Australian subsidiaries of Chevron, ExxonMobile, Shell, Osaka Gas, Tokyo Gas, and Chubu Electric. The venture will process 15 million tonnes (16.5 million tons) per year of liquefied natural gas (LNG) and 300 terajoules per day of domestic gas on Barrow Island, 70 km (43 mi) off Western Australia’s Pilbara Coast. The gas processing portion of the project will be located on Barrow Island, limited is size to 300 hectares (741 acres), or 1.3 percent of the island.

In order to commission the plant, every employee and subcontractor to Astec Australia had to be approved and participate in an extensive induction program. The program consisted of an initial thirteen-page application to be inducted onto the project. Documentation included all licenses and tickets relevant to the person and the work to be completed. All inductees were flown to Perth, Western Australia, to attend inductions for Kellogs Joint Venture, Fulton Hogan, and Ertech. Each person had an extensive medical exam and an elevated work platform ticket check and competency demonstration. Upon arrival onto Barrow Island, the induction included a campsite and environmental inspection. The plant was commissioned on Barrow Island in October 2012.

Trailer-Mounted Mobility

The Astec, Inc. portable asphalt plant for Fulton Hogan is comprised of various components that are all trailer-mounted on ten trailers for complete compliance with the strict ADR compliance rules in Australia. If the plant does not comply with ADR standards, the plant will not be allowed to be transported and would make the portability null and void. The main challenge was to ensure that no trailer was wider than 3.2 m (10 ft, 563/64 in).

Fulton Hogan also acquired two Roadtec Pavers (RP170 and RP190) for paving on Barrow Island. Both pavers also endured the stringent shipping, quarantine, and commissioning requirements.

Astec Australia is devoted to continuously meeting the needs of its customer—and by working hand in hand with Fulton Hogan's people were able to design, build, deliver, install, and commission this highly portable asphalt plant even under the extreme logistical challenges presented by the Gorgon Project on Barrow Island.

Michael Thompson, who is Fulton Hogan's national operations manager, airports, enjoys the challenge of tackling these logistically difficult projects. Michael said that the old saying "the devil is in the details" is very true, especially when it comes to the amount of planning, preparation, and management that is required to be successful on these types of projects. Michael also said that the key ingredients for success are safe, dedicated, reliable, and persistent people supported by high-quality reliable equipment. Michael continued that with Fulton Hogan's Astec plant and equipment, he felt extremely confident that Fulton Hogan was working with a company that listened intently to its needs, and had designed and built a plant accordingly.

Astec stands by its equipment and provides unwavering support no matter the endeavor...

"Not only that, I know that Astec stands by its plant and equipment, and that they will always be there to support us wherever and whatever we do. Sure, there will be the odd occasions when things don't go quite as you expect, but with Astec we know that they have a very good understanding of our business, and we know that we are dealing with very honest and reliable people that will always respond and support us," said Michael.

To further test the portability and reliability of its new highly portable Astec Double Barrel® asphalt plant, following the completion of its Barrow Island project, Fulton Hogan plans to transport back to Australia's east coast to tackle the refurbishment of the runway on Brisbane's International Airport. Fulton Hogan knows that when they do, Astec will be there to support them.