Varanus Island Tank Life Extension

Santos is an Australian natural gas company. Established in 1954, the company is proud to deliver the economic and environmental benefits of natural gas to homes and businesses throughout Australia and Asia.

With extensive experience in the safe execution of tank construction and maintenance projects, Primero have been repeatedly engaged to deliver sustaining capital projects for Santos at Varanus Island. Successful project delivery that has culminated in the safe execution of over 45,000-man hours on the island.

MAINTENANCE | CONSTRUCT

ENERGY

The Varanus Island hub has a reliable capacity of 290TJ of gas per day and provides ongoing benefits to Western Australia by ensuring an independent gas supply into the DBNGP.

Tank C

In May 2017, Santos (formally Quadrant Energy) engaged Primero to execute multiple scopes of work related to the 16-year life extension of the 57m diameter, 250,000-barrel crude oil storage Tank C-101. Tank C is one of three main crude oil tanks used by Santos for storage prior to processing and exporting at Varanus Island. While executing the Tank C works, Santos retained the services of Primero to execute the 13m diameter T-201 water tank floor repair scope. Responsibilities included:

  • Design analysis, procurement and structural repairs to comply with API 650 & API 653 requirements.
  • Re-plating of primary wind girder, ~180 linear meters.
  • Patch plating of secondary wind girder where excessive corrosion was identified.
  • Repairs to the tank shell where excessive corrosion was identified.
  • Design, fabrication and installation of the foam deluge system including foam deluge ring main and foam dam wall on the tank floating roof.
  • Tank floor repairs where excessive corrosion was established.
  • Management of all site welding, materials control and NDT testing.

Primero were able to rapidly deploy in-house resources when required, thus fast-tracking components of the schedule. Over 20,000 man hours were worked LTI free.

Tank B

In February 2019, Primero were invited to return to Varanus Island and complete a tank floor and wind girder support replacement project following the success of the C Tank maintenance the year prior. Tank B-101 is the second of three main crude oil tanks used by Santos for storage prior to processing and exporting at Varanus Island. The 16 year life extension scope of work included:

  • Design, procurement and structural repairs to comply with API 650 & API 653 requirements.
  • Fitting new floor over existing floor, 1540 linear meters welding.
  • Change position of 12 tank nozzles, replace 2 off ‘clean out doors’ and roof drain replacement.
  • Replaced 128 Primary and Secondary wind girder supports.
  • Management of all site welding, materials control and NDT testing.

The project was executed ahead of schedule, incident free and culminated in some fantastic feedback.

The [Santos] project team decided on selecting reputed Australian resources engineering and construction company Primero to complete the B Tank work for Santos. Primero’s record with Quadrant is strong, already having a hand in the safe refurbishment of Crude Oil tank C which was completed successfully last year.


The Project team has begun exceptionally well with an impressive safety record and progress so far is tracking to schedule. The project is a great example of using the four p’s synonymous with Santos mission vision and values, performance, people, partners and protection.