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M80 Widening Project

Client :

APA_Group_(Australia)_logo

Project Date

2018

Length

0.26Km

Pipe Diameter & Type

350mm

Relocation of 260m of the steel transmission Brooklyn – Corio pipeline located underneath the M80 Ring Road for APA Group.

Relocation of 260m of the steel transmission Brooklyn – Corio pipeline located underneath the M80 Ring Road for APA Group. Works included design and construction of a 248m horizontal directional
drill through basalt rock and significant excavation for both the launch and retrieval HDD pits either
side of the freeway. Commissioning of the pipeline included double isolation of the Brooklyn – Corio
pipeline with two DN200 bypasses operating to maintain supply whilst tie-ins were conducted. Following the successful tie-ins and commission of the new pipeline, the existing section of the Brooklyn – Corio pipeline was abandoned and both major excavations backfilled with approved APA backfill material.

Major activities

Major activities undertaken for this project included:

Provision of construction management plans for the pipeline including; Health and Safety Plan, Site Environmental Management Plan, Quality Plan.
Site setup and survey of pipeline alignment.
Provision of HDD management plans and design for the rock bore underneath the M80 Ring Road.
Bulk earthworks for both the East and West excavations to expose the existing Brooklyn – Corio pipeline and enable setting up of the HDD rig.
Stringing, welding, testing and coating of the pipeline string to AS2885 standard as required for transmission pipelines.
Drilling, reaming, cleaning and installation of 248m horizontal directional drill in basalt rock underneath the M80 Ring Road (works conducted during day and night shifts).
Live welding of 4 sets of stopple, bypass, baghole and TOR fittings on the existing Brooklyn – Corio pipeline in preparation for tapping, isolation and cutting.
Tapping by TD Williamson of 16 fittings in preparation for isolation of main.
Fabrication and installation of two DN200 steel bypass lines to maintain gas supply.
Coating integrity test following pullback of the DN350 HDD pipeline to confirm the successful installation.
Installation of bends to bring the newly installed pipeline on line with existing pipeline prior to final hydrotest to 9,650kPa.
Commissioning of bypass and isolation of Brooklyn – Corio pipeline using TDW stopples and bags (double block and bleed) to ensure gas free whilst cutting the main.
Oxy-cutting of the existing DN350 pipeline and final welding to tie-in new pipeline. Commissioning of new section of Brooklyn – Corio pipeline following confirmation that the two golden welds have passed the non-destructive testing.
Coating of final tie-in welds and hot-tap fittings remaining on the pipeline using HBE-95. Entire pipeline coating tested using Holiday Detector to find and repair any coating defects.
Cutting and removal of existing gas free pipeline before abandoning section underneath the freeway using flowable grout.
Backfill around the new pipeline with APA approved bedding material and supporting of new pipeline with stabilised sandbag piers.
Bulk backfilling of the two major excavations using a 47 ton excavator and soil compactor to achieve compaction of above 95% standard as required by VicRoads.
GALLERY

View photos of our team in action

View photos of the work undertaken for this project: M80 Widening Project
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