East Perth Power Station Pipeline – Excellence in Civil Construction Award-Winning Project

October 2024

DM Civil proudly claimed the 2024 WA Earth Awards for Excellence in Civil Construction for the $10-30 million project value category for its work on the East Perth Power Station (EPPS) Pipeline project. This award marks not only a significant achievement for the company, but is also a testament to the innovation, quality, and meticulous project management that define DM Civil’s operations.

Project Overview

The East Perth Power Station Pipeline project, commissioned by ATCO Gas Australia, involved constructing a 7.5 km high-pressure steel gas pipeline. The project was split into two major packages:

Package A: Construction of a new 7.4 km DN250 steel high-pressure gas pipeline from the Bayswater Pressure Reduction Station (PRS) to Alexander Drive in Dianella, ensuring continuous gas supply to the Perth CBD.
Package B: Installation of a 200m DN250 steel high-pressure gas pipeline in East Perth, bypassing the existing PRS and connecting the newly derated HP152 pipeline to the existing HP059 pipeline.

This project represents ATCO’s largest pipeline construction effort in Australia to date and DM Civil’s first significant foray into natural gas pipeline construction, with a project value of over $18 million. The scale, complexity, and timeline showcased the capacity of DM Civil’s project management, innovation, and technical capabilities.

Construction Challenges and Complexities

The East Perth Power Station Pipeline project presented a unique set of challenges. DM Civil’s team successfully navigated simultaneous operations (SIMOPS) with other third-party contractors, intricate stakeholder management, and complex environmental factors. Key challenges included:

Simultaneous Projects in Bayswater Light Industrial Area: The team worked alongside several major infrastructure projects, including the Tonkin Gap project, Bayswater Evolve project, and another ATCO gas pipeline project, all within a 1km radius. Daily meetings with affected parties ensured no delays or conflicts.
Built-Up Residential and Industrial Areas: The pipeline installation traversed heavily populated areas, including narrow suburban streets, major roads like Alexander Drive and Grand Promenade, and industrial zones in Bayswater. Stringent traffic management plans, coordination with local authorities, and innovative construction methodologies were vital to minimising disruptions to businesses and residents.
Groundwater and Contamination Issues: A significant challenge arose from encountering contaminated groundwater (PFAS) in the Bayswater Light Industrial Area. DM Civil executed major dewatering operations, including 24/7 tankering, to ensure safe disposal of the effluent while keeping the site dry and safe for pipeline construction.

Innovative Solutions and Construction Techniques

DM Civil employed various innovative construction techniques throughout the project, setting a new standard for ATCO and future projects. Some notable innovations include:

Horizontal Directional Drilling (HDD): A substantial portion of the pipeline was installed using HDD, particularly through busy intersections like Beaufort Street and Grand Promenade, without disrupting traffic. The use of HDD in built-up suburban areas significantly reduced the impact on residents and businesses compared to traditional open excavation methods.
Pilot Boring: Pilot boring was utilized to install sections of the pipeline where HDD or open excavation was not feasible. This method allowed for accurate, trenchless installation of pipes beneath existing water mains and roads.
Pipe Welding Mid-Pullback: To avoid disturbing well-established trees and verges in suburban areas, DM Civil implemented a novel solution of welding pipe sections mid-pullback during HDD, reducing the size of excavations and protecting the community’s landscape.
Coating Material Trials: DM Civil introduced a new heat shrink sleeve coating system to expedite installation, which, if adopted, could improve productivity on future pipeline projects.

These innovative approaches not only mitigated project risks but also saved time and reduced costs, showcasing DM Civil’s commitment to delivering high-quality cost effective solutions for its clients.

Leadership and People Development

The success of the East Perth Power Station Pipeline project can be attributed to the strong leadership and teamwork demonstrated by DM Civil’s project management team. A notable aspect of this project was the “lead from the front” approach, where the Project Manager was on-site for the majority of the project, ensuring seamless communication and problem-solving in real time. This hands-on leadership style created a motivated and engaged workforce, which proved crucial in overcoming the project’s complexities.

The project also provided opportunities for people development and training, with multiple leading hands promoted to supervisory roles and gaining valuable experience in gas pipeline construction. The project engineer for this contract, deeply involved in all aspects of the project, was later promoted to Project Manager for subsequent gas pipeline projects, highlighting the developmental impact of the project on DM Civil’s workforce.

Safety and Environmental Management

DM Civil’s unwavering commitment to safety and environmental stewardship was evident throughout the project. The company’s safety management plan, accredited to ISO 45001:2018, included a thorough hazard identification workshop (HAZID) and regular safety discussions with ATCO. The successful use of a specialised “cold-cutter” for cutting existing gas pipelines without producing heat exemplifies the innovative safety measures implemented on-site.

Environmental management, accredited to ISO 14001:2015, was equally robust. DM Civil engaged arborists to protect significant street trees during excavation and developed a noise management plan that received praise from local authorities for its effectiveness during nightworks. Additionally, DM Civil’s handling of contaminated groundwater through dewatering and effluent disposal ensured no adverse environmental impact, setting a precedent for future projects in the area.

Stakeholder Management

Effective stakeholder management was critical to the success of the East Perth Power Station Pipeline project. DM Civil worked closely with local residents, businesses, and government authorities to minimize disruptions and maintain positive relationships. The team carried out extensive community engagement, including door-knocking and letter drops, to keep stakeholders informed and address their concerns. The proactive approach to managing community relations resulted in minimal complaints and strong positive feedback from local councils and businesses.

Legacy and Future Impact

The East Perth Power Station Pipeline project leaves behind a legacy of innovation, efficiency, and excellence in civil construction. DM Civil’s success in managing this complex project has established the company as a major contender in the gas pipeline construction industry. The innovative methodologies developed during this project, such as the use of HDD in difficult areas and the pilot boring technique, have since been adopted by ATCO for future pipeline projects, further cementing DM Civil’s reputation for delivering high-quality solutions.

Additionally, the strong working relationship forged with ATCO during this project has led to DM Civil securing multiple pipeline contracts with the company, showcasing the long-term value created through successful project delivery.

The East Perth Power Station Pipeline project is a highlight example of DM Civil’s commitment to excellence in civil construction. The team’s ability to overcome significant challenges, implement innovative solutions, and deliver a high-quality project on time and within budget has been rightfully recognised with the 2024 WA Earth Award for Excellence in Civil Construction.

The successful completion of the East Perth Power Station Pipeline project showcases the company’s capacity to meet complex challenges head-on with innovative and efficient solutions. As DM Civil continues to build on this foundation, the lessons learned and breakthroughs achieved on this project will inspire future advancements, positioning the company as a leader in civil construction and setting new standards for the industry.